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Author: Livia In-Albon

Discover the future of machine elements and drive technology in Dresden

The Dresden Machine Elements Colloquium (DMK) will take place on 14 and 15 May 2024. The latest research results and practical, industrial applications in the fields of machine elements and drive technology as well as sensor technology and artificial intelligence will be presented.

PROSE employee Felix Saur will give a presentation on wheelset torsional vibrations, in which he will describe how high dynamic torsional moments in the wheelset shaft can be reduced by optimising the design of drivetrain components.

There are still places available, take your chance and grab a ticket here: https://www.mdesign.de/en/news/dmk-2024/

 

Examination of an updated production process of the SBB bogie revision maintenance site in Basel

Customer: SBB, Switzerland

Project tasks

  • Project and stakeholder management
  • Process analysis and documentation
  • Identification and development of proposed solutions

Our Approach

Thanks to PROSE’s existing expertise in the areas of maintenance facilities, railway production and operations, the PROSE experts were able to quickly drive forward the creation of the production concept in consultation with the responsible site manager. The first step was to record the existing production process on site and define the target process for efficient handling of the production volume (technical inspection, wheelset processing). Any problems arising from the necessary changes to the feed process were analysed by the PROSE experts in consultation with the internal departments and solutions were proposed. Finally, the entire processes, systems and production equipment at the site were documented.

Customer benefit

Thanks to the PROSE experts’ existing knowledge, SBB benefited from rapid implementation of the production concept and focussed, solution-oriented processing of the identified problem areas.

 

Transformation in action

We are proud to present our latest collaboration with the metro operator for SL, where we played a crucial role in the refurbishment and improvement of 270 C20 metro trains.

PROSE has worked closely with various suppliers to ensure a first class finish. From the early stages of development to the start of production, we made sure that each step followed seamlessly from the next. Our work began with the redesign of the driver’s cab, focussing on ergonomic improvements and workplace efficiency. In parallel, the passenger compartment was redesigned to increase passenger comfort and safety. This required careful planning and implementation to ensure that every change met strict safety and quality standards.

Our proactive approach to quality assurance in the development and production phases has helped to raise quality standards and increase customer satisfaction.

At PROSE, we are passionate about progress and quality to exceed our customers’ expectations. Find out more about this project here.

Safety and reliability on rails – An insight into our latest project

At PROSE,  we always strive to maximise the safety and longevity of our customers’ vehicle fleets. In our latest project, we carried out comprehensive inspections on the X60A vehicles to ensure their structural integrity.

Using non-destructive testing, including magnetic particle and ultrasonic testing, we were able to identify and document surface defects as well as internal cracks and material inhomogeneities. These thorough examinations have enabled us to precisely identify any potential weaknesses and plan targeted maintenance measures to ensure the safety and reliability of the vehicles.

Thanks to the detailed documentation in nine inspection reports, our customer now has a clear overview of the condition of each unit in their fleet, making it easier to make informed decisions about maintenance and repair measures.

We are proud of our work to improve operational safety and support our customer in strategic planning for the long-term maintenance of their vehicle fleet. Take a look at the reference for this new project.

 

Inspection and assessment of carbody, cracks and corrosion

Project tasks

  • Project management
  • Planning of the project
  • Inspections
  • Establishing an assessment report

Our Approach

As part of the project implementation, PROSE AB carried out thorough inspections on all 9 X60A vehicles to ensure their structural integrity. This was carried out with visual inspections of the vehicle frames and bodies to identify visible damage. This meticulous approach made it possible to precisely document every potential weak point, which allowed targeted planning for necessary repair work. Through the comprehensive inspection and documentation, PROSE AB ensured that all vehicles’ safety and quality requirements were met, improving their operational safety and longevity.

Customer benefit

​By providing nine detailed inspection reports, one for each vehicle, the customer benefited from a comprehensive and accurate overview of the condition of their vehicle fleet. The individual reports provide an accurate assessment of each vehicle’s condition and maintenance needs. This structured and detailed documentation enables the customer to make informed decisions about necessary maintenance and repair measures, helps to optimise operational safety and supports effective resource planning. The reporting thus increases transparency and facilitates strategic planning for the long-term maintenance of the vehicle fleet.

 

     

QA of suppliers and production for driver’s desk refurbishment in C20 Metro

Project tasks

  • Quality assurance of sub-suppliers
  • Supervision of prototype phase
  • First class installation
  • Delivery inspections

Our Approach

PROSE have worked closely with the suppliers from an early phase in the development process to ensure a smooth transition from development through prototype to the production ramp-up phase and to ensure stable quality throughout the serial production.

Customer benefit

By improving the supplier delivery early in the project, the customer could benefit from minimizing quality issues just before the start of production. PROSE’s wide range of available services helped the customer in many stages of the project.

 

Enhancing Rail Safety with Tailored Brake Repair Solutions

In one of our most recent projects, our customer commissioned us to create precise welding plans and thorough documentation to ensure effective and safe brake repairs. Our team used advanced scanning technology to create customised welding drawings and detailed documentation, addressing specific requirements of the brakes.

The direct benefits for our customer include significant reduction in downtime, cost savings through in-house repair capability, and extended lifespan of critical brake system components. These tailored solutions ensure that magnetic rail brakes maintain their essential function in the safety and efficiency of rail transport.

At PROSE, we’re dedicated to deliver innovative solutions that drive efficiency and safety in railway systems. For more information check out our new reference.

 

This is how we improve the quality of our design reviews!

Is the design optimised for production? Is accessibility given for welding and assembly? Can the components be replaced quickly and easy during maintenance?

To answer these questions easier and more specific, PROSE uses the support of Mixed Reality for design reviews. The objects and components can be inspected in their original size with HoloLens 2 glasses.

The benefits for you as our customer are:

  • Reduced manufacturing costs
  • Less time and effort for mounting
  • Simplified maintenance

We want to be your solution provider. Contact us today to start your next project together.

 

 

Digitalisation is revolutionising the maintenance of historic vehicles

We are proud to be working with owners and operators of historic rolling stock on a ground-breaking project that is taking maintenance organisation and fleet management into the digital future. Following the specifications of the Swiss Federal Office of Transport, we have taken on the challenge of bringing historic vehicles and their maintenance specifications in line with European standards and digitising them. 

With the introduction of the ZEDAS maintenance software and our expertise, we are creating comprehensive maintenance plans. This work includes the digitalisation of fragmented instructions and the adaptation to modern standards, taking into account the valuable voluntary contributions of associations. 

We are pleased to support owners and operators of historic rolling stock on their way to becoming a modern, digital maintenance organisation.

Check out our new reference for further information. 

 

Optimisation of the bogie removal/installation process in a maintenance shop of the Swiss Federal Railways

Customer: Swiss Federal Railways (SBB) Passenger Division, Switzerland

Project tasks

  • Solution development
  • Solution assessment
  • Project management

Our Approach

PROSE worked with responsible persons within SBB and other external planners to develop a wide range of possible solutions. On the one hand, solutions for the Basel site were developed, which have been technically tested and already take the site’s production capacities into account. On the other hand, the possibility of outsourcing the work to external service providers was examined due to the challenges in Basel. All solutions were examined in detail, including, for example, the transport of the bogies and vehicle relocations.

Customer benefit

SBB received an overview of 17 solution versions, including an opportunity/risk assessment. Some of these were analysed more thoroughly, including an initial profitability calculation, which forms the basis for the decision on how to proceed

Verification of a maintenance shop for a new vehicle type

Customer: Swiss Federal Railways (SBB) Passenger Division, Switzerland

Project tasks

  • Capturing requirements
  • Checking integrability and identifying problems
  • Definition of measures
  • Project management

Our Approach

The existing infrastructure was used to check which maintenance tracks in the SA Basel were generally suitable for the RABe 512. As soon as the vehicle was available, various inspections and clarifications were carried out directly on the vehicle on the relevant tracks, together with the relevant responsible persons for facilities and occupational safety. All components were systematically analysed, and the need for modifying existing systems or additional auxiliaries was recorded.

Customer benefit

Measures were defined and handed over to the customer for implementation, particularly regarding safe access to the train head and the roof. This way, the procurement requirements for modifying the service facility were bundled before the maintenance, ensuring occupational safety and enabling efficient maintenance tasks.

Maintenance plan for a maintenance shop of the Swiss Federal Railways

Customer: Swiss Federal Railways (SBB) Passenger Division, Switzerland

Project tasks

  • Creation of maintenance plan

Our Approach

​PROSE developed the plan in close cooperation with SBB’s responsible persons. The understanding of the maintenance shop in Basel gained from past assignments and experience with other maintenance facilities helped ensure efficient project implementation.

Customer benefit

SBB received a production concept that describes the interaction of the production resources in the context of the business process model to enable an in-depth understanding of the site within SBB. The target group of the production concept includes the management personnel at the site, partner organisations within and outside the site, the management of SBB Passenger Traffic Production and the facility management.

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