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Technician performing digital railway bogie inspection using augmented reality (AR) headset and tablet during rolling stock maintenance.

Implementing Digital Maintenance with Augmented Reality

Project tasks

  • Defining a relevant digital maintenance use case
  • Parametrising the AR-based inspection system
  • Localising software and adapting interfaces
  • Setting up and supporting an on-site pilot project
  • Training personnel and supporting prototype testing
  • Evaluating results and delivering an application report

Our approach

PROSE implemented an AR-supported prototype for a railway sector customer as part of a pilot project to digitalise maintenance processes for bogies. The objective was to replace paper-based inspection workflows and improve data quality and traceability.

The selected use case covered dimensional inspection under defined load conditions with structured checkpoints and tolerances. PROSE digitalised existing inspection processes and transformed them into guided digital workflows for mobile devices and AR headsets. Nominal values and wear limits were integrated to ensure systematic inspections and direct recording of deviations. The application enables hands-free operation as well as structured real-time data capture and further processing.

The pilot project included configuration of the application, execution under real workshop conditions, and evaluation with regard to usability, data quality, and operational limits.

PROSE combined railway engineering expertise with digital technology know-how and worked with a specialised AR partner.

We defined a suitable use case together with the customer and implemented it directly on-site as part of the pilot project. We configured and validated the application iteratively based on real maintenance processes.

Our approach included close collaboration with customer personnel, rapid adaptation of digital workflows, and targeted training of users.

Customer benefit

The customer received a validated prototype demonstrating how digital and AR-supported maintenance can improve efficiency and quality. Paper-based processes are reduced, training time is shortened, and inspections become more consistent and guided.

Hands-free operation and real-time documentation improve usability and data quality in workshop environments. At the same time, digital records enhance traceability and support integration into existing maintenance systems.

Through PROSE’s independent expertise and cross-industry insights, the customer gained a solid basis for further development and implementation of digital maintenance solutions.

 

Augmented Reality assisted maintenance

Project tasks

  • Collecting European use cases
  • Providing a report for chosen use cases and a presentation on various customer sites
  • Prototyping of an on-site application
  • Definition of the use cases
  • Initial parametrisation of the Augment Reality inspection system
  • Software localisation
  • Definition of performance parameters
  • Setup of pilot project on site
  • Tuning of the parametrisation of the AR inspection system
  • Training of personnel for prototype application testing
  • Digital O&M prototype usage instructions and application report

Our approach

The project addressed the need to identify, assess, and practically evaluate digital technologies for rolling stock maintenance used in Europe. The objective was to provide transparent insight into proven and emerging digital maintenance solutions for railway vehicles, including trains and rolling stock fleets, based on information available in the public domain.

On top of that, the project aimed to move beyond theory by implementing and validating a selected digital maintenance use case. A virtual reality (VR)-supported maintenance application was chosen and realised at one of the customer’s major production sites to validate feasibility and operational relevance under real industrial conditions.

PROSE conducted a structured survey of European digital maintenance technologies based on industry experience, expert exchanges, and reference projects implemented by railway operators and maintainers. The resulting report focused deliberately on non-patented, legally uncritical use cases to ensure transparency and independence. Based on this assessment, we supported the selection of a suitable digital maintenance application with high practical relevance.

We then realised a VR-supported digital operation and maintenance application directly at the customer’s site. For that purpose, we coordinated a specialised VR technology partner and combined advanced digital tools with our in-depth railway maintenance and engineering expertise. Our independent role and hands-on industry knowledge ensured a solution that was both technically robust and operationally relevant.

Customer benefit

By selecting PROSE, the customer gained access to deep, experience-based insight into European digital maintenance practices beyond pure desk research. The survey provided realistic, industry-proven solutions grounded in actual railway projects and expert discussions.

Through the realisation of a concrete VR maintenance use case, the customer was able to validate digital technologies in practice rather than relying on theoretical concepts. PROSE’s combination of independent consulting, deep railway domain expertise, and the ability to bridge technology providers with operational requirements enabled a reliable and low-risk introduction to digital maintenance innovation, strengthening long-term maintenance efficiency and capability.

 

Train driver cab with diagnostic display screen and control panel inside a FLIRT1 electric multiple unit.

Ensuring long-term availability of FLIRT1 EMUs

Customer: Hessische Landesbahn GmbH, Germany

Project tasks

  • Obsolescence analysis
  • Definition of replacement hardware architecture
  • Software porting to new Compact-PCI platform
  • Linux OS adaptation
  • EMC planning (EN 50121-1)
  • CSM analysis
  • Requirement capture
  • Test specification development
  • Laboratory validation
  • Prototype retrofit support (on-site)
  • Creation of retrofit documentation
  • Support during fleet rollout

Our approach

The FLIRT1 Electric Multiple Units (EMU) operated by Hessische Landesbahn GmbH were equipped with a Compact-PCI diagnostic computer that became obsolete and unavailable on the market.

The diagnostic computer records vehicle events and fault logs while displaying failure messages and troubleshooting guid-ance to the driver. Although the system is not safety-relevant, it is operationally essential for efficient maintenance and fleet availability.

Due to increasing component ageing and an expected rise in hardware failures, the obsolete unit had to be replaced by a successor model with full functional equivalence. The validated vehicle software architecture needed to remain unchanged, in order to classify the measure as maintenance acc. to (EU) 2016/797.

PROSE developed a risk-minimised hardware migration concept that preserved the existing vehicle software architecture.

We replaced the obsolete MEN Compact-PCI computer with a Duagon Compact-PCI successor model and ported the existing application software to the new platform. The Linux operating system environment was adapted to ensure identical system behaviour.

We implemented necessary interface adjustments without changing the validated vehicle software architecture. Our scope included:

  • Porting and validation of the application software
  • Creation of installation images
  • Development of test specification
  • Execution of a Common Safety Method (CSM) analysis
  • Requirement capture documentation
  • Preparation of an Electromagnetic Compatibility (EMC) plan according to EN 50121-1
  • Laboratory validation and on-site prototype verification

We implemented and validated a prototype retrofit as the basis for a seamless fleet-wide rollout. In close collaboration with a specialised software partner, we ensured efficient implementation and full technical traceability.

Customer benefit

Hessische Landesbahn secured the long-term availability of its FLIRT1 fleet without functional changes or impact on the validated vehicle software architecture.

The reuse of the existing installation space reduced retrofit effort and vehicle downtime. The structured CSM process and comprehensive documentation ensured regulatory compliance and full technical traceability.

Through a structured engineering approach and comprehensive documentation, PROSE ensured regulatory compliance, tech-nical traceability and a reliable basis for long-term fleet opera-tion. Our independence from original equipment manufacturers enabled a pragmatic, lifecycle-oriented solution focused on availability and maintainability. A successfully validated prototype forms the basis for the fleet roll-out currently being prepared.

 

      

TILO FLIRT train of SBB in Switzerland during service life extension project, modern electric multiple unit on track.

Vehicle life extension TILO FLIRT

Customer: SBB, Switzerland

Project tasks

  • Overall project management of the TILO FLIRT service life extension
  • Project reporting to the steering committee
  • Project planning and realisation of the detailed concept phase
  • Funding application ARPV
  • Project planning and implementation of the realisation phase
  • Leading the SBB project team

Our approach

Swiss Federal Railways (SBB) operates 54 Flirt trains with TILO. These trains were purchased in five phases between 2007 and 2020 and were designed for a service life of 25 years. In order to be able to replace all TILO Flirt trains simultaneously as part of a new procurement project, SBB plans to extend the service life of the two oldest sub-fleets to 32 years.

PROSE is responsible for the overall management of the project to extend the service life of the TILO train fleet. Over 2 ½ years, we led a dedicated project team within SBB, ensuring seamless collaboration between customer requirements, technology, development, production, quality, and supply chain management.

A key milestone was the detailed concept phase, where PROSE’s structured approach ensured that requirements management, technical concept development, and prototype conversion were all completed on time and within budget. Our expertise in certification played a crucial role in securing the necessary licences for both Switzerland and Italy, a fundamental step in keeping the project on track.
PROSE also spearheaded the successful funding application (ARPV) to the responsible cantons and the Federal Office of Transport (FOT), securing approval to finance the conversion of the entire fleet of 30 trains.

During the production phase, we worked closely with the SBB production plant to ensure a smooth transition to series conversion. With production successfully underway, PROSE carefully handed over the project to SBB, ensuring continued progress and a reliable future for the TILO fleet.

Customer benefit

With PROSE as a partner, the customer benefits from comprehensive expertise in the areas of project management, stakeholder management, project planning, change management and cost control. An entrepreneurial approach, sound technical knowledge, but also knowledge of SBB processes and organisation are essential for successful project implementation.

Beyond technical know-how, our understanding of SBB’s processes and organisation was a key factor in keeping the project on track. By working with PROSE, the customer was able to bridge resource gaps, tap into our extensive railway industry network, and benefit from independent, expert advice that led to a successful project outcome.

 

    

BDe 576 railcar retrofitted with an energy measurement system for Makies AG in Switzerland.

Engineering and integrating an energy measurement system

Customer: Makies AG, Switzerland

Project tasks

  • Program management
  • Project planning
  • Electrical engineering
  • Mechanical engineering
  • Technical documentation

Our approach

Makies AG wanted to retrofit the BDe 576 railcar with an energy measurement system. PROSE, together with our workshop partner, carried out this trial installation. PROSE was responsible for the electrical dimensioning, product selection and the final conversion documentation. The workshop partner was responsible for product procurement, installation of the Energy measurement system (EMS) components, wiring and commissioning.

We developed a structured the template for the installation instructions and completed it with all product selection-relevant data for the current and voltage converter, Ecomodul, fuse protection and router. Product selection was defined based on the infrastructure requirements and existing onboard installations, incorporating experience gained from comparable system installation and operation. The final installation documentation includes the complete installation instructions and the product list.

Customer benefit

By commissioning PROSE, the customer benefits from our extensive experience in rail vehicle integration engineering. The proposed mechanical and electrical solutions supported a robust and sustainable energy measurement system installation. Our neutral advisory role ensured effective coordination between all project participants, particularly the workshop, reducing interface risks and supporting efficient implementation.

 

  

Assessing locomotive compatibility on an SJ Rc6 electric locomotive in Sweden, showing roof-mounted pantographs and high-voltage equipment at a station platform.

Assessing locomotive compatibility under increased overhead line voltage

Customer: SJ AB, Sweden
End customer: Trafikverket, Sweden

Project tasks

  • Technical investigation
  • Documentation research
  • Identification of possible changes in locomotive high-voltage circuits
  • Cost estimation of the changes
  • Integration of the changes in the actual system

Our approach

PROSE began with a structured review of the Rc6 high-voltage system, analysing design documentation, component specifications, and historical modification records to establish the vehicle’s current technical baseline. Based on this analysis, we evaluated the impact of the increased maximum voltage on insulation coordination, component voltage margins, and protection systems. Where necessary, we developed alternative technical solutions to ensure compliance with the new operating conditions. Each option was assessed from both a technical and economic perspective, including feasibility, implementation effort, operational implications, and associated risks. The work was carried out in close dialogue with SJ as operator and Trafikverket as infrastructure owner to ensure transparency and alignment throughout the project.

Customer benefit

The customer gained a transparent and technically sound decision basis for operating the Rc6 fleet under increased overhead line voltage. Our independent assessment clarified voltage margins, component limitations, and protection requirements, creating full visibility of technical risks and modification needs.
By systematically comparing refurbishment scenarios, including cost and implementation implications, we enabled SJ and Trafikverket to prioritise measures based on safety, operational reliability, and long-term investment protection. With PROSE’s in-depth knowledge of Swedish rolling stock and infrastructure interfaces, the operators secured a technically robust and future-proof solution aligned with updated network standards.

 

Open door of a C20 metro driver cab in Sweden, illustrating onboard modifications and the need for verified electrical documentation.

Documenting a reconstructed electrical design for a metro driver cab air conditioning system

Customer: MTR Tech AB, Sweden

Project tasks

  • Collection of as-built electrical information from customer
  • Technical review and consolidation of handwritten updates
  • Reconstruction of electrical schematics
  • Verification of correctness and consistency
  • Formal release of approved drawings

Our approach

The project addressed the absence of controlled and verified electrical documentation following the installation of a new air-conditioning unit in the driver cab of a C20 metro vehicle operating in Sweden. The modification had been implemented by the customer, with electrical schematics updated manually, resulting in missing traceability, inconsistent information, and non-compliance with railway documentation standards. The objective was to reconstruct the as-built installation, verify the electrical design, and formally document and release correct, complete and compliant electrical drawings.

PROSE collected and reviewed all available technical input from the customer, including as-built installation details and handwritten updates to existing schematics. Based on this information, we analysed, consolidated, and reconstructed the electrical design and documented it into formal electrical schematics in accordance with applicable railway documentation standards. The resulting drawings were verified and issued under PROSE authorship, in close coordination with the customer’s engineers, ensuring accuracy, traceability, and controlled release. PROSE’s independence and deep understanding of railway electrical systems enabled efficient reconstruction even with incomplete and informal source material.

Customer benefit

By selecting PROSE, the customer obtained verified and formally released electrical documentation that accurately reflects the as-built installation. This restored full traceability, ensured compliance with railway documentation standards, and created a reliable basis for safe operation, maintenance, and future modifications. PROSE’s independent engineering approach and experience in reconstructing and validating modified or legacy designs reduced project risk and relieved pressure on the customer’s internal engineering resources.

 

   

Preparing and migrating technical documentation into the PRO(doc) documentation system

Customer: Transdev, Germany

Project tasks

  • Project management
  • Software management
  • Structure of the document management system
  • Uploading documentation to PRO(doc)
  • Training

Our approach

Transdev Hannover GmbH took over 13 Bombardier ET425.5 electric multiple units that were in service on the Hanover S-Bahn between 2008 and 2022. With the fleet takeover, the operator received the complete manufacturer documentation, including operating manuals, maintenance manuals and maintenance instructions.

PROSE was commissioned to adapt and consolidate the existing documentation and to merge manuals, instructions and guidelines into a unified documentation basis. An important part of the project was to prepare the documentation for integration into the XML-based PRO(doc) system to ensure structured data,
standardised content and controlled version management.

The work also included training Transdev employees in uploading, editing and maintaining documentation in PRO(doc). The project was based on close collaboration between PROSE Sweden and PROSE Germany in order to combine expertise in documentation management with operational vehicle knowledge.

PRO(doc) was used as the technical documentation environment, specifically tailored to train maintenance. We combined expertise from PROSE Sweden and PROSE Germany, covering project management, MadCap Flare, document management, stylesheets, rules, XML structuring, and problem solving.

All available material was imported into the editing environment. PDF documents were converted to Word and harmonised in terms of styles, metadata, and layout. The document structure and design were developed in MadCap Flare, where the content was organised into a consistent product-based hierarchy and a maintainable table of contents.

Azure DevOps was used solely for source code management and version control to enable parallel work. A document list, created and maintained in Excel in line with the standard’s product-based structure, served as a working document and checklist throughout the project. Continuous technical support and transparent communication ensured efficient collaboration and traceability of decisions.

Customer benefit

Transdev now works with a standardised and well-structured documentation set that supports efficient maintenance and daily operations. The PRO(doc) documentation system, developed by PROSE, provides a searchable database with controlled version management, ensuring reliable access to approved content and updates.

The consolidated and migrated documents are published in a unified structure that simplifies future revisions. PRO(doc)’s responsive design enables use on any device, while document creation and updates are managed in MadCap Flare and exported to PRO(doc). With the training provided, Transdev can manage its documentation independently, supported by PROSE’s independent and specialised expertise when required.

 

         

Visualisation of SBB’s future long-track maintenance hall in Ticino, Switzerland, showing both a realistic rendering of the exterior with mountainous background and a technical 3D layout of the facility design.

Production concept and plant layout for a new maintenance workshop

Customer: SBB, Switzerland

Project tasks

  • Project management
  • Requirements analysis
  • Concept development
  • Client support

Our approach

SBB plans to build a state-of-the-art maintenance workshop for its vehicle fleets at the new NSIF industrial plant in the canton of Ticino. The long-track hall plays a central role: it is primarily intended for operational maintenance and the commissioning of vehicles after overhauls. The hall will be specially designed to meet the requirements of the latest SBB fleets and must therefore meet the highest standards of flexibility, efficiency and technical equipment. In addition to the infrastructure, the planning also includes operating resources, processes and interfaces to logistics and component reconditioning.

PROSE supported SBB with an experienced team of specialists in the design and planning of the long-track hall. The project approach was based on a thorough analysis of the vehicle fleets to be maintained and the existing operating processes. From this, we developed a production concept that combines proven methods with innovative technologies. The focus was on optimising processes, designing the plant layout, selecting suitable tools, media connections and operating resources, and integrating an automated logistics concept into production. In addition, safety standards and possible automation solutions were also examined. To support the client, PROSE also assisted SBB with the verification of plant plans, the development of internal decision-making bases, and workshops on plant layout with internal and external partners.

Customer benefit

SBB benefits from a robust, future-proof production concept tailored to the specific requirements of the long-track hall and takes production interests into account. Media connections, tools, and operating resources are defined with clarity and precision, enabling direct implementation during construction The optimised infrastructure enables efficient and safe maintenance of modern vehicle fleets.

By combining technical, operational, and workshop-level expertise, we ensured high acceptance among stakeholders and delivered a highly practical concept. As an independent engineering partner, PROSE provides objective guidance and a comprehensive view across processes, interfaces, and operational requirements.

 

 

Blue and white Västtrafik tram on route 3 to Kålltorp travelling through a historic city street in Gothenburg, Sweden.

Reverse engineering of new gears and housing for trams

Customer: Västtrafik AB, Sweden

Project tasks

  • Measuring of the gearbox housing
  • 3D modelling and technical drawings
  • Material definition
  • Definition of applicable standards
  • Risk assessment
  • Criteria for quality control

Our approach

PROSE applied a hybrid reverse-engineering method that combined mobile 3D scanning, mesh processing, and feature-based CAD modelling to reconstruct the gear housing. In parallel, we coordinated with the third-party supplier Zoerkler to perform precision gear measurement, material analysis, and hardness verification.
All interfaces, tolerances, and functional surfaces were systematically cross-checked against the physical components and validated through a structured CSM-RA risk assessment.
Based on these inputs, PROSE established updated 3D/2D documentation and a technical specification defining material, heat treatment, tolerances and surface-finish requirements in accordance with railway safety and documentation standards.

Customer benefit

The long-term availability of spare parts is ensured through updated and complete technical documentation that enables reliable future manufacturing of spare parts. This significantly reduces the risk of obsolescence for the parts involved.
Thanks to PROSE’s hybrid reverse-engineering approach, combining mobile 3D scanning, mesh processing, and feature-based Computer-Aided Design (CAD) modelling, the technical documentation was delivered in a time-efficient manner. At the same time, we ensured an uncompromised level of safety and quality compared with the current gearbox parts.
Throughout the project, PROSE maintained continuous dialogue with all involved actors to achieve solutions that meet the customer’s needs, supported by our independent position and broad engineering expertise.

 

Bid management for regional train maintenance contracts

Customer: EuroMaint Sweden

Project tasks

  • Bid coordination
  • Development of maintenance strategy
  • Depot and resource planning
  • Technical documentation
  • Obsolescence and component lifecycle analysis
  • Cross-functional team leadership

Our approach

PROSE acted as Bid Leader, and coordinated a cross-functional team consisting of engineering, procurement, and production experts. The team jointly developed technical and operational documentation, including maintenance plans, depot strategies, and component handling procedures. The work was carried out in close collaboration with stakeholders to ensure alignment with operational needs and regulatory requirements. The documentation was structured to support both strategic decision-making and practical implementation within the bid.

Customer benefit

By selecting PROSE as a partner, the customer gained access to structured and well-documented maintenance solutions tailored to the specific fleet and operational context. The collaborative approach ensured that procurement and production perspectives were integrated early in the process, reducing risk and improving feasibility. The final documentation supported the customer’s ability to submit competitive and technically sound bids, with clear strategies for lifecycle cost control and fleet availability.
The customer also benefited from PROSE’s independent expertise, broad rolling stock knowledge, and ability to deliver practical and implementation-ready material.

 

Blue and red trains at a snowy outdoor station platform at night, illustrating rail coupler upgrade and electrical interface integration for snowblower wagon type B257

Coupler upgrade and electrical interface integration

Customer: MTR Tech AB, Sweden

Project tasks

  • Requirements capture and definition of electrical interface
  • Design review
  • Update of technical documentation
  • Verification of electrical connections and signal integrity
  • Official drawing release and configuration control
  • Coordination with MTR during implementation and validation

Our approach

PROSE contributed to the design definition of the new electrical interface and collaborated closely with MTR engineers during system implementation of the upgraded coupling system be-tween the Snowblower Wagon Type B257 and the C20 train.
While MTR carried out on-site installation and testing, we re-viewed, clarified, and consolidated the draft electrical updates and ensured that all connections and signal interfaces complied with safety and operational requirements.
The verified and approved information was issued as official electrical drawings, released under PROSE authorship and re-viewed by MTR engineers.
This cooperative approach ensured full traceability, correctness, and compliance with railway documentation standards.

Customer benefit

​The customer gained a reliable and standardised coupling solution that reduced manual work in demanding winter conditions. The upgraded interface improved operational efficiency by ensuring full mechanical and electrical com-patibility between the snowblower wagon and the C20 fleet. Independent engineering review by PROSE ensured high quality and compliant documentation, providing confi-dence in the safety and integrity of the system. The result is a future-ready solution that supports safe, efficient, and well-documented winter operations.

 

 

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