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Assembly of a red funicular carriage with new air suspension chassis during the modernisation of an alpine funicular railway, accompanied by PROSE.

Chassis development funicular railway

Customer: Steurer Seilbahnen AG, Switzerland

Project tasks

  • Project management
  • Weight management
  • Feasibility study
  • Concept development
  • Verification concept and load assumptions
  • Strength calculation
  • Manufacturing support

Our approach

As part of the modernisation of the funicular railway from Unterwasser to Iltios in the Toggenburg region, Steurer Seilbahnen AG selected PROSE as its partner for the development of a custom running gear with air suspension – specially designed for funicular railway applications.

Steurer Seilbahnen AG has designed an innovative concept for a funicular railway chassis with air suspension and one-sided longitudinal force transmission. Building on this foundation, PROSE worked with Steurer to develop detailed requirements specification and carried out a concept validation. The constructive realisation was carried out at Steurer with technical support and coordination from PROSE. Our team handled the full structural design and strength verification, including equalisation safety. We also defined the measuring point plan for the test runs and delivered a comprehensive comparison report to support strength validation. To ensure an optimal solution, close cooperation between all parties involved was key during the iterations between design and strength.

Customer benefit

The combination of Steurer’s and PROSE’s expertise in funicular railways and air suspension resulted in a constructive and efficient co-operation that always kept an eye on all aspects, right through to verification. PROSE’s flexibility and proactive project management – together with Steurer’s practical insight – enabled design optimisations to be seamlessly integrated during procurement and manufacturing. This close cooperation ensured a technically sound, thoroughly verified solution tailored to the specific needs of funicular railways.

 

        

High-speed rail track symbolising strategic procurement and commercial project management for international rolling stock programmes by PROSE.

Strategic commercial project management for the procurement of high-speed rail vehicles

Project tasks

  • Strategic support in the procurement process
  • Project planning and management (deliverables, deadlines, costs, quality, risks)
  • Preparation and implementation of pre-qualification for lessors
  • Commercial support for operational leases, contract drafting and LCC assessment

Our approach

The project aimed to ensure that a major European railway operator was well and strategically prepared for an upcoming procurement process for new international high-speed rolling stock. The key challenge was to clarify complex commercial, contractual and strategic requirements at an early stage, to structure them and to coordinate them with each other. This particularly concerned the operating lease model, life cycle costs, contract structures and the prequalification of suitable lessors. Without this targeted preparation, significant risks related to cost, quality, and schedule, as well as limited and ineffective market engagement, would have been likely. The project therefore focused on creating a solid commercial and strategic foundation for a complex international procurement procedure.

PROSE approached the task strategically, systematically and methodically, first analysing and clearly defining the commercial, contractual and time-related requirements of the procurement project. Based on our expertise in international procurement projects and rolling stock leasing models, PROSE developed a clear and practical methodology to prepare the customer for the tender process. We established a transparent project structure and consistently managed deliverables, costs, quality, and risks. In parallel, PROSE supported the pre-qualification of potential lessors and established the basis for well-founded commercial decision-making. Our advisory services also covered the development of robust and market-aligned contractual models. We worked closely with the customer as external commercial project managers on a mandate basis, focusing on solutions and open exchange in order to identify risks at an early stage and create a solid basis for decision-making.

Customer benefit

By working with PROSE, the customer received independent, manufacturer-neutral, and commercially focused support that brought structure, transparence and clarity to a complex procurement project. PROSE combined deep expertise in international procurement, leasing models, and life-cycle cost considerations. Our pragmatic and solution-oriented approach enabled the customer to identify risks early, well-founded commercial decisions, and prepare the pre-qualification process efficiently. As a result, the customer benefited from measurable relief of internal resources, clear decision-making foundations, and professional, structured preparation of the overall tender process.

 

   

Bogie development for a shunting locomotive

Customer: SCHÖMA Lokomotiven GmbH, Germany

Project tasks

  • Project management
  • Concept development
  • System analysis, System specification, System integration, system design
  • Construction of 3D model of bogie
  • Strength calculation according to EN 13749
  • Proof of driving safety and derailment safety according to EN 14363
  • Bolt calculation in accordance with VDI 2230
  • Design Reviews with peers

Technical data

  • Track gauge: 1435 mm
  • Speed: 80 km/h
  • Minimum track curve radius: 90 m
  • Distance between bogie pivots: 5.8 m
  • Centre distance: 2 m
  • Frame length: 11.8 m
  • Vehicle mass: 60 t
  • Bogie mass less than: 8.8 t
  • Mass of the car body (m1) approx.: 40.4 – 43.4 tons
  • Maximum vehicle mass: 61 t
  • Minimum vehicle mass: 58 t
  • Maximum wheelset load: 15.25 t

Our approach

The project is part of a shunting locomotive platform programme in which SCHÖMA supplied a shunting locomotive to Alstom for a transport authority in Manila, Philippines. The vehicle is a four-axle, diesel-hydraulically driven shunting locomotive for standard gauge with a total vehicle mass of 60 tonnes. PROSE was commissioned to carry out the complete mechanical development of the bogie.

The scope included the design and engineering of the bogie frame, wheelsets, axle boxes, and the integration of all relevant systems and components. A key technical focus was the limited available installation space and, the safe transmission of longitudinal traction and braking forces from the bogie to the carbody, without significantly altering wheelset loads. The project therefore required a robust, space-efficient, and safety-compliant bogie design suitable for effective production and reliable operation.

At PROSE, rail vehicle development follows the V-model in accordance with EN 50126. For this project, the bogie development was focused on the concept design and final design phases, ensuring an efficient and targeted engineering process. Throughout the development, PROSE placed particular emphasis on a production-oriented design approach, using cost-effective and manufacturing-friendly welded structures wherever possible.

In parallel, the design was optimised regarding both production and life-cycle costs, while consistently meeting safety and performance requirements. Compliance with all relevant safety-related EN standards was embedded in the design process. PROSE’s extensive experience in bogie engineering and our deep understanding of standards and manufacturing constraints enabled a balanced and efficient development approach tailored to the customer’s needs.

Customer benefit

Thanks to the timely and successful completion of the project, the customer received rapid and reliable engineering support within a short timeframe. By selecting PROSE, the customer benefited from in-depth expertise in bogie development, significantly reducing internal effort and development time. PROSE delivered a complete, production-ready bogie design, including a full 3D model, proof of strength, track guidance analysis, and detailed component specifications to support procurement.

All relevant systems, including primary and secondary suspension dampers, gearbox, brake system, and longitudinal and transverse stops, were successfully integrated. The critical challenge of transmitting longitudinal forces without increasing wheelset loads was solved through a cranked pull/push rod with a deep linkage connected to a balancer, resulting in low pitching moments and stable wheelset behaviour. Although no specific standards were required by the end customer, PROSE provided comprehensive and standard-compliant proofs of strength and derailment safety, demonstrating conformity with relevant standards such as EN 13749:2024, EN 13979, DVS 1612 and EN 14363:2016.

 

 

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.

 

Railway axle handling equipment with a workshop fixture and CAD model of the axle lift and support console

Design and delivery of an axle lift and support console

Customer: Göteborgs Spårvägar, Sweden

Project tasks

  • Requirement capture
  • Engineering design
  • Manufacturing and logistics
  • Delivery within time, budget and quality
  • Training
  • Verification

Our approach

Our engineering team worked closely with the customer to define the functional and safety requirements for the axle lift and support console. Based on these inputs, we created the original design delivered three years ago, providing a stable and safe solution for axle handling.  For the repeat order, we coordinated the detailed design updates and worked with one of our trusted manufacturing partners to produce the second unit. This follow-up delivery allowed us to refine the proven concept with targeted improvements informed by the customer’s operational experience.

Throughout the project, we ensured clear communication, organised the necessary verification steps, and provided training to support safe and consistent use in the workshop.

Customer benefit

​The customer receives a fixture that supports safer and more controlled axle handling in the workshop. The design reduces the risk of axle movement and helps protect personnel and equipment during maintenance activities.
By working with PROSE, the customer benefits from a partner capable of managing the full chain from requirement capture to design, manufacturing coordination, verification, and training. Our independent engineering approach and familiarity with workshop processes ensure that the delivered solution is practical, reliable, and straightforward to integrate.
The decision to procure a second unit confirms that the original solution met the customer’s expectations and that the updated version continues to support their operational needs.

 

 

Mounted bogie swivel arm assembly with rollers and fastened components during workshop installation.

Training for the assembly of bogie components

Customer: Alstom Schweiz AG, Switzerland

Project tasks

  • Training
  • Technical documentation
  • Organisation of the training

Our approach

PROSE supplied Alstom Switzerland with the swivel arm units for the GoldenPass Express bogie and created the assembly and maintenance instructions. Now, both Alstom and the end customer sought PROSE’s expertise to provide comprehensive training in assembly and testing.

PROSE carried out a multiple-day training course at the customer’s site, using the existing installation, maintenance, and work instructions as a foundation. The participating personnel were instructed step by step on how to perform the tasks independently. Our training covered the entire process, from preparation to mechanical, pneumatic and electrical assembly, as well as component testing and the creation of test protocols.

Customer benefit

As PROSE had already been responsible for and accompanied the assembly of the entire series, the customer was able to benefit from our extensive expertise and take over the assembly activities independently within a very short time.

 

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.

 

 

Virtual representation of a train maintenance hall with roof structure, trains on parallel tracks and a yellow crane arm positioned above the vehicle for maintenance work.

Concept development for maintaining a new fleet in a historic depot

Customer: SBB, Switzerland

Project tasks

  • Project management
  • Requirements analysis
  • VR simulation & validation
  • Concept development

Our approach

New vehicle fleets are to be introduced at the service facility in Lucerne, which will require additional roof access, in particular through the use of a crane. At the same time, there is a need for extensive renovation and replacement measures within the depot and its surroundings. Planning these structural modifications is challenging due to monument protection, limited space and ongoing operations.

PROSE analysed the maintenance requirements of the new vehicle fleets in a structured process and developed several infrastructure options. Each variant was systematically developed, evaluated and documented to support transparent decision-making. Acting as interim project manager, PROSE coordinated specialist planners and internal experts and carried out the detailed elaboration of the variants to ensure consistent progress across all areas. We also supported coordination with monument protection authorities and used virtual reality (VR) technology to simulate, test and validate the proposed solutions under realistic conditions.

Customer benefit

Through comprehensive support during the study phase and our expertise in maintenance planning, PROSE created a transparent and objective basis for all further decisions. The customer gained a clear overview of the planning status of all trades as well as coordinated cost and schedule plans. This enabled a smooth handover to the next project phase. The use of virtual reality (VR) technology supported the evaluation and optimisation of the infrastructure variants and helped to identify an optimal solution that met both operational and heritage conservation requirements.

 

   

Integration and Authorisation Management: Polish Train Radio, Radio Stop Module, Interior and Exterior Foliation

Customer: ODIG – Ostdeutsche Instandhaltungsgesellschaft mbH, Germany

Project tasks

  • Integration engineering of the Polish train radio
  • Integration engineering of the radio stop module
  • Adaptation of the MESA23 system
  • Consideration of the interior and exterior foliation as well as the modification of the train radio system within the verification process
  • Homologation management
  • Authority communication

Our approach

ODEG – Ostdeutsche Eisenbahn GmbH operates passenger transport services in northern and eastern Germany. The fleet consists of Desiro Classic (BR 642) multiple units, among others, manufactured by Siemens Mobility (SMO). The maintenance and repair of the vehicles is carried out by ODIG – Ostdeutsche Instandhaltungsgesellschaft mbH. This is a 100% subsidiary of ODEG. The vehicles currently operate with the existing German authorisation and a German train radio system on a section of line that runs over Polish territory. In future, the vehicles will have to be equipped with Polish train radio system and a radio stop module (RSM). The RSM is a device that is connected to the existing train radio system and integrated into the vehicle’s safety loop via an electromagnetic valve. In this way, the responsible dispatcher can give the “radio stop” command, which opens the vehicle’s safety loop and brings the vehicle to a standstill. In addition, interior foliation in the WC and full-surface exterior foliation had to be installed.

The functionality of the existing MESA23 system will be expanded to include operation with Polish train radio and the radio stop module (RSM). The foliations are handled with regard to all requirements.

Customer benefit

Thanks to the cooperation with PROSE, the customer was able to successfully convert the Desiro Classic railcars (BR 642) to use Polish train radio and the radio stop module (FSM). This not only offers ODEG passengers increased safety during the journey, but also enables smooth operation on the section of line through Polish territory. The application of the interior and exterior foils also contributes to the attractive appearance of the vehicles.

PROSE managed the project from the initial idea to the authorization strategy, preparation of evidence documents and coordination with NoBo/DeBo/AsBo through to communication with the authorities, so that ODIG was able to obtain a significant part of the project scope from a single source.

 

    

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