Skip to main content

Design and authorisation strategy for a rail-bound maintenance machine

Customer: SCHÖMA, Germany

Project tasks

  • Vehicle authorisation strategy
  • Design assurance (Systems Engineering)
  • Concept development
  • Technical evaluation of offers and technical coordination with suppliers
  • Project management

Our approach

SCHÖMA plans to develop a proven, powered, three-part rail-bound maintenance machine with cab, loading platform and crane called HERO. SCHÖMA needs support in developing the authorisation strategy to fulfil the EN 14033 standards and in defining the design process including verification and validation.

PROSE developed the decision-making basis for the authorisation process enabling a defined combination of the three vehicles of the working machine to be approved and the verifications and evidence according to EN 14033 to be provided. PROSE also supported SCHÖMA in the budget planning phase of the development of the HERO work machine in the evaluation of supplier offers for systems and components such as the power train, braking system, power generation, train protection (ETCS) and heating, ventilation and air conditioning (HVAC). In addition, PROSE defined the design phases and the design assurance process according to the systems engineering methodology to ensure a defined and structured design process.

Customer benefit

PROSE has structured and optimised SCHÖMA’s development process by systematically applying the system engineering methodology. This approach has not only minimised development risks associated with costs and timelines but has crucially enhanced the predictability and likelihood of obtaining the necessary authorisation.

 

          

Digitalisation of maintenance requirements

Customer: SBB Historic, Switzerland

Project tasks

  • Research: Review and analysis of the existing documentation (e.g., old regulations)
  • Expert Interviews: Enrichment of the database with know-how from specialists
  • Documentation: Creation of maintenance plans for the 14 rail vehicles and 3-4 wagon fleets
  • Approval: Incorporation of client feedback and final adjustments

Framework conditions:

  • Utilisation of old regulations as the basis
  • Supplementation through reverse engineering and other methods to address data gaps
  • Collaboration with the client, particularly in providing knowledge and feedback

Our approach

The project was initiated by SBB Historic to gradually align the existing maintenance organisation and fleet management with European standards. The core challenge lies in transforming a fragmented documentation base. Many of the historic vehicles have only partially available operational and maintenance manuals, as the original manufacturers either no longer exist or the documentation has been lost over time.

Additionally, the introduction of the ZEDAS maintenance software is intended to support and future-proof the maintenance processes. The project aims to create a consistent and standard-compliant maintenance plan landscape for the historic rail vehicles, enabling efficient, safe, and resource-conscious maintenance. At the same time, the transition will ensure compliance with European norms and facilitate maintenance activities carried out by in-house teams, associations, and third parties.

To achieve these objectives, PROSE adopts a structured approach comprising several interconnected work steps. The process begins with extensive research, focusing on reviewing and analysing old maintenance regulations to compile and prepare existing content. Subsequently, PROSE conducts expert interviews to incorporate historical knowledge from specialists, fill existing gaps, or update outdated guidelines. Based on this, maintenance plans are developed for the 14 rail vehicles and three to four wagon fleets. These plans are created iteratively, incorporating client feedback to ensure a tailored solution. Finally, the plans are integrated into the new maintenance concept and adapted to the requirements of the ZEDAS software.

The PROSE team, consisting of experienced experts, guarantees a professional and quality-orientated implementation. If necessary, the team is supported by other experts to ensure the quality and efficiency of the implementation.

Customer benefit

The project provides the client with numerous advantages that go beyond merely developing maintenance plans. By establishing a consistent, standards-compliant planning framework, the maintenance of historic vehicles can be carried out safely, efficiently, and cost-effectively. The integration of existing regulations and the supplementation of missing content through expert interviews not only reduces time and financial expenditure but also ensures that the plans are highly practical and relevant.

Another significant benefit lies in the introduction of the ZEDAS maintenance software, a key component for future digitalisation and optimisation of processes. The combination of technical and operational expertise provided by PROSE ensures that the plans are seamlessly integrated into the new software ecosystem, creating a high level of efficiency and transparency.

With transparent pricing and an agreed cost ceiling, the project remains financially predictable and manageable. At the same time, SBB Historic and the participating organisations benefit from PROSE’s extensive experience and proven competence. PROSE delivers tailored and sustainable solutions in the railway sector. The outcome is not only technically flawless but also an economically viable solution that guarantees the long-term safe operation of the historic fleet.

 

 

General Contract of Use for freight wagons (GCU) in Railway Undertakings (RU)

Customer: SBB Cargo, Switzerland

Project tasks

  • Analyse the current state, identify weaknesses and strengths, and document responsibilities and workflows
  • Develop a target model with clear responsibilities, efficient processes, and the use of new digital tools such as the GCU-Broker
  • Implement the new processes, including employee training and the establishment of overarching responsibility for GCU

Our Approach

The project to optimise the GCU (General Contract of Use for freight wagons) tasks within SBB Cargo’s RU (Railway Undertaking) role addressed the growing demands of European freight transport and the increasing expectations for legal and process compliance. The primary goal was to establish a clear and robust organisation of responsibilities within the RU role, meeting both the requirements of the GCU and relevant EU regulations. This realignment was achieved through a systematic review of existing processes and structures. Key challenges included the precise delineation of roles between the railway undertaking and the wagon keeper, as defined by the GCU provisions. In particular, the requirements arising from oversight by the Swiss Federal Office of Transport (FOT) necessitated reorganisation, as unclear responsibilities had previously hindered audit outcomes.

Additionally, action was required for key operational processes such as the re-commissioning of freight wagons after repairs, the verification of GCU-compliant wagons within train formations, and the retrieval of technical wagon data from third-party keepers. These areas are critical for ensuring safety and quality standards. At the same time, the entire scope of GCU tasks is subject to increasing regulation, which will be further intensified by the BAV (Federal Office of Transport in Switzerland) from 2026 onwards. To meet these demands, SBB Cargo’s internal processes must not only become more efficient but also legally sound.

The project was implemented in multiple phases. In the first phase, the current state of GCU tasks was documented, and key strengths and weaknesses were identified. This analysis was completed by May 2024. Building on this, by August 2024, a target process was developed that defines clear responsibilities, optimises existing workflows and incorporates digital solutions such as the GCU-Broker. This tool is intended to replace the manual processing of damage reports, thereby modernising data exchange. Starting in January 2025, the target process will be implemented, with a focus on appointing a central overall responsibility for GCU tasks, covering both strategic and operational duties. The project team included PROSE internal experts and external consultants from BAHNVERSTAND, who provided methodological support and strategic recommendations.

Customer benefit

​The implementation of the project delivers significant benefits for customers through more efficient and reliable handling of GCU tasks. Clear responsibilities and improved processes reduce delays and enhance legal certainty in operations. The integration of digital solutions, such as the GCU-Broker, lowers administrative costs and accelerates data exchange. Furthermore, compliance with new legal requirements, particularly EU and FOT regulations, ensures long-term legal security and minimises liability risks. Overall, the project strengthens SBB Cargo’s position in the European freight transport market and ensures sustainable future viability.

 

3rd party assessment of exterior camera installation

Customer: MTR Tech, Sweden

Project tasks

  • Assessment of proposed and installed solutions of camera installation
  • Highlighting risks and deviations from industry standards and recommendations

Our Approach

MTR has operated and maintained the X60 Coradia fleet on behalf of the Stockholm Region until 2024. The region has ordered installation of cameras from Alstom to support the drivers and improve visibility around the door-area, particularly on platforms with curved tracks.

PROSE has extensive experience in mechanical and electrical design as well as design processes, especially in adhesive bonding. Based on our expertise, an iterative assessment process has taken place to assess the proposed and installed solution. It includes recommendations in line with industry best practice for both mechanical design and bonding – as well as design and processes – in accordance with EN17460.

Customer benefit

​Adding additional equipment to an existing fleet without impacting the basic design requires experience and know-how about production methods and the original design. With PROSE as an independent assessor, the client received an independent assessment of the proposed and installed solution as well as the identification of potential short- and long-term risks in the proposed design of both the bonded joints and the mechanical parts.

 

      

Program Management ATO Sector Program

Customer: BLS Netz AG, Dr. Florian Kappler, Switzerland

Project tasks

  • Program Management
  • Project Planning
  • Coordination among all Swiss ATO projects
  • Leading the marketing team to develop and maintain the ATO website
  • Quarterly reporting to the steering board (railway undertakings, infrastructure managers and industry)
  • Coordination with stakeholders, such as the national authority BAV, as well as the industry
  • Supporting specific ATO projects with technical-, operational- and business advisory

Our Approach

In May 2022, the Federal Office of Transport called on the rail sector to align and better coordinate future ATO activities within the Swiss rail sector.

PROSE was commissioned to manage the programme for all Swiss ATO projects. In close cooperation with the ATO core team, PROSE established regular monthly exchanges and jointly identified and developed central cross-cutting topics.

In addition, PROSE also led the communication team and worked with this team to develop and maintain the ATO industry website (https://voev.ch/ato). Furthermore, PROSE initiated an ATO-related conference day that invited and actively involved the industry in ATO developments.

Customer benefit

With PROSE as a partner, the customer benefits from comprehensive expertise in the areas of on-board signalling, ETCS and ATO, both on the line and on the vehicle side. An entrepreneurial approach, in-depth technical knowledge and market knowledge are essential for a successful programme design in the first year.

The customer does not need to develop its own project-specific management resources, as PROSE, as an independent consultant, coordinates the related interests of all project managers.

 

   

Corrosion repair

Project tasks

  • Creating a CAD model of the carbody from a set of drawings
  • Creation of an FE model of the carbody
  • Strength assessment of the condition without corrosion
  • Consideration of corrosion damage in the calculation model
  • Analysis and determination of minimum wall thicknesses
  • Specification of measures for corrosion repair
  • Preparation of drawings to document the repair solution

Our Approach

Corrosion damage to the lower structure of the carbody was discovered during the planning of conversion measures on dining carriages. The wagons are welded steel constructions from 1990 and due to the advanced age of the vehicles, the operator did not have any CAD models or strength documents. PROSE was commissioned to assess the utilisation of the carbody in terms of strength. First in their original, corrosion-free state and then considering the identified corrosion damage. Additionally, we were asked to develop solutions to prolong the service life of the vehicles.

In a first step, a CAD model was created from the set of drawings. This model then served as the basis for creating the Finite Element (FE) model, which embodies the target condition of the carbody structure. A subsequent strength analysis then showed how many theoretical reserves the structure still had.

In the next step, the FE model was updated to include corroded areas, and the calculations were repeated. In this way, the effect of corrosion on the structural strength of the carbody could be determined and evaluated.

Using an iterative approach, a maximum corrosion depth could be determined for the damaged areas. For areas where it was foreseeable that the corrosion would penetrate too deeply, repair solutions were also developed, which included welding in new profiles, and their strength was verified.

Customer benefit

Thanks to PROSE’s work, the customer now has access to a CAD model of the carbody. The strength analysis has enabled the determination of minimum wall thicknesses for vehicle areas typically affected by corrosion, which the customer can use to evaluate the extent of corrosion damage. For areas where corrosion has penetrated too deeply, the customer now possesses localised repair solutions. This can significantly extend the service life of the vehicles.

 

          

Process for managing component reverse engineering

Customer: AB Transitio, Sweden

Project tasks

  • Develop a reverse engineering process
  • Ensure parts availability
  • Address business aspects

Our Approach

AB Transitio owns and leases out various EMU and DMU fleets in many regions of Sweden. For rolling stock owners, the lack of documentation and obsolescence, which can occur for different reasons, is a common challenge. Through this project, AB Transitio aims to establish a standardised process and methodology for managing specific cases of obsolescence using reverse engineering. The above-depicted process defines the general tasks, requirements, and responsibilities for handling reverse engineering cases, regardless of who operates and maintains a particular fleet.

PROSE has extensive experience in reverse engineering, safety management and vehicle acceptance procedures. Based on this expertise, we have developed a step-by-step process for the reverse engineering of parts, systems or components. This process ensures that all relevant standards and regulations are complied with. The result is a financially sound, maintainable and sustainable solution that ensures the vehicle can be maintained, repaired and overhauled throughout its life cycle.

Customer benefit

Reverse engineering plays a crucial role in fleet management and ensures sustainable, stable, and long-term maintenance of the fleet. By applying the methodology and process developed by PROSE, customers have access to parts and components that are available for maintenance, repair, or overhaul throughout the vehicle’s lifetime. This process also takes into account the commercial aspects of each case and ensures that the organisation carrying out the work has the necessary skills and expertise.

 

 

Vehicle Authorisation

Customer: various customers

Project tasks

  • Carrying out requirements capture and preparing the safety evaluation, including risk analysis
  • Preparation and management of evidence documents
  • Cooperation and coordination of NoBo, DeBo and AsBo
  • Support in preparing several declarations and dealing with online registers like ERATV or ERADIS
  • Management of the change notification to the ERA or national safety authorities like EBA for changes not requiring an authorisation
  • Management of authorisation applications via One Stop Shop to the ERA for changes requiring authorisation
  • Coordination with the ERA and national safety authority

Our Approach

Vehicle operators or leasing companies make changes to their vehicles for very different reasons, e.g. for obsolescence reasons or to offer passengers a better service by customising the interior and adding features such as sockets or WLAN. In addition to providing engineering services, PROSE supports such projects by taking over the entire approval management process, including communication with all the bodies and authorities involved.

The authorisation process ensures safe rail transport and the best possible interoperability throughout the EU. However, implementing changes to rolling stock presents a significant challenge to operators, keepers, and owners.

At PROSE, we recognise that each railway vehicle is unique. Our team of experts develops vehicle authorisation strategies that address the specific challenges of our customer’s products and needs. From Requirements Capture to One Stop Shop, our experts have the knowledge to guide you through the process. Whether you only need assistance with a single task or are looking for a complete solution, we can provide solutions to meet your particular requirements.

Customer benefit

Modernisations and retrofits guarantee enhanced reliability and superior passenger comfort and open up new applications by integrating new systems. Whilst operators and workshops can focus on their primary tasks, PROSE can handle all the “paperwork” from the engineering and the preparation of evidence documents to the assessment and authorisation phases with bodies and authorities involved. Due to our comprehensive service portfolio, we help reduce interfaces and effort because all services are coordinated and come from a single source.

PROSE ensures that our customers’ railway vehicles comply with the latest standards and regulations. From document preparation to submission, we make sure that vehicle approval hurdles don’t derail your success.

 

      

Authorisation Management – Change of Radio Devices

Customer: various costumers

Project tasks

  • Integration of the new radio device
  • Implementation of additional country-specific equipment for operation outside Germany
  • Requirements capture and safety evaluation
  • Preparation and structuring of evidence documentation
  • Management of the different bodies (NoBos, DeBos, AsBos)
  • Support with the several declarations to be issued
  • Support with ERADIS and ERATV
  • Management of the application at the involved authorities (ERA and NSAs

Our Approach

As Germany’s largest railway infrastructure company, DB InfraGO wants to switch off analogue train radio on many routes. This means that vehicle operators are obliged to retrofit their vehicles with GSM-R digital train radio if they do not yet have the appropriate equipment.

For the first time since the introduction of the 4th railway package, many vehicle operators have been faced with the task of carrying out vehicle modifications that require authorisation. Many small and medium-sized regional transport companies do not have the capacity to deal with the complex authorisation processes and are reliant on external support.

PROSE responds individually to vehicle operators’ needs and provides support throughout the entire chain, from the specification of the required radio equipment to the receipt of the new authorisation in precisely those areas where the vehicle operator has a need.

PROSE determines the individual project requirements for each customer enquiry. The customer’s preliminary work and the desired in-house services are taken into account, and clear interfaces are created so that the project realisation runs hand in hand. The flexibility to respond to short-term customer requests to increase or reduce the project scope is a matter of course for us.

Customer benefit

Due to the large number of projects in this area, we have very good contacts with several bodies and authorities, which enables uncomplicated coordination even before the project begins. In regional transport, where operators often belong to a group, PROSE provides strategic advice on the selection of the proposer, the entity managing the change and the workshops, taking into account several points to keep the overall project costs arising from assessments, audits etc. as low as possible and to be able to exploit synergies, e.g. in cases where different operators of the group operate the same vehicle serie. The operators can focus on their core business and do not even have to take part in the coordination rounds with the authorising entity and/or national safety authorities during the authority’s application assessment phase, as PROSE can do this for the operators on request using a power of attorney.

Authorisation Support – Repainting of ET425.5 EMUs

Customer: Transdev Hannover GmbH, Germany

Project tasks

  • Project management
  • Requirements capture
  • Authorisation support
  • Communication with NoBo and DeBo
  • Preparation of evidence and admission documents
  • Preparation of a change notification

Our Approach

Transdev Hannover GmbH changed the existing colour scheme of 13 EMUs of the type ET425.5 from the Deutsche Bahn “Verkehrsrot” to the Transdev branding in blue and white. PROSE supported with authorisation management concerning TSI LOC&PAS, TSI PRM and German NNTR as well as requirements capture and evidence documents. The main obstacle was to find a way to establish the evidence documents of the fire protection as no spare parts existed to conduct the necessary experiments.

Due to the great experience and good networking within the industry, it was possible to agree on a feasible way of proving fire protection with the assessment bodies as early as the tendering phase. In combination with the close support of the customer in every phase of the project, loops or lengthy discussions could be avoided.

Customer benefit

PROSE led Transdev Hannover through the authorisation process including communication with the assessment bodies and project management. This ultimately resulted in the timely submission of the documents and rapid final processing by the national safety authority (EBA) including the final “Go”.

 

 

Independent technical and operational assessment of ATO GoA2 implementation variants

Customer: Rhaetian Railway, Switzerland

Project tasks

  • Expert interviews
  • Technical and operational assessment
  • Independent evaluation of implementation variants

Our Approach

As part of the development of a technical specification for equipping an existing vehicle fleet with a driver assistance system (DAS) / ATO GoA2 (Automatic Train Operation, semi-automatic operation) , PROSE supported Rhaethian Bahn AG (RhB) with neutral expertise on technical implementation variants.

Specifically, the focus was on the interface and functionality to be implemented for the interface between the DAS and the vehicle control system, as well as the interaction of the locomotive crew with the DAS. In particular, the different implementation variants focused on the DAS activation and implementing the traction/braking force target values on the vehicle.

Based on the European specification analogue to SUBSET-125 and SUBSET-139, the adapted draft specifications, and internal implementation proposals, PROSE carried out a neutral evaluation of the variants using a two-stage methodology.

In the first step, selected RhB representatives from the areas of vehicle technology and locomotive personnel were interviewed. The purpose of the interview was to determine the significance of the individual evaluation criteria.

In the second step, the PROSE experts verified the fulfilment of the criteria for both variants based on the technical specifications and the expert interviews. In particular, the opportunities, risks, suitability for vehicle acceptance, migration capability, acceptance of the systems by the locomotive personnel, and an initial qualitative assessment from the HOF (Human-Organisational-Factors) perspective of the variants were compared and evaluated.

Customer benefit

RhB benefited from the neutral and independent assessment of the PROSE experts and the methodical approach involving the relevant internal representatives. PROSE’s expertise ensured fast and efficient processing and the necessary depth of detail.

 

  

ECM consulting & support

Customer: various customers

Project tasks

  • Kick-off workshop / training
  • Creating a mapping table
  • Gap analysisand elaboration of suggestions for improvement
  • Advice, suggestions, support on specific topics (as required)
  • Review of documents (e.g. process descriptions, procedural instructions, forms, etc.)
  • Suggestions for improvement

Our Approach

​The customer is supported in understanding and implementing the ECM requirements, whereby a gap analysis determines the maturity level of the maintenance organisation. Basic training on ECM topics can be offered in advance. In the trial audit, documents are checked, weaknesses are identified, and assistance is provided to rectify them. The certification audit starts with a Stage I audit, after which PROSE offers support in implementing the auditor’s comments. PROSE can also inspect the customer’s workshop and identify potential weaknesses before the audit.

Customer benefit

The customer is accompanied on the path to successful certification of ECM functions in accordance with Regulation (EU) 2019/779. The organisation’s existing knowledge on these topics is brought up to date. The organisation is enabled to meet the requirements and pass the audit with the certification body.

Moreover, support in the daily ECM challenges regarding:

  • Risk management according to CSM-RA
  • Competence management
  • Documentation process
  • Supplier management
  • Audit plan
  • Definition of Safety Critical Components according to Article 4
  • Interface definition and information flow between the functions
  • Independent delta assessment in order to improve the internal procedures and processes

Why support by PROSE? For saving time and money by becoming more efficient and due to lack of know-how.

 

      

info@prose.one

 

Our solutions

 

© PROSE. All rights reserved
Disclaimer    Privacy Policy