Skip to main content

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.

 

    

Project management and remote monitoring for a Proof of Concept SS-149

Customer: SBB, Switzerland

Project tasks

  • Project Management
  • Project Planning
  • Solution Architecture
  • Requirements Engineering
  • Sourcing
  • Supervision of the supplier’s Installation, Integration, and Commissioning
  • Data analysis and Reporting

Our approach

​Switzerland, as one of the first ETCS-only countries, required all active fleets to monitor malfunctioning Eurobalises, as per a national requirement (NNTR). With the TSI-2023 release, this NNTR had to be transferred and further developed into Subset–149, Online Monitoring System.

In December 2022, when the draft specification of the Subset–149, Online Monitoring System became available, PROSE was appointed by the rail infrastructure manager of Swiss Federal Railway to develop and conduct a Proof of Concept. The goal was to evaluate the suitability and completeness of the proposed protocol.

PROSE developed the system architecture and related requirements for an online monitoring of the MVB bus in the ETCS Onboard Unit (OBU) manufactured by Siemens and installed in a new Stadler FLIRT EMU owned and operated by Schweizerische Südostbahn. Railnova was identified as a suitable supplier and provided the related solution, both onboard (sniffer and gateway), and wayside. PROSE performed integration engineering as well as authorisation support.

Once the solution was in operation, PROSE closely monitored the wayside infrastructure and analysed the data and feedback to correct and improve the DRAFT Subset-149, contributing directly to its current maturity and reliability.

Customer benefit

With the assignment of PROSE, the customer benefits from the extensive experience of PROSE in the field of on-board signalling, ETCS and online monitoring, both wayside and onboard. PROSE’s combination of technical insight, hands-on experience, and understanding of the market landscape contributed to a solution that was both robust and fit-for-purpose. The customer could rely on PROSE to manage the project without needing to build up internal resources. In addition our independent advisory role ensured a neutral perspective, while maintaining alignment between the various stakeholders involved in the project.

 

  

Auxiliary bogie development for trams in workshop

Customer: Würzburger Straßenbahn GmbH, Germany

Project tasks

  • Auxiliary bogie development
  • 3D model (3D geometries for individual parts are part of the 3D model)
  • Combined welded assembly and machining drawings
  • Assembly drawing
  • Strength calculation results
  • Track guidance report

Our approach

PROSE has developed a workshop-compatible auxiliary bogie for temporarily relocating low-floor vehicles during maintenance work. The design is deliberately kept simple and allows the vehicles to be picked up without twisting. The aim was to create a solution that is functional, robust and at the same time designed in such a way that it can be manufactured and used independently by the operator. PROSE was responsible for the complete design – from the concept to the production-ready documents.

PROSE has a close relationship with Würzburger Straßenbahn GmbH (WSB), which has developed over the last few years through various successful co-operations. We were able to start designing the bogie quickly thanks to our familiarity with the technical requirements of the WSB fleet.

Our approach was to quickly determine the wheel diameter and by confirming the chosen parameters with the customer. This allowed us to move directly into engineering with a clear, shared understanding.

Throughout the 3.5-month design phase, we kept the process lean and efficient. Monthly status updates ensured the customer remained well-informed without requiring intensive involvement. Thanks to PROSE’s broad technical expertise, unnecessary iterations were avoided, contributing to a timely project delivery.

Customer benefit

Thanks to our close collaboration with the customer and our deep technical understanding, we were able to start development particularly quickly. The customer benefited from our in-depth expertise and understanding and was able to save a lot of time and effort. The solution was tailored precisely to the requirements of the workshop. The complete production-ready documentation, including 3D model, proof of strength and track guidance report, ensured rapid realisation. Thanks to our comprehensive and in-depth knowledge of industry standards, the conditions in the WSB workshop and close collaboration with the customer, we were able to anticipate challenges before they arose.

 

 

Operating load measurement and assessment of fracture mechanics

Customer: RAlpin AG, Switzerland

Project tasks

  • Operating load measurement
  • Wheelset shaft calculation
  • FE calculation
  • Fracture mechanics assessment

Our approach

The customer required two fracture mechanics analyses. On the one hand, the aim was to investigate what causes cracks to form on the back of the wheel flange and which factors contribute to crack growth. On the other hand, there was a need to provide a mathematical basis for the specified inspection interval for the wheelset shafts. Real operating load data should be used as the basis for the fracture mechanics investigations of PROSE.

PROSE carried out an unaccompanied measurement to record the operating loads on the routes travelled. For this purpose, a measuring system was installed directly on a bogie frame. This recorded the position of the vehicle combination over several days using an associated GPS antenna as well as the lateral and vertical acceleration and the rotational speed of the bogie using appropriate sensors. The measurement signals were continuously sent to a central storage unit via the mobile phone network. The real operating loads measured in this way formed the basis for the subsequent fracture mechanics tests.

The wheel disc cracks were investigated using two wheel types used by the customer. The load on these wheel types was simulated using MBS simulation based on the real load data.

To assess the fracture mechanics of the wheelset shafts, a wheelset shaft calculation according to EN13103-1 was carried out in a first step for orientation and to assess the general utilisation of the wheelset shaft. In a second step, cyclic crack propagation calculations were carried out at the critical shaft positions (positions with the highest bending stresses).

Customer benefit

Our fracture mechanics tests confirmed that the cracks in the wheel discs were not caused by braking behaviour or contact with the wheel control arm. Residual stresses were identified as a possible cause of the crack propagation. However, the fracture mechanics assessment of the wheelset shaft also confirmed that the existing test interval provides sufficient safety.

PROSE’s neutral and independent position and in-depth technical understanding gave the customer a solid starting point for further investigations. By utilising data from operational load measurements, the investigation could be tailored to real operating conditions, improving the quality of the results and increasing the client’s confidence in the findings. PROSE’s unique railway engineering expertise and extensive experience with rolling stock provides a bespoke, unbiased analysis that supports effective decision-making and long-term asset management.

 

 

info@prose.one

 

Our solutions
© PROSE. All rights reserved
Disclaimer    Privacy Policy