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Project audit of the implementation of a depot management system

Customer: Verkehrsbetriebe Zürich (VBZ), Switzerland; PSI Transcom GmbH, Germany / Switzerland

Project tasks

  • Project audit
  • External advice
  • Second opinion
  • Mediation

Our Approach

​Verkehrsbetriebe Zürich (VBZ) is procuring a new depot management system (BMS) from PSI Transcom GmbH to control its tram depots and bus garages. PROSE carried out an independent project audit on behalf of both parties. The audit aimed to determine whether the project was being handled by both parties in accordance with the requirements for a project in the public transport sector. In addition, VBZ wanted to clarify the extent to which the supplier’s project organisation ensured qualitative and timely project execution. Furthermore, it should be clarified whether any suboptimal project organisation could result in additional financial expenditure on both sides.

PROSE carried out the audit in a two-stage process. In the first phase, both parties were interviewed on-site in an audit meeting about the key issues identified and their respective views were recorded. In a subsequent joint meeting, the first draft of the audit report, including the recommendations of the PROSE auditors, was used as the basis for an initial review. The second phase was organised by focusing on individual key topics in joint meetings of all three parties. Finally, the findings based on the audit report and the recommendations were discussed and finalised.

Customer benefit

VBZ and PSI benefited from the PROSE auditors’ independent perspective and experience in project management and operational issues. By analysing individual key topics, it was possible to illuminate the respective points of view and highlight the perspectives of both parties. As a result, both parties were able to identify potential for improvement in the collaboration.

 

 

Expert report for approval of new trams in Dortmund

Customer: HeiterBlick GmbH, Germany

Project tasks

  • ​Assessment of running dynamics

Our Approach

For the approval of the new trams of the operator DSW21 in Dortmund, the manufacturer HeiterBlick GmbH in Leipzig commissioned the EBA-approved expert Stefan Bühler to assess the running dynamic behaviour according to the regulations for trams in Germany, BOStrab.

The new vehicles have been authorised and in operation since April 2024. Modernised vehicles will be assessed in a further phase.

​PROSE agreed on the scope of verification with the technical supervisory authority of North Rhine-Westphalia (TAB NRW) and the manufacturer HeiterBlick GmbH. Dr Johannes Keudel, a specialist in running dynamics simulations, supported Stefan Bühler in the assessment of the provided evidence. Finally, the expert report was drawn up.

Customer benefit

It is essential for the customer that the authorities accept the assessors. Thanks to the appraisal team’s high level of expertise, the customer HeiterBlick GmbH knew precisely what evidence he had to provide and in what form. For this reason and thanks to the high level of customer orientation of the PROSE team, the expert report could be prepared quickly and in good quality. Although the input on this specialist area was only available very late, this hardly caused any delay to the authorization of the trams.

 

Expert report on metre-gauge flat wagons with cogwheel brake

Customer: PVF Trade, s.r.o., Czech Republic

Project tasks

  • Project management
  • Definition and procurement of input data
  • Review and appraisal of all input documents
  • Preparation of expert report

Our Approach

PROSE was commissioned by the company PVF Trade, s.r.o., to prepare an expert test report (SV report) on the test report of suspension tests of the vehicle “four-axle service – flat wagon 1000mm track with cogwheel brake”.

The report is intended to provide information on the compliance of the brake tests according to the test report “Flat wagon with toothed wheel brake suspension tests” with the provisions of the AB-EBV and their fulfilment.

All documents submitted were checked for completeness and plausibility. The check was carried out against all relevant requirements from the FOT guidelines AB-EBV.

In the event of inconsistencies and/or missing information, these were requested from the client or other project partners. On this basis, a final expert report was prepared and submitted to the client.

Customer benefit

​PROSE’s prompt preparation of the expert report guarantees a smooth and rapid handling of the authorisation procedure. The intensive review of the documents provided ensures that the report meets the highest quality standards and that the vehicle is guaranteed to operate safely. The intensive project supervision by the PROSE expert regarding adjustments and requirements for the documentation with all project partners relieves the customer of this organisational work and ensures rapid and high-quality processing.

 

 

Delivery of four dummy bogies

Project tasks

  • Project management
  • Manufacture

Our Approach

PROSE was commissioned to develop and manufacture four customised dummy bogies for the depot. The main challenge was to design robust bogies suitable for use in the demanding conditions of a workshop environment. These bogies not only need to have a high load capacity but also have to offer flexible adaptability to different vehicle types and maintenance requirements of the depot. The manufacturing process required carefully selecting materials and technologies that ensure long-term durability and resistance to mechanical stresses and environmental influences. In addition, special attention was paid to ergonomics and user-friendliness to ensure the safety of depot employees and increase the efficiency of maintenance processes. The technical specifications were worked out in detail in close cooperation with the customer to ensure that the finished bogies are optimally adapted to the depot’s specific requirements and existing infrastructure.

PROSE tackled this task with a focused approach to quality and functionality. The four dummy-bogies were manufactured under strict quality control and using high-quality materials. Each bogie was carefully designed to meet the specific requirements of the depot, with particular attention paid to durability and ease of maintenance. The noise reduction target of >1dB set at the beginning of the project was successfully achieved with a theoretical analysis.

Customer benefit

​The provision of these four customised dummy-bogies offers the customer considerable advantages. Thanks to the improved reliability and robustness of the bogies, maintenance work can be carried out more efficiently and safely. This leads to a significant reduction in downtime and an increase in operational safety in the depot. The customised bogies, therefore, not only support daily routines but also help to improve the service life and performance of the vehicles maintained in the depot.

 

   

Gearbox investigation on vehicles

Project tasks

  • Project management
  • Create a feasibility study
  • Test proposals based on the preliminary study
  • Evaluation from tests
  • Recommendations

Our Approach

The feasibility study involved testing the sealing proposals recommended by PROSE on two different gearboxes of the vehicle. One gearbox was found to have a minor leakage, while the second gearbox showed similar levels of leakage as before, despite the use of a sealing compound and a regular O-seal. These tests helped to evaluate the effectiveness of the various proposed sealing methods and provided valuable data for the further development of the solutions.

Customer benefit

​Based on the results of the tests, PROSE can now make specific recommendations for further steps. PROSE, therefore, recommends that the next step is to test the X-seal and simultaneously apply two lines of sealant to the motor output shaft. This recommendation is based on the observed performance of the tested seal variants and aims to develop a more robust solution to prevent oil leakage. This strategic approach allows the customer to make targeted adjustments and improvements to resolve the problem in the long term and improve the operational reliability and service life of the gearbox.

 

    

Expert opinion on carbody structures

Project tasks

Verification of

  • Design Concept and Philosophy
  • Carbody calculation specification
  • Carbody crash specification
  • Validation plan
  • Finite element descriptive document
  • Calculation results
  • Weldings

Our Approach

PROSE supported the established European rail vehicle manufacturer with reviews to ensure that the development of its carbody structures complies with all requirements (safety, durability, strength/rigidity) specified in the standards and is supplemented by customer requirements.

Two essential characteristics of carbody structure are crashworthiness and fatigue strength. To check these properties, design principles and calculation methods must be evaluated.

The evaluation focused on the customer’s stress report, which PROSE carefully checked. In addition to evidence of carbody straining by standardised loads, evidence of results from load scenarios in the end customer’s country is required. Such load scenarios are not directly defined in a standard but must be analysed. As this task is more complex, PROSE scrutinised this part of the report with particular attention.

Customer benefit

PROSE helped ensure the development of a cutting-edge aluminium carbody structure. The customer and the end customer highly valued its independent expert opinion as quality assurance.

With PROSE as an independent assessor, the customers had a further means of reducing design risks by using the expertise of PROSE’s seasoned engineers.

 

  

Variant study for the further development of a metre-gauge railway workshop

Customer: Compagnie du Chemin de Fer Montreux Oberland bernois MOB, Switzerland

Project tasks

  • Analysis and documentation of the current situation
  • High-level requirements definition
  • Development of variants

Our Approach

The MOB operates the approximately 10-kilometre Vevey — Les Pléiades line with adhesion and cogwheel sections. The light maintenance of the vehicles travelling on this line is carried out in Vevey. As Vevey’s workshop infrastructure is insufficient for heavy maintenance, the vehicles are transferred to other workshops. Due to the small number of vehicles, the facility in Vevey is only used for around one week per month.

To reduce the maintenance costs of the vehicles concerned, MOB would like to equip the Vevey site so that heavy maintenance can also be carried out there. PROSE was commissioned to examine how the Vevey site could be further developed to meet these requirements.

PROSE documented the site’s maintenance infrastructure. The maintenance processes were then analysed to determine what infrastructure the site would need to meet the future requirements of centralised maintenance. Finally, options were developed for further development.

Customer benefit

​The MOB received a comprehensive range of variants that took into account the current and future challenges at the site and on the Les Pléiades line. The variants were assessed in terms of requirements compliance and risks. Finally, further actions were outlined, and a concrete recommendation for the next steps was formulated.

Requirements for battery vehicles

Customer: SBB AG, Switzerland

Project tasks

  • Review of the standard requirements catalogue
  • Classification of the requirements
  • Categorisation and adaptation of requirements
  • Integration of the requirements into the requirements management system
  • Evaluation of the offers
  • Conversion and import of the requirements specification

Our Approach

Swiss Federal Railways SBB is preparing for the tender to procure new vehicles that replace the Tm 234 fleets of the first, second, and third series. These new vehicles must fulfil the operational requirements of both existing fleets and be climate-neutral. As the Federal Office of Transport (FOT) has yet to approve finalised regulations for battery-powered vehicles, SBB is facing challenges regarding the approval of battery operation. Therefore, SBB needs support for the battery subsystem to correctly integrate the specific requirements for the battery system into the specifications.

PROSE supported SBB in reviewing the content of the standard requirements catalogue for the battery subsystem (SAK – System Batterie). The task included not only suggesting content adjustments and additions but also classifying the requirements into functional and non-functional categories. In addition, PROSE categorised and adapted the requirements according to the “MUST” and “SHOULD” criteria and submitted proposals for weighting these criteria for the evaluation matrix.

Based on this preliminary work, the specified requirements were integrated into the requirements management system Re-qSuite®. There, the requirements were evaluated individually, and a corresponding binding force was given to evaluate the bids received in the upcoming tender. The specifications were then converted into a format that SBB could import into its requirements management system, Polari-on®.

Customer benefit

SBB received a clear catalogue of questions and an annotated requirement specification, which made the requirements more precise and easier to understand. Checking, evaluating, and identifying requirements that require a risk assessment contribute to quality assurance and minimise potential risks in the project. The risk assessment and the binding nature of the requirements enable better preparation for the tender, which improves the quality of the bids received. Converting the specifications into a compatible format for SBB’s requirements management system ensures smooth integration and utilisation of the requirements by the customer.

 

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

Customer: SBB, Switzerland

Project tasks

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

Our Approach

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

Customer benefit

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

 

Inspection and assessment of carbody, cracks and corrosion

Project tasks

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

Our Approach

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

Customer benefit

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

 

     

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

Project tasks

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

Our Approach

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

Customer benefit

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

 

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

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

Project tasks

  • Solution development
  • Solution assessment
  • Project management

Our Approach

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

Customer benefit

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

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