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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

Verification of a maintenance shop for a new vehicle type

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

Project tasks

  • Capturing requirements
  • Checking integrability and identifying problems
  • Definition of measures
  • Project management

Our Approach

The existing infrastructure was used to check which maintenance tracks in the SA Basel were generally suitable for the RABe 512. As soon as the vehicle was available, various inspections and clarifications were carried out directly on the vehicle on the relevant tracks, together with the relevant responsible persons for facilities and occupational safety. All components were systematically analysed, and the need for modifying existing systems or additional auxiliaries was recorded.

Customer benefit

Measures were defined and handed over to the customer for implementation, particularly regarding safe access to the train head and the roof. This way, the procurement requirements for modifying the service facility were bundled before the maintenance, ensuring occupational safety and enabling efficient maintenance tasks.

Maintenance plan for a maintenance shop of the Swiss Federal Railways

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

Project tasks

  • Creation of maintenance plan

Our Approach

​PROSE developed the plan in close cooperation with SBB’s responsible persons. The understanding of the maintenance shop in Basel gained from past assignments and experience with other maintenance facilities helped ensure efficient project implementation.

Customer benefit

SBB received a production concept that describes the interaction of the production resources in the context of the business process model to enable an in-depth understanding of the site within SBB. The target group of the production concept includes the management personnel at the site, partner organisations within and outside the site, the management of SBB Passenger Traffic Production and the facility management.

Welding drawings and calculations for repairing Magnetic Brakes

Project tasks

  • Scanning of specific parts
  • Drafting welding drawings
  • Performing design calculations
  • Clarifying questions about the deformed magnetic brake
  • Project management

Our Approach

PROSE used precise scans of the magnetic rail brakes to create customised welding drawings and detailed documentation for their repair. This work included the development of technical drawings and calculation documents tailored to the specific requirements of the brakes. Our approach ensured that the repairs met the highest safety standards and could be carried out efficiently. By providing comprehensive guidance for the welding work, we ensured our customer could perform the necessary repairs accurately. Our commitment to quality and technical excellence enabled a sustainable solution to restore the functionality and safety of the magnetic rail brakes.

Customer benefit

With the welding drawings supplied by PROSE, the customer is now able to repair deformations on magnetic rail brakes accurately and efficiently. These customised drawings enable the customer’s team to carry out accurate repairs that restore the brakes’ performance and safety. The direct benefits to the customer include significantly reduced downtime, cost savings through in-house repair capability, and extending the life of critical brake system components. These customised solutions ensure that the magnetic brakes maintain their essential function in the safety and efficiency of rail transport.

 

Development of rail operation and technology strategy 2050

Customer: Rhätische Bahn AG, Switzerland

Project tasks

  • Strategy development
  • Analysis and conception
  • Stakeholder management & methodology
  • Project management, incl. Stakeholders, Communication and Change-Management

Our Approach

Due to the technology’s long life cycle and high investment volume, investments in railway technology require a comprehensible focus and demonstrable benefits. In collaboration with the RhB specialists, PROSE developed an operational target picture and operational use cases for the year 2050 based on the identified challenges of daily operations. Based on this target picture, the benefits created by technology and target systems are clearly identified, and the technology strategy can be aligned with the fulfilment of the target picture.

Based on the operational target picture, the ACTUAL system architecture and the known life cycles were recorded with the RhB experts. Based on the information on the current situation, PROSE was able to develop a proposal for the TARGET system architecture, including migration planning and implementation concepts.

With the help of modern methods and targeted workshops, PROSE and RhB achieved the project goal in a very short time and presented the first results to the strategic steering committee.

Customer benefit

RhB benefited from the PROSE experts’ overall system knowledge and technical expertise in railway operations & automation. In combination with the methodical and analytical approach of the PROSE project team, RhB was able to develop and discuss initial approaches for the implementation of the strategy across all areas. This includes, for example, a migration map with the life cycle of systems and vehicles to identify possible migration windows for the systems, the visualisation of the operational target processes with the target degree of automation and possible implementation variants on the RhB route network.

   

Digitalisation Maintenance Instructions

Customer: SBB Historic, Switzerland

Project tasks

  • Research: Review of the old maintenance regulations for each vehicle
  • Expert interviews: Ensuring the transfer of expertise to supplement/correct the old maintenance regulations
  • Documentation: Creation of maintenance plans for each vehicle
  • Release: Incorporation of customer feedback and internal release of the maintenance plan

Our Approach

PROSE supports the client in creating maintenance plans for the first 14 traction units and 3-4 coach fleets. These can only be partially derived from old regulations and thus completed and adapted accordingly and transferred to a digitalised maintenance concept. A significant proportion of the maintenance work is carried out voluntarily by associations. This particular situation must be taken into account in the concept development. PROSE also provides relevant support for introducing the ZEDAS maintenance software on the customer side.

Customer benefit

The client receives a digitalised, standardised and consistent maintenance plan landscape for the vehicles to ensure the safe, standard-compliant and efficient planning and implementation of maintenance measures using in-house, association and external services.

The logic and conceptual design of the maintenance plans, regardless of whether they relate to steam locomotives, electric locomotives or multiple units, will be aligned accordingly, thus creating content, processes and documentation specifications that are much easier to understand and can also be communicated to volunteer maintenance staff to ensure safe rail operations.

The implementation already considers European standards for safe maintenance and their functional allocation in the organisational development. This will ensure a gradual expansion of the client’s maintenance services towards a modern, digital maintenance organisation.

   

Fire Safety Assessment and Consulting

Project tasks

  • Consultancy
  • Development and creation of fire protection concepts
  • Development and creation of evacuation concepts
  • Analyses of fire protection requirements
  • Compilation of required fire protection test reports
  • Communication with authorities, manufacturers and testing laboratories
  • Integration of fire safety systems
  • Preparation of approval documents relevant to fire protection

Our Approach

PROSE analyses the given situation and develops solutions that meet the applicable fire protection requirements. To this end, PROSE advises the customer and identifies various solutions in order to find an efficient way of achieving the required fire protection for railway vehicles in accordance with EN 45545. Our experts calculate the thermal load of the vehicle during the design and propose measures for its reduction.

Customer benefit

The customer benefits from our many years of experience in the field of fire protection for all types of rail vehicles in accordance with EN 45545, including not only advice but also the creation of concepts, the preparation of the necessary fire protection certificates, contact with manufacturers of fire protection-compliant components and communication with approval authorities. The aim is to place fire protection suitable vehicles into service.

PROSE Documentation services – Technical documentation

Project tasks

  • Technical writing
  • Information analysis
  • Document management
  • Review process work
  • Coordination of projects
  • Administration and management
  • Translation: Terminology management (English, German, Swedish)
  • Document management system PRO(doc)

Our Approach

PROSE assists in the creation and translation of new technical documentation, as well as revising and updating existing documents. Our technical writers help you create technical documents such as technical descriptions, maintenance manuals and spare parts lists. We review, both on the supplier and customer side, the language, structure, and contents of the technical documents, and perform quality control in line with established documentation requirements.

The technical writers produce technical documentation, working both in office and together with technicians and system engineers on site, to understand complex functioning of products and systems, thus creating clear documentation. The quality is assured through detailed checklists, verification on site and validation with the customer.

PROSE’s technical translators work with the support of professional translation software. The creation of custom dictionaries allows us to help you manage your company-specific terminology. At PROSE, we offer translation to, and from, Swedish, English and German.

We also offer our own document management system, PRO(doc). PRO(doc) is a customised online documentation management system. Developed by PROSE, it enables you to easily manage your documentation, such as technical drawings, maintenance instructions, trouble-shooting remedial actions, spare parts information and so on.

Customer benefit

PROSE has contributed to many projects by creating new technical documents, as well as by translation, review and coordination. The documents are written for train drivers, maintenance staff and training instructors, are verified on site and validated with the customer.

PROSE works both on the supplier side and on the customer side, contributing to a large amount of important documentation. Work in the depot environment ensures that complex functions are understood, to create clear documentation. This helps operators to understand the updated products and systems, ensures correct use of the products and enables and guarantees safety in maintenance work.

Vehicle procurement – Manufacturing Supervision, Quality Control and Factory Tests

Customer: various customer

Project tasks

  • Acceptance of the welded car bodies / bogie frames
  • Paint inspection and acceptance
  • Intermediate acceptance of main electrical components
  • Intermediate acceptance of interior fittings
  • Factory acceptance/customer acceptance

Our Approach

By regular participation in the vehicle acceptance tests and constant coordination with the team of the vehicle manufacturer, PROSE checks the quality of the production. The customer is permanently kept up to date by the acceptance team regarding the progress of the production as well as possible complications or deadline postponements. He immediately receives the results of the production controls and acceptances and can follow up changes, modifications etc.

The dates for the acceptance of components, intermediate assembly stands and vehicles ready for delivery follow the production plan but are also handled operationally and flexibly in order to be able to react to specific occasions. In this way, control of the construction process is always ensured and there is the possibility of intervention in the event of difficulties such as quality slumps, scheduling, supply, or capacity problems.

Customer benefit

With manufacturing supervision, the manufacturer’s quality assurance process is checked and monitored in addition to the product quality, because every vehicle has gone through this process before it is presented for factory acceptance. Continuous construction supervision ensures consistent quality at a high level.

      

Authorisation support for the installation of a Speed-Sensing system

Customer: Matterhorn Gotthard Bahn, Switzerland

Project tasks

  • Review of the planned changes
  • Scheduling
  • Assessment of the changes according to risk assessment norm RTE 49100
  • Preparation of documents and expert assessment reports for submission to the Federal Rail Authority

Our Approach

The aim is to support the Gornergrat Railway by taking over the following activities:

  • Review of the planned modification based on the draft schematics, drawings and descriptions prepared by the Mat­terhorn-Gotthard Railway
  • Preparation of a schedule for the authorisation procedure
  • Provision of the documents for authorisation to the Swiss Federal Rail Authority (FOT)
    • Assessment of the changes in accordance with risk assessment regulation RTE 49100
    • Preparation and submission of all documents required for authorisation by FOT
    • Preparation of an expert report on the speed-sensing system

Customer benefit

PROSE’s support ensures that the authorisation process runs smoothly and promptly. This leads to an accelerated execution of the refit project. Reviewing the planned modifications based on draft schematics, drawings, and descriptions from the Mat­terhorn-Gotthard Railway ensures that the modifications meet the highest quality standards. The provision of all necessary documents for authorisation by the FOT, including the risk assessment per RTE 49100, ensures that all regulatory requirements are met. The preparation of an expert report on the speed sensing system promotes trust between the Gorner­grat Railway and the relevant authority, as the technical aspects of the modifications are documented in detail and professionally.

Managing system and electrical engineering for a tramway

Project tasks

  • Project management
  • System engineering
  • Electrical engineering

Our Approach

Managing the systems engineering of tramways demands a methodological and detail-oriented approach. Bearing the technical responsibility for systems and electrical engineering in the new rail vehicles, our approach is characterised by precision, innovation, and meticulous attention to every intricate detail. We ensure that every aspect aligns with the highest industry standards.

Customer benefit

Our commitment to overseeing tramway systems engineering delivers tangible benefits to our customers. By assuming comprehensive technical responsibility for the systems and electrical engineering of the new rail vehicles, along with substantial involvement in their development, we guarantee a product of unmatched quality. For the vehicles, this translates into enhanced reliability, operational efficiency, and cutting-edge innovation, where our customers are granted risk mitigation, shorter time to market and overall satisfaction at every turn.

     

Grand-Tour luxury train maintenance plan

Customer: Arlington Fleet France, France

Project tasks

  • Project management
  • Maintenance management
  • Homologation support

Our Approach

The “Le Grand Tour” project is creating a luxury cruise train in France, using refurbished coaches from Deutsche Bahn. Arlington Fleet France (AFF) is overseeing the project, using existing maintenance data from DB and new system designs.

In the first phase, PROSE formalised existing data from Deutsche Bahn, which is crucial for creating the maintenance plan. Now, in the second phase, we’re taking the lead in drafting the maintenance plan and the Maintenance Documentation File, ensuring compliance with homologation requirements for seamless introduction and operation on the French network.

Customer benefit

Based on PROSE’s extensive experience, the entire maintenance plan was created by integrating the existing and newly added systems. This allows the customer to have a solid maintenance file for the train approval and the vehicle authorisation and, subsequently, to plan future maintenance operations.

    

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