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Tag: Maintenance support & optimisation

Maintenance support and optimisation – our solutions

Västtrafik regional train used in a heavy maintenance tender project supported by PROSE through technical documentation and Bills of Materials.

Establishing the technical basis for a heavy maintenance tender

Customer: Mantena, Norway

Project tasks

  • Reviewing and analysing technical documentation
  • Identifying and verifying maintenance components
  • Developing and structuring Bills of Materials (BOMs)
  • Validating technical data and document consistency
  • Providing technical support for supplier enquiries and cost estimation

Our approach

Mantena required technical support to prepare its bid for Västtrafik’s heavy maintenance contract covering the X5x, X61 and Y31 regional train fleets.

A key challenge was to establish a reliable technical basis for maintenance planning within a limited tender timeframe. The available technical documentation was extensive and varied in structure, making it difficult to identify the components and materials required for planned maintenance activities. Accurate Bills of Materials (BOMs) were therefore needed to support supplier enquiries, cost estimation and the definition of maintenance scope. The project required high technical accuracy, consistent engineering deliverables within a demanding tender schedule.

PROSE applied a structured and agile engineering approach tailored to the demanding tender schedule and the complexity of the available technical documentation. Our specialists systematically reviewed, analysed and consolidated information from multiple documentation sources to develop accurate and consistent Bills of Materials (BOMs).

Deliveries were provided incrementally, allowing Mantena to initiate supplier enquiries and cost estimation in parallel with the ongoing engineering work, thereby reducing schedule risks. Throughout the project, PROSE worked in close collaboration with Mantena, to validate assumptions, resolve documentation inconsistencies and adapt priorities to changing project needs.

Customer benefit

By engaging PROSE, Mantena gained a reliable technical foundation for preparing a well-informed and competitive heavy maintenance tender.

The verified Bills of Materials (BOMs) enabled efficient supplier communication, more accurate cost estimation and well-informed purchasing decisions within the tender timeframe. Delivering the work in stages allowed engineering activities and supplier pricing to progress in parallel, reducing schedule risks and helping Mantena to meet the tender deadline. PROSE combined railway engineering expertise with technical documentation competence to provide an independent and dependable engineering service. This improved data quality, increased transparency and gave Mantena a robust technical basis for making informed decisions throughout the tender process.

 

 

Technician performing digital railway bogie inspection using augmented reality (AR) headset and tablet during rolling stock maintenance.

Implementing Digital Maintenance with Augmented Reality

Project tasks

  • Defining a relevant digital maintenance use case
  • Parametrising the AR-based inspection system
  • Localising software and adapting interfaces
  • Setting up and supporting an on-site pilot project
  • Training personnel and supporting prototype testing
  • Evaluating results and delivering an application report

Our approach

PROSE implemented an AR-supported prototype for a railway sector customer as part of a pilot project to digitalise maintenance processes for bogies. The objective was to replace paper-based inspection workflows and improve data quality and traceability.

The selected use case covered dimensional inspection under defined load conditions with structured checkpoints and tolerances. PROSE digitalised existing inspection processes and transformed them into guided digital workflows for mobile devices and AR headsets. Nominal values and wear limits were integrated to ensure systematic inspections and direct recording of deviations. The application enables hands-free operation as well as structured real-time data capture and further processing.

The pilot project included configuration of the application, execution under real workshop conditions, and evaluation with regard to usability, data quality, and operational limits.

PROSE combined railway engineering expertise with digital technology know-how and worked with a specialised AR partner.

We defined a suitable use case together with the customer and implemented it directly on-site as part of the pilot project. We configured and validated the application iteratively based on real maintenance processes.

Our approach included close collaboration with customer personnel, rapid adaptation of digital workflows, and targeted training of users.

Customer benefit

The customer received a validated prototype demonstrating how digital and AR-supported maintenance can improve efficiency and quality. Paper-based processes are reduced, training time is shortened, and inspections become more consistent and guided.

Hands-free operation and real-time documentation improve usability and data quality in workshop environments. At the same time, digital records enhance traceability and support integration into existing maintenance systems.

Through PROSE’s independent expertise and cross-industry insights, the customer gained a solid basis for further development and implementation of digital maintenance solutions.

 

Augmented Reality assisted maintenance

Project tasks

  • Collecting European use cases
  • Providing a report for chosen use cases and a presentation on various customer sites
  • Prototyping of an on-site application
  • Definition of the use cases
  • Initial parametrisation of the Augment Reality inspection system
  • Software localisation
  • Definition of performance parameters
  • Setup of pilot project on site
  • Tuning of the parametrisation of the AR inspection system
  • Training of personnel for prototype application testing
  • Digital O&M prototype usage instructions and application report

Our approach

The project addressed the need to identify, assess, and practically evaluate digital technologies for rolling stock maintenance used in Europe. The objective was to provide transparent insight into proven and emerging digital maintenance solutions for railway vehicles, including trains and rolling stock fleets, based on information available in the public domain.

On top of that, the project aimed to move beyond theory by implementing and validating a selected digital maintenance use case. A virtual reality (VR)-supported maintenance application was chosen and realised at one of the customer’s major production sites to validate feasibility and operational relevance under real industrial conditions.

PROSE conducted a structured survey of European digital maintenance technologies based on industry experience, expert exchanges, and reference projects implemented by railway operators and maintainers. The resulting report focused deliberately on non-patented, legally uncritical use cases to ensure transparency and independence. Based on this assessment, we supported the selection of a suitable digital maintenance application with high practical relevance.

We then realised a VR-supported digital operation and maintenance application directly at the customer’s site. For that purpose, we coordinated a specialised VR technology partner and combined advanced digital tools with our in-depth railway maintenance and engineering expertise. Our independent role and hands-on industry knowledge ensured a solution that was both technically robust and operationally relevant.

Customer benefit

By selecting PROSE, the customer gained access to deep, experience-based insight into European digital maintenance practices beyond pure desk research. The survey provided realistic, industry-proven solutions grounded in actual railway projects and expert discussions.

Through the realisation of a concrete VR maintenance use case, the customer was able to validate digital technologies in practice rather than relying on theoretical concepts. PROSE’s combination of independent consulting, deep railway domain expertise, and the ability to bridge technology providers with operational requirements enabled a reliable and low-risk introduction to digital maintenance innovation, strengthening long-term maintenance efficiency and capability.

 

AI-based tram rail lubrication system showing data acquisition from acoustics and GPS, fleet swarm intelligence, and predictive lubrication decisions.

Noise and wear reduction for trams with AI-based rail head lubrication

Customer: BERNMOBIL, Switzerland

Project tasks

  • Project management
  • Concept development
  • System integration
  • Data analysis

Our approach

The operation of a railway vehicle causes noise and wear on wheels and rails. These issues can be reduced by lubricating the wheel-rail contact point. However, excessive lubrication can pose a safety problem, as it reduces traction forces and increases braking distance, potentially causing ecological pollution.

Together with our partners, we have developed a system as part of a research project supported by the Federal Office of Transport (FOT) that makes it possible to condition the rail head as needed. Sensors installed on the vehicle measure status parameters and feed them to an AI installed on the vehicle. The machine learning model analyses the data, determines the need for conditioning and synchronises this with other vehicles operating on the rail network. Based on this information, each vehicle decides for itself at which point in the rail network conditioning must be initiated by the on-board lubrication system.

Customer benefit

In addition to fully automatic lubrication, the customer has access to comprehensive noise monitoring, which allows sources of noise to be localised at an early stage if they have not already been completely eliminated by the system. Since relevant influencing variables are known through the machine learning model, most noise sources can already be detected predictively and avoided altogether.

Communication between the vehicles creates a form of fleet-wide intelligence, enabling complete coverage of the fleet and the entire route network without having to equip each individual vehicle with expensive measurement technology. Thanks to the measuring system installed, other conditions can be monitored in addition to noise, such as ride comfort, wear between wheel and rail, and the infrastructure.

The customer benefits from our deep understanding of wheel–rail interaction and tram system behaviour, as well as our hands-on technical engagement throughout development.

 

   

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.

 

 

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.

 

   

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.

 

 

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