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Tag: Maintenance support and optimisation

Maintenance support and optimisation – our solutions

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 an 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.

 

 

Wear monitoring for meter gauge railway

Customer: Montreux-Oberland-Bahn (MOB), Switzerland

Project tasks

  • Project management
  • Concept development
  • System integration

Our approach

The Montreux Oberland Railway (MOB) was faced with a challenge when it was suddenly confronted with increased noise and heavy wear on the wheels and rails of a large number of vehicles in its fleet. Various vehicles showed unexpectedly high signs of wear.

PROSE carried out two days of acoustic measurements on a vehicle travelling on the MOB network. We used wireless microphones that were magnetically attached under the car body on each side of the train. The acoustic signals were sent wirelessly to a laptop inside the vehicle. With the help of special acoustic software, these acoustic signals were transferred from the time domain to the frequency domain in real time. Based on the amplitudes in certain frequencies, the problem of noise and wear in certain curves of the network could be localised. Additional measurements on the rails showed that the wheel flange lubrication on the rail was inadequate and was causing noise and wear. After manually lubricating around 10 curves on the 45 km network, the wear disappeared completely and the noise was reduced.

Customer benefit

The MOB had to reduce its services as the wear and noise pollution were no longer acceptable. After the problem was analysed and localised by PROSE-experts on the MOB network within a day of the measurement, noise and wear were reduced to a minimum and the MOB was able to resume regular operations.

 

  

Investigation on European EMU brake systems

Customer: leading international brake equipment manufacturer

Project tasks

  • Project management
  • Requirements capture
  • Concept development
  • System integration

Our approach

The project aimed to assist a leading international brake equipment manufacturer in navigating the complex landscape of European brake system regulations, generic design principles, and requirements for brake certification. The primary challenge was to provide the manufacturer with a consistent and clear understanding of these regulations to facilitate the development and certification of their brake systems for the European market. This support was crucial for ensuring compliance with stringent European safety standards and improving the manufacturer’s competitive edge in the international market.

Based on publicly available information and own experiences, PROSE provided a comprehensive investigation report with following main chapters:

  • European and American design philosophy and safety principles for emergency braking in EMU
  • Brake performance of current EMU train designs in Europe
  • Redundancy on emergency braking command and functions
  • Emergency Braking according EN 16185-1 and EN 15734-1
  • Brake system requirements for EMUs according to European TSI regulations
  • Brake system control signal according to EN 15611:2020

Customer benefit

As a result of this project, PROSE’s customer obtained an in-depth and detailed understanding of the general requirements and best practices associated with European EMU brake design. This comprehensive insight enabled the manufacturer to align their products with European standards, thereby enhancing their ability to meet certification requirements. Additionally, the detailed investigation report served as a valuable reference for the customer’s engineering and design teams, facilitating informed decision-making and innovation in brake system design. Overall, the project significantly boosted the customer’s capability to produce compliant, reliable, and competitive brake systems for the European rail market.

 

      

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.

 

      

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.

 

          

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.

 

      

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.

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.

 

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.

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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