Train Bogie Overhaul Line Process Improvement

Business Case

A tier-one supplier won a key contract to deliver a major bogie overhaul program for an entire regional passenger train fleet. A number of issues during mobilization — including a lack of engineering information, unclear quality specifications, poor workplace organization and internal logistics — led to delays in program delivery. Our team was engaged to accelerate delivery and establish a streamlined overhaul line and processes.

Approach

Based on initial reviews and observations, a recovery plan was developed with cross-functional stakeholders across the value stream, and governance meetings were initiated to resolve or escalate any risks or concerns in a timely manner.

Shop layout was changed using Lean workplace-organization principles, ensuring material flow to and from the point of use. Standard process steps and times were established — including safety, quality and ‘knacks’ requirements — with input from highly experienced line workers.

Overhaul build plans were developed and visualized on short-interval control boards to improve progress visibility and communication within teams.

Results

• 51% reduction in overhaul hours
• 54% reduction in existing footprint
• Streamlined standard operating procedures
• Improved communication and process progress visibility