In the rail vehicle industry, precision and seamless documentation are crucial for safety and quality. An impressive example of how mobile worker guidance optimizes complex assembly processes is provided by Stadler Rail with the successful PG implementation in bogie assembly and overhaul.
Stadler Rail has been developing and producing rail vehicles since 1942 - from regional trains and streetcars to customized one-off products. The company employs around 7,000 people at eleven locations worldwide and stands for maximum precision in rail vehicle construction.
Precision, reliability and quality are crucial in production - especially in safety-relevant bolting processes on bogies, which are manufactured and overhauled at the Winterthur site and other plants.
Stadler produces high-quality trains using state-of-the-art technologies and experienced specialists. The large number of variants in production requires flexible yet safe processes - particularly in terms of product liability.
In bogie assembly at Stadler Winterthur AG, the company faced several critical challenges - especially with regard to the exact, traceable documentation of the screwing processes.
"For reasons of product liability, exact inspections and complete documentation are required for bolting processes in production. In this way, individual bolting operations can be traced even years later," explains Ronny Böhler, Head of Bogie Assembly, Stadler Winterthur AG.
The European standard DIN EN 17976 for the safe bolting of rail vehicles has further increased the requirements for process reliability and traceability.
"Before the introduction of PG, we worked with table-based lists, some of which were almost impossible to keep track of. A lot of information was available, but simply not relevant for everyday work," says Böhler.
Stadler became aware of CSP through the recommendation of project partner Intool, the supplier of the WLAN-supported torque wrenches. The PG (Process Guidance) software presented was convincing due to its manufacturer independence, simple integration and consistent support of DIN EN 17976.
"The introduction of PG was modular and uncomplicated. Within a very short time, our workers were able to work step by step directly on the bogie - with clear instructions and without additional training."
- Ronny Böhler
"Digital worker guidance allows us to clearly specify the production sequence and ensure that best practices are consistently adhered to."
The implementation went quickly and smoothly: the first workstations were up and running with PG within just a few days.
"The 'keep it simple' principle is crucial for PG. The corresponding instructions for the workers based on images could be created very easily and quickly from within the company," reports Ronny Böhler.
"Changes to the process - such as adding a work step after an error - can be implemented flexibly and quickly. The employees are automatically informed of this during the next run."
Mobile worker guidance is particularly suitable for assembly projects that do not have a standardized sequence. Stadler Winterthur AG also uses the system successfully in bogie overhaul and at other locations.
The major advantage: processes can be flexibly adapted to the available space, order situation and production requirements.
"Since the introduction of worker guidance, we have been able to significantly reduce the error rate in production and documentation. In addition, the entire production process can be organized more flexibly, as instructions can be managed centrally and adapted easily."
"The paper-based documentation has been completely replaced by digital instructions. This saves time and prevents old drawings from being used inadvertently."
The introduction of mobile worker guidance shows clear measurable success:
A particular success was the simultaneous programming of worker guidance and the initial assembly of three new bogie types in the EC 250 Giruno project.
"The visual support and clear structure of the digital instructions increase process reliability and minimize queries. New employees also find their way around much more quickly."
The high stability of the system is particularly pleasing.
"The worker guidance runs almost without interruption - contrary to other typical experiences with new software."
"High flexibility, smooth processes and full compliance with standards - it's impossible to imagine our day-to-day production without the system," says Ronny Böhler.
"The training period for more complex workstations has been noticeably reduced thanks to the step-by-step instructions. This allows us to train new team members more quickly without additional training."
The mobile solution offers further potential: information and work instructions are now available electronically across all sites - even outside of production, for example in quality assurance and maintenance.
The success of PG at Stadler Rail impressively demonstrates how mobile worker guidance can revolutionize complex assembly processes in the rail vehicle industry.
From confusing Excel tables to intuitive, visual step-by-step instructions - PG has significantly increased quality, efficiency and transparency.
With its support for DIN EN 17976, its manufacturer neutrality and mobile flexibility, PG worker guidance sets new standards for process reliability and productivity in rail vehicle construction.
Would you like to find out how PG can also optimize your assembly processes? Contact us for a non-binding consultation.
Stadler Rail has been a successful customer of CSP since 2015 and continuously uses PG for quality assurance in bogie assembly.