Production & Manufacturing Consultancy

01 Objective

Structuring and optimizing production lines, process flows, and manufacturing organization for the serial production of wagons, bogies, and railway vehicle components in compliance with EN 15085, TSI, and related international standards.

Scope

Manufacturing of wagon and bogie main and sub-components, welded production solutions, machining and sheet metal forming operations, production line balancing, and enhancing production efficiency.

Service Components

01 Layout of Wagon and Bogie Production Lines

Planning station-based manufacturing lines and welding processes for wagon bodies and bogie main structures.
Sequencing and flow planning for carrier and structural components (sidewalls, floors, roofs, traverses, bogies, etc.) within production lines.

02 Takt Time, Line Efficiency, and Buffer Stock Management

Determining takt time, station balancing, and buffer points.
Ensuring flow optimization and balanced lines between production processes.

03 Welded Manufacturing Processes (EN 15085)

Structuring welded manufacturing processes fully compliant with EN 15085.
Planning welding activities, preparing WPS/PQR documentation, ensuring welder qualifications, and defining quality control steps.

04 Machining Solutions

Planning CNC-oriented machining processes for wagons, bogies, and auxiliary components.
Establishing part tolerances, surface quality requirements, machining sequences, and alternative supplier pools.

05 Sheet Metal Forming and Operational Flow

Process-based structuring of sheet metal cutting, bending, weld preparation, drilling, blasting, and surface preparation operations.
Planning intra-line and inter-line process flows.

06 Casting and Forging Material Management

Casting and forging material solutions for bogie components, fasteners, and special parts.
Preparing mold designs, selecting forging/casting methods, and final processing plans.