Workshop systems, machinery and equipment

We can provide you with the following products: Development support for plants and processes Are the plants or technologies available to you simply not enough? Are you developing them to such an extent they are coming up against the limits of existing regulations? The increasing competitive pressure being felt on the market by rail transport companies, vehicle maintenance providers and component maintenance providers means they need to keep on developing their manufacturing and production processes all the time. This must be done in the context of the changing regulatory landscape and when new processes are introduced into production, this often requires proof of equal safety or different safety methods (CSM). DB Systemtechnik supports you on this path to increasing the RAM/LCC performance of existing systems and finding new technologies for replacement investments, from the idea to implementation, through to validating the effect of new technologies. Our services: Innovation management and cross-sector technology monitoring Execution of vulnerability analyses Value stream mapping Optimisation of production/treatment processes Identification of potential fields for research and development Estimation of technology readiness level Technology transfer across companies and sectors Evaluation or proof that technologies comply with regulations, formulation of necessary supplementary and adaptation measures for quality management systems Your benefits: Increase the efficiency of your workshops Continuous further development to ensure competitiveness Cost-effective implementation of regulatory requirements Avoidance of production losses and restrictions from introducing immature, inappropriate or insufficiently prepared technologies Process development for production and maintenance What potential is there for optimising your production process? Can you exploit this potential using infrastructure or organisational means? Process analysis and subsequent process optimisation serve to continuously and sustainably improve the efficiency of existing business and production processes, as well as utilisation of the required resources. Through our nationwide deployment in maintenance workshops, we have up-to-date expertise in the production and supporting processes around vehicle and component maintenance. We can share this knowledge with you in workshops and discussions in order to improve performance in terms of vehicle provision and maintenance, intralogistics, component production or plant maintenance. Our services: Process analysis and process optimisation in production, work scheduling, maintenance and logistics Identification of vulnerabilities Identification and quantification of optimisation potential Preparation, facilitation and evaluation of workshops Preparation of the results in different stages as concepts process and sequence illustration coordinated proposals and descriptions of measures Design description of infrastructure adaptation measures Your benefits: Efficient formulation and high quality of results through incorporating benchmarks from solutions implemented in DB workshops nationwide integrating planning concepts for infrastructure design Internal acceptance through neutral facilitation and calculation documentation Optimisation of operations Do you want to reduce the costs of maintaining your plant capacity or increase its performance quality? Plant, machinery and equipment are integrated systems with numerous control variables affecting their operation. Conceptual design errors, operational shortcomings or inadequate plant maintenance can lead to unexpected costs and also jeopardise the intrinsic value of the plant technology, vehicles and their components. A review of plant performance therefore often reveals measures that can be implemented to tap potential in terms of both quality and cost. Identification and implementation require expertise in the specific technology, cross-site experience and a methodical approach to implementation. DB Systemtechnik is here to support you as a neutral partner. Our services: Selection of suitable plant parameters and plant sites for the analysis Recording and comparison of defined plant parameters, analysis of the key performance indicators derived from them Recommendation on how to optimise the operating and maintenance parameters, proposal of expansion or adaptation measures for the plants Implementation support and realisation monitoring Your benefits: Reduction in the costs of maintaining your plant capacity through a holistic consideration of all cost items from the areas of operation, maintenance and depreciation Use of best practice experiences of other plant operators Exploitation of the full performance potential of your production plant Calculation and profitability evaluation of efficient expansion and development options Tender documents for framework contracts Do you need a maintenance contract for your plant? Do you need to keep procuring plants on a recurring basis? Then a framework contract is the thing for you. You get all the advantages of a standardised product at a reasonable price that is easy to call off and has a short lead time. This is based on a standard service catalogue that describes the products to be procured in technical terms, irrespective of the specific case in question, and structures them into cross-manufacturer requirement categories and modules. Call-off orders are issued by those employees in the various divisions who are authorised to create call-off documents. This leads to competition among suppliers for larger annual production batches and facilitates attractive conditions over a defined period of time, both in terms of procurement price and delivery terms. We are happy to assist you with preparation, tendering, contract awarding and calling off. Our services: Determination of demand for recurring products in your workshops Review of whether it is possible to consolidate these products across the board Formulation of a standard service catalogue as a basis for the tender, including a description of the required products and further sub-products Selection of suitable suppliers based on technical suitability criteria including references Support in calling off services via call-off documents Your benefits: Realisation of procurement synergies Reliable costs for defined services over the long term Elimination of time-consuming and expensive national and Europe-wide tenders in favour of short-term ordering via call-off forms for the framework contract Procurement of standard equipment (e.g. lifting jacks, work platforms) and services (e.g. inspection services) in accordance with the latest state of the art

We help you to identify infrastructure requirements from your production task, translate them into different implementation variants, then evaluate these by comparing them against one another. We offer: Maintenance consulting for tendering teams How do you find the right maintenance concept for your bid and which cost items does this require, in which amounts? Transport contracts are won by bids with favourable cost structures. They become a business success when they contain the necessary level of investment to enable operations to run as efficiently as possible over the entire term. During the bidding phase, we can help you to navigate the process of configuring, selecting and costing the maintenance concept for your transport bid quickly and to a high standard. For this purpose, we use reference values from current projects, both for the maintenance requirements of the vehicles and for implementation of the infrastructure. Our services Analysis and combination of boundary conditions: market requirements; technical, structural, legal or regulatory requirements and restrictions Identification of required maintenance, modification or construction of new workshop, treatment and track systems during the contract period Drafting of an infrastructure profile with details of the operating concept, capacity determination, workshop equipment and interfaces with service facilities Key financial data with estimate of cost plan and list of annual instalments Support in the detailed coordination of documents with the agencies involved Your benefits: Cost and decision certainty for your business plan or business case Anticipation of competitor bids by costing other competing concepts High quality of evidence and ability to assert your case if measures are being financed by the purchaser Long-term auditability of documents, e.g. for external audits Reliable implementation thanks to coordinated information for scheduling as well as for further cost and profitability analyses Investigations into different variants What are the development options for your production? What does this mean for your workshop and treatment infrastructure? In a saturated market for maintenance services, competitive pressure is high. A strategically oriented infrastructure that can be developed further is essential for ensuring the future viability of such work. We work together with you to design development variants for implementing your maintenance concepts and help you to make decisions on the core factory planning issues of maintenance engineering, production systems and technologies. And we do all this for projects that are about building new vehicle and component workshops or treatment plants, or modernising existing ones. Our services Compilation of basic conceptual requirements for the vehicle and operating concept, production and infrastructure Formulation of requirement attributes such as the requirements matrix, vehicle working states and maintenance functions in workshops together with the client Development of technology and solution variants Development of conceptual designs such as equipment, space requirements, material logistics, personnel deployment, infrastructure requirements, including estimation of the costs Assessment of requirements for specific maintenance equipment Comparison and evaluation of variants, e.g. by means of utility value or portfolio analysis, SWOT or profitability analysis How you benefit Decision-making certainty for actively developing your production portfolio Efficient formulation and high quality of results through the specific background of the rail vehicle workshop designers incorporating benchmarks from solutions implemented in DB workshops nationwide Targeted documentation of the variants for your decision-making processes Feasibility studies How can the preferred variant be further developed into a project? To answer this question, we will prepare an initial systematic preliminary feasibility study for your projects. This is a solid foundation for developing the project further and contains the framework data you will need to make an investment decision. Concept studies help to flesh out competitive and sustainable workshop scenarios, as well as to verify sites. Our services Procurement and analysis of boundary conditions and basic data Planning procedures according to VDI 5200 "Factory planning" Factory strategy with maintenance functions o Production systems for new vehicle classes Structural scoping with structural layout for workshops and logistics Adaptation of the requirements and development of implementation variants at the site Conceptual layout of workshops Logistics Track and transport facilities Estimation of investment requirements, implementation time and initial risk assessment Comparison and evaluation of implementation variants How you benefit High level of decision-making certainty thanks to consideration of operational, production-related, structural, financial and planning law factors extensive experience from specific workshop projects for rail companies Professional processing of the results of investigations 3D visualisation for a realistic illustration of the structural situation Information for scheduling as well as for further cost and profitability analyses

During the operating phase, we can take care of numerous infrastructure-related tasks on your behalf. This is to ensure you meet your responsibilities in terms of facilities and to support your interests in protecting and caring for your plant and machinery.

We can provide you with the following individual products: Design books Do you want to procure an item of plant, machinery or equipment? The design and procurement of an item of plant, machinery or equipment requires a specific procedure that only addresses selected parts of the HOAI scope of work up to service phase 3. Simplified procedures and documents have been developed within the DB Group for this process, which are used to apply for external approvals and the internal release of funds for procurement. If the investment volume exceeds EUR 200,000, this is summarised in the design book. Our services: Drafting of complete and up-to-date design documents in terms of content and form The design book has a set structure and includes the following: Description of the current status Description of the target status Design variants Reactions Target price quotations Cost estimates for the preferred design variant Profitability analysis Description of project risks and an evaluation of the same Your benefits: Reduction in design effort thanks to specific procedures and documents High level of acceptance for the design results by having experienced workshop equipment designers incorporate subsequent users into the design process Increase in decision certainty by using standardised decision papers Making things easier for end users in their day-to-day work, e.g. by taking care of interfaces with process participants in production, accident insurers, OSH professionals Machine technology technical design and procurement support Are you about to procure an item of plant, machinery or equipment? In order for the project to be a success for your workshop, a multitude of details have to be considered: careful design from the perspective of workshop production processes; drafting of tender documents for a legally compliant award of contract; bid evaluation; review of the works design; specialist construction supervision; acceptance and, finally, warranty monitoring. We stand ready to guide you through these steps in the process with our specialists in specific aspects of plant engineering, whether you need us only in selected phases or want us to take responsibility for everything on the client's side. Our services: Formulation of design books Drafting of functional tender documents Evaluation of bids and technical consulting on the award of contracts Execution supervision and quality assurance of prefabrication Acceptance and commissioning support Your benefits: Cost savings in procurement through functional tendering High adherence to project deadlines and budgets, reliable execution and quality through the use of mechanical engineering specialists in workshop equipment Functional tender documents Do you need an item of plant, machinery or equipment and have to invite tenders from the market? Qualified enquiry documents enable suppliers of plant, machinery and equipment to submit an attractively priced bid with reliable deadline commitments: the clearer the tender, the lower the risk premiums. Functional performance specifications stipulate the requirements for the intended use and define functional, technical, financial and design-related frameworks. The structure, scope and content of the document are designed in such a way that they reliably meet the requirements of public procurement regulations. Our services: Drafting and revision of site plans, functional sketches, sample solutions, framework schedules and action plans Formulation and coordination of the tender documents with the requester: functional performance specifications, price composition and evaluation matrix Your benefits: Cost savings in procurement through functional tendering Opening up to a wide range of supplier competition Enabling the use of manufacturer-specific, modular standards Reduced risk of claims due to high-quality specifications Reduced costs for construction drawings (HOAI phase 5) and reduced need for coordination thanks to clearly defined interfaces High degree of legal certainty in awarding contracts through the use of process documents that have been coordinated with legal and purchasing departments Best practice through comprehensive market and product knowledge of the workshop equipment suppliers, including current user feedback from DB depots Bid evaluation and contract award monitoring Do you want to compare bids and award contracts to the best ones in a way that is legally compliant? Systematically comparing tender documents from different bidders is time-consuming and often requires specific knowledge of the market and product structures involved. Furthermore, if you are bound by public procurement regulations, special requirements apply to the evaluation procedure used, its level of transparency and the criteria that are applied. The relevant legal regulations, which set different requirements depending on procurement volume, are vital here. DB Systemtechnik supports you in finding the right process for your project and in applying and handling the necessary procedures. Our services: Selection of suitable bidders via technical and commercial suitability criteria and evaluation of references Design, coordination and application of an evaluation matrix to determine the bid offering the best value for money Evaluation of bids based on the tender documents, the specified criteria and with reference to the state of the art Formulation of a questionnaire to act as a basis for technical discussions with bidders Answering technical questions from bidders, secondary assistance in award negotiations Formulation of the award proposal Your benefits: Procurement of products according to the state of the art Reduction in costs by identifying functional over-scoping and hidden surcharges High-quality data behind the decision to award the contract, while at the same time allowing project managers to focus on their core function in the line organisation Minimised risk of delays due to aspects of public procurement regulations such as complaints or challenges Execution supervision and quality assurance Do you need a high-quality delivery and assembly service? To ensure the quality of new installations, the client must supervise the entire manufacturing process. When it comes to technical questions about the project or to design changes, things become very specialised, very quickly. This process is characterised by constantly comparing the target condition (the service to be delivered) with the actual situation (the mechanical engineering functionalities or the scope of delivery during the execution phase). DB Systemtechnik provides you with professional support throughout this process, with the aim of achieving the best possible result you can. Our services: Technical support for the requester during the works design phase Review of design documents and technical descriptions Review of execution documents and support during sign-off Technical support for preliminary and interim acceptance at the supplier's premises Consulting with the client or requester in the form of statements, recommendations and technical representation during the execution phase Your benefits: High-quality data flowing into preparations for commissioning, while at the same time allowing project managers to focus on their core function in the line organisation Discussion, negotiation and decision-making on an equal professional footing with contractors in the event of non-conformity and change requests Close monitoring of assembly processes and interface into the workshop increases reliability in terms of Events functions budget by preventing revised estimates Support for acceptance and commissioning Do you want to put plants into operation in a way that is legally compliant? The acceptance and commissioning of constructed plants represent significant milestones in the project workflow. They are associated with legal consequences such as the passage of risk and the start of the warranty period; in commercial terms, they are usually associated with reaching payment deadlines. It is rare for these milestones to be passed with only insignificant defects at the first attempt for high-quality or integrated plants. Which makes it all the more important to detect and document points of deficiency and services that are owed, including binding and target-oriented agreements on how to eliminate the defects. DB Systemtechnik supports you through this by providing specialists who are experienced in the workshop systems in question. Our services: Comparison of the constructed plant components with the scope of deliverables ordered and defined in the context of procurement Preparation for and execution of mechanical engineering acceptances, functional tests at the contractor's premises, as well as preliminary, interim and final acceptances Review of documentation records for compliance with legal regulations and reconciliation with the required and necessary scope Technical support for the contractually defined trial period, evaluation of malfunctions occurring during the trial period, follow-up on punch lists Your benefits: Systematisation and qualification of the commissioning decision Binding guarantee of all contractual claims through assessment on an equal technical footing with suppliers generating and documenting contractual liability avoiding business risks such as premature acceptance, premature start of warranty and unjustified passage of risk Development support for tools and devices Are you procuring a new class? How can you efficiently manage the workshop/vehicle engineering/special tools interface? Design differences between new and old vehicles limit the efficiency with which you can maintain a new generation using existing procedures. This applies to the available infrastructure – designed for the existing fleet – as well as to activities on the new vehicles, which are to be executed within defined standard times. What special tools are available from the manufacturer or in depots with a comparable fleet profile to help achieve the corresponding production times? Can these tools be used in your workshop? Do other devices need to be designed for your specific site? We support you through this development process with expertise and experience of specific machine technology and the maintenance task at hand. Our services: Analysis of the vehicle engineering and workshop interfaces for the new vehicles Validation of new work instructions for local feasibility Compilation of specific workflows and frequencies of work to be performed in a workshop as a basis for assessing new workflows Evaluation of the usability of special tools recommended by the manufacturer, identification of alternatives and measures to optimise tools for local conditions Conceptual design and procurement support for special tools not available on the market Communication of potential points of conflict to local depots for review Monitoring and evaluation of component development tests Your benefits: Acceleration of your workshop's efficiency learning curve when introducing new vehicles Objective evaluation of manufacturer recommendations Sharing in best practice from other workshops Economies of scale by creating synergies through central processing when introducing in several workshops

We can help you to shape and prepare your project in order to create all the conditions you will need for qualified implementation. We offer: Development of infrastructure projects Are you creating the necessary conditions to start a project? Translating the results of a feasibility study into a specific project takes energy, time and a structured approach to ensure that the project requirements specification is formulated to a sufficient degree and the necessary structures are set up. We support you through this important phase methodically and with our extensive experience in the conceptual design, planning and implementation of projects aiming to design infrastructure for rail vehicle maintenance and component reconditioning. Our services: Facilitation of workshops and processing of their results in order to coordinate project requirements and tasks Compilation of qualified project requirements specifications for infrastructure projects Formulation of project structures and workflows, definition of targets for sub-projects, assessment of the necessary resources on the client side Support in identifying funding opportunities and applying for funding Consulting and engineering services in accordance with VDI 5200 "Factory planning" in the project and process analysis phases Active involvement in transferring the project to the planning phase How you benefit Reduction in the additional burden on your line organisation during the project set-up phase Creation of a reliable basis for project execution through the use of workshop-specific empirical data, quality standards and quality gates during project preparation Professional support in the preparation of draft resolutions and the compilation of all documents and data required for further planning Profitability analyses Do you need to assess whether the planned variant or the continuation variant of an infrastructure development is the best value option for you? Of course, such details are worked out in close collaboration with your company's commercial departments and you yourself will know best how the content fits together and what the fundamental arguments are. However, we can take care of manual implementation in the software tools for you, as well as coordinating the detailed figures with those involved from the production department. We have extensive experience in the vehicle maintenance production environment, as well as with the calculation programs commonly used within the DB Group. This means we can quickly provide statements on realistic parameters for design variants, so your decision will have the necessary resilience. Our services Innovation management and cross-sector technology monitoring Creation of a transaction in DB Invest or using alternative methods Collection, consolidation and validation of data Entry of data into IT forms Creation of variants Compilation of the results How you benefit The end user does not have to bother with the training and registration required for DB Invest or alternative methods High level of decision-making certainty thanks to the provision of validated data from projects that have already been carried out The calculation, all initial data and variants are permanently documented and archived centrally Application of standardised, professional calculation methods takes into account all current concerns such as public subsidies, tax issues and the situation on the financial markets Design and project review Is your workshop project on the right track? There are numerous internal instruments and committees that seek to ensure the quality of project implementation, but having external experts review designs at defined milestones can be a valuable aid. From our many years of experience in all phases of conversion and new-build projects for rail vehicle and component reconditioning workshops, we have extensive expertise that you can leverage in your project to qualify design results or assess changes. We can also help you to evaluate budgets and action plans; to assess the appropriateness of the visions that have been drawn up; and to resolve conflicts within the project by formulating neutral opinions and alternative design approaches. Our services Review of design results and the associated accompanying documents as well as basic data from the main planning phases Definition of the scope of the design results Evaluation of defined targets, identification of criteria for evaluating designs Development of evaluation matrices and proposed weightings Evaluation of design results and project risks (second opinion) Formulation of proposals for increasing quality or supplementing designs Design review and underpinning of mechanical engineering designs How you benefit Reduced project risks through objective project evaluation Increased acceptance of project results through external validation Uncovering of potential savings through restriction to functional solutions incorporating benchmarks from solutions implemented in DB workshops nationwide

We can provide you with the following products: Condition assessment for plant, machinery and equipment Is your plant getting on a bit? Do you need an estimate of its remaining economic life? It is often difficult to know whether continuing to run an existing plant or procuring a new one is the most cost-effective option. In order to make the right decision, all cost blocks and additional sales potential must be identified and prepared accordingly. We support you through this decision-making process with expertise and experience of specific machine technology and the maintenance task at hand. If you decide to continue running an existing plant, we develop concepts to improve maintenance and operation. If you decide to invest in a replacement, we suggest cost-effective variants suitable for your production needs. Our services: Recording the condition of the machinery Load history and state of wear Reliability, operating and maintenance costs Evaluation of plant maintenance intervals, tasks and processes Identification of optimisation measures and potential savings Forecasting of required maintenance expenses and re-investment dates for plant, machinery and equipment Description of performance characteristics of suitable successor machines Your benefits: Qualification of decision-making processes for procuring plant Independent validation of maintenance budgets or profitability analyses for new plant procurement Reduction of plant failures Reliable estimation of the time and resource requirements of procurement projects Proof of efficiency through external benchmarks Workshop interfaces for new and converted vehicles Are you expanding your vehicle fleet with new or modified classes? Then you need an analysis of the workshop interfaces for these new classes as early as possible. It is important to bring together all three perspectives here: maintenance production, vehicle and component engineering, and implementation of the infrastructure in mechanical and civil engineering. DB Systemtechnik achieves this with experienced railway engineers from the specialist maintenance engineering department. As a result, you get planning and cost certainty for exactly those new construction, conversion or adaptation measures that are needed to perform cost-effective vehicle maintenance on the new fleet. Our services: Development of vehicle-related maintenance concepts for workshops Analysis of existing and definition of required documentation for vehicles Drafting of vehicle and fleet-related workshop requirement profiles Presentation of effects on existing infrastructure, identification of design solutions on the infrastructure and vehicle side Preparation and documentation of workshop interfaces as drawings, geometry and weight specifications, free lifting heights, force application points and special tools Your benefits: High quality of project preparation without any additional burden on the line organisation Planning and budget security for infrastructure measures Narrowing down of task descriptions for infrastructure/equipment planners Cost transparency by working out the functional infrastructure requirements of new classes, staggered according to maintenance levels Early knowledge of the impact on workshops enables overall cost-minimising measures to be introduced on the vehicle design side Warehouse and logistics concepts Are you facing changes in your workshop's product portfolio? Do you need to build or expand a spare parts or large components warehouse? The first step on the path to realising high-performing and cost-effective systems is a warehouse and logistics concept for supplying materials to work stands and production lines that is tailored to your on-site conditions. As specialists in the field of function-oriented infrastructure planning for rail vehicle workshops, we take a holistic approach to maintenance processes. We support you with high-quality consulting and design services to create your very own warehouse technology and intralogistics concept. Our services: Material consumption analyses for guaranteeing and making decisions with regard to scoping and structure Review and plausibility check of initial spare parts requirements that are reported Drafting of concepts and selection of processes, transport and storage systems for designing old/new parts and operating material logistics for work stands Conceptual design and potential evaluation of the use of driverless material-handling equipment Design of high-density, automated small parts storage systems and automatic storage and retrieval units for pallet racking systems Drafting of tender documents and involvement from the awarding of contracts through to realisation and implementation Your benefits: Efficient formulation, high-quality results and future-oriented solutions by incorporating benchmarks from solutions implemented in DB workshops nationwide Production-oriented conceptual design and planning by experienced workshop engineers Restriction on warehouse inventories and space requirements by optimising the provisioning process and the storage location strategy Production and factory planning: Component manufacturing How can you further develop your component manufacturing? We can help you to answer this question by providing expert consulting and design services, from analysis to implementation and commissioning of new plant components or production lines. We provide you with state-of-the-art solutions for meeting your conceptual maintenance requirements cost-effectively, whether in the context of production reorganisation projects or product portfolio expansions. When it comes to design, we are your expert contact for the HOAI or VDI planning procedure, or for creating synergetic designs based on both procedures. Our services: Analysis of your component workshop Recording of the current status Investigation into the maintenance process, material flow and intralogistics Optimisation potential in manufacturing processes and mechanical engineering Design of your component workshop Identification of requirements from the ECM 2 maintenance rules Formulation of the target status in variants Cost estimates Coordinated results report Concept and detailed layout design of the workshops Formulation of performance specifications for plant and machinery Your benefits: Efficient formulation and high quality of results through incorporating benchmarks from solutions implemented in DB workshops nationwide involving DB Systemtechnik's specialist component services Detailed knowledge of the supplier market of specific machine technology 3D scan of maintenance sheds and plants Does your new plant fit into the existing building? What needs to be converted for this to happen? Your as-built plans do not correspond exactly to the reality on the ground in the workshop. When you start creating new plans, experience has shown that a 3D laser scan depicts the current status more accurately. We can help you by recording your maintenance sheds, workshops and facilities using terrestrial 3D laser scans. These provide you with an illustration that is updated daily and that we can overlay with new plans so their fit can be checked and optimised at an early stage. You will see a depiction of any clashes and, if required, the data can be prepared in such a way that it can be viewed on your own PC in a suitable viewer. We use products from Leica and Autodesk. Our services: 3D laser scan recording of your maintenance sheds, workshops and facilities Further processing of the data: Assembly Reconditioning for 3D CAD Provision to the client Depiction of deviations from the target geometry, e.g. uneven floors shown in a different colour Clash detection for newly planned installations and fixtures Re-recording of partial areas with already existing 3D scan data Virtual tour of workshops Your benefits: Up-to-date as-built documentation in the latest, BIM-compatible formats Clear representation of deviations from the target status Highly reliable feasibility assessments in confined spaces Clear presentation of the workshop and the planning procedure

We develop workshop facilities that meet the functional needs of your production processes and draft designs in accordance with the scope of work laid out in the HOAI or the VDI "Factory planning" guideline.