updateCustomer magazine of Deutsche Plasser

ISSUE 13, DEcEmbEr 2019

RETROFIT Modernise and retain approval

cONVINcING bENEFITS

03 Editorial

04 A lot in favour of retrofit

08 Successful upgrade

10 Two machines back in shape

12 SSP 110 SW restored

14 Deutsche Plasser Poland

14 Vibration measurements

16 more space for a better service

17 PKP Seminar on maintenance

18 TrAKO 2019

19 ISO 9001:2015 certification in Poland

20 International centre of excellence

23 The new service package

24 News

IMPRESSUM

PublisherDeutsche Plasser bahnbaumaschinen GmbHFriedrich-Eckart-Str. 35, 81929 münchenTelephone: +49 89 93008-0Telefax: +49 89 93008-115E-mail: info@deutsche-plasser.dewww.deutsche-plasser.de

PhotosDeutsche Plasser, Plasser & Theurer,

PrintedDruckwerkstatt, Wien

Contents

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DP UPDATE 03

Dear readers,

Steve Jobs once said, “It doesn’t make sense to hire smart people and tell them what to do; we hire smart people so they can tell us what to do.”

This thought emphasises the huge value employees have for a company. Their know-ledge and experiences, their different approaches and problem-solving strategies – all this contributes considerably to the success of a company and for me is the guiding principle for managing our office in Poland.

Over 50 years ago, Plasser & Theurer delivered the first machine to Poland, an SLc 06-16. This marked the beginning of the success of the company as a partner of Polish track construction and maintenance. To date, over 300 Plasser & Theurer machines have been supplied to Poland for a wide range of tasks on the track.

In recent years, we have noticed a clear upturn in the Polish market, and we are looking forward to further machine deliveries. We will continue to support these machines to the proven quality standards with our team on site.

The foundations for this success have been laid over many years and are largely due to the work of committed and talented people. The quality of the machines unquestionably speaks for itself, but this, too, is a result of excellent technical competence and experience of the engineers in charge.

We want to build on this great foundation and strengthen it further in future. To achieve this, we have increased our Polish team to 16 people, nine of which are working in the service department. They have come from various industries and different companies. Thus, they bring a wealth of experience to our team, creating completely new synergies.

Deutsche Plasser is committed emphatically to valuing this pool of experience, talent and capabilities, both in Poland and Germany. We are working in a corporate environ-ment where new ideas are not just welcome but are expressly promoted.

Each input from our team members is important and will be looked at seriously and carefully – for each input has the potential to drive our development as a modern, customer-focused company forward. Very much in the spirit of Steve Jobs we have committed to this “mission future” in Poland and are pleased to report about its successes in this issue of DP update.

YoursWojciech MusialHead of Poland office

EditorialWojciech musial

„Mission Future: an experienced team for the Polish market.“

Wojciech MusialHead of Poland office

„

AFTER ThE RETROFIT you can see straight away that the Plasser & Theurer machine in its new design looks like new.

Is it worthwhile to upgrade a machine that is 20 to 30 years old? Would it not be more economically efficient to procure a new machine? These are questions that many machine operating companies are faced with again and again. Deutsche Plasser has a clear-cut answer: Retrofit. The new upgrade programme saves you cost and time and enhances existing operators’ workplaces significantly.

A lot in favour of retrofit

UPGrADING A mAcHINE AND rETAINING ITS APPrOVAL

Decades of use leave their mark on every machine. This does not change the fact that the basic elements of the machines can still be in good condition.

04 DP UPDATE

You do not get rid of a machine easily that has been working well for decades. You know what it can do. You appreciate the experience your

staff have gained in operating the machine. On the other hand, technologies change over the years; this can reduce the economic ef-ficiency of a machine over time or even cause issues for fulfilling certain contracts.

With its retrofit, Deutsche Plasser now offers a service programme that is tailored to precisely that situation. A retrofit upgrade means that the intact basic elements of the machine remain and that only those areas are reconditioned and renewed that the custo-mer requested. Only those components are replaced that result in higher productivity due to new technologies. Typical examples would be the DrP data recording device, the new SmartALc guiding computer or the latest rotation speed modulation. All work is plan-ned in cooperation with the machine ope-rating company and will therefore match its available spending volume. Following such an upgrade, the machine will be operational again for years to come.

Cost and time speak in favour of a retrofit

Of course, a lot depends on the current condition of the machine but upgrading a machine to the latest technology is nowhere near as cost-intensive as the purchase of a new machine. We assume that the cost of a retrofit is considerably lower than the purchase price of a new machine.

Even more favourable is the time compa-rison. A retrofit takes eight to ten months, depending on the scope of work and the size of the machine. After that, the machine will go straight back to work on the track. If requested, the machine operating staff can even be involved in the retrofit. This way the staff will continue working and can gather valuable experience about the machine during the upgrade work. This knowledge can come in very handy for maintenance work later on.

DP UPDATE 05

A look inside the machine reveals how thorough and extensive the upgrade work is.

!Retrofit saves time & money

06 DP UPDATE

The approval remains validAfter an upgrade, a machine can only be de-ployed straight away if the approval remains valid. Deutsche Plasser will ensure that this is the case. As a partner of Plasser & Theurer, we have direct access to the machine master data, and so we know exactly what upgrade work can and cannot be performed. We also have direct contact with the Approvals Depart-ment at Plasser & Theurer, which can provide clear information in case of uncertainty. With some workshops offering similar services to retrofit there is the risk that problems may arise afterwards with regard to approvals; that way, the time frame will increase exponentially.

Proven machines continue working

many customers particularly appreciate the SSP 110 type ballast ploughs. Numerous machines of this type are still in use. A retro-fit provides the opportunity to upgrade this machine without losing its approval. This means, the machine can operate economi- cally for years to come.

The staff are pleased about the upgraded operators’ workplaces

The issue of staff shortages in track con-struction is well-known. One possibility to retain one’s own staff better is to offer more attractive workplaces. retrofit makes just that possible. The staff do not need to part from the machine with which they have

worked for many years and which they know inside out, but they will get their machine back in a completely new and substantially upgraded condition. And – as mentioned above – they can even take part in the upgrade work. A clear win-win situation for everybody involved.

An up-to-date machine for years to come

The Deutsche Plasser retrofit upgrades a ma-chine that is 20 to 30 years old so it can op-erate in an economically efficient manner for years to come. The cost of this is clearly below the procurement cost of a new machine. The time required is considerably less. The approval remains valid. For some machine types, such as the SSP 110, it opens up the

possibility to continue operating at all. In ad-dition to these clear benefits, another plus is that the staff can continue working on their machine. On a machine they have known for a long time and which they will appreciate even more once it has been upgraded and become even more attractive to work with.

The hydraulics system of this machine was renewed completely.

DP UPDATE 07

„The approval of the machine is retained!“

„Andreas Senfleben

Technical Sales

hyDRAUlICS AnD ElECTRICS no longer look like they used to when the machine was originally delivered. But this can be changed, too.

08 DP UPDATE

Successful upgrade

rETrOFIT IN OPLADEN

A typical case. The Unimat 08-475/4S Turnout Tamping machine has been in use for the maintenance and

expansion of DB’s infrastructure since 1995. Since every-body was very happy with the machine’s performance,

the operating company decided at the beginning of 2018 to have it fully upgraded by Deutsche Plasser.

RETROFIT OF ThE UnIMAT 08-475/4S operated by Joseph Hubert. To start with, the machine was completely dismantled in January 2019.

DP UPDATE 09

The Unimat 08-475/4S is an impor-tant part of the modern machine fleet at the Joseph Hubert com-pany. For many years, it has been

used for turnout tamping and also for working short sections of track. With great success. After 23 years, the machine started to dis-play signs of wear due to its age, and key components of the equipment were no longer state of the art. At the beginning of 2018, the company contacted Deutsche Plasser to dis-cuss the possibility and commercial viability of a retrofit. At that point the machine was still in full operational use.

Major check-up in summer 2018In August 2018, the Unimat 08-475/4S ar- rived at the Leverkusen-Opladen maintenance workshop for a major check-up. At the same time, we contacted Plasser & Theurer in Linz to find out which upgrade measures were possible without jeopardising the machine approval. Equipped with this information, we had another round of talks with the experts at Joseph Hubert. This was eventually used to define the scope of the contract and the timescale of the project.

Retrofit start in January 2019The machine eventually arrived at the Lever-kusen-Opladen maintenance workshop and, to start with, was completely dismantled. Hydraulics, measurement technology, cabs, work and drive units were fully disassembled. All that was left of the machine was the frame. Then the gradual rebuild began, starting with sanding down the frame, which was to be painted in line with the new machine design. Within about 9 months, the following work, amongst others, was carried out:

• Fittinganewhydraulicsystem (including valves)• Partialrenewaloftheelectrics• Bogiesoverhaul• Fittinganew,morepowerfuldriveunitwith

exhaust gas treatment• Reconditioningandinstallationofthework

units (lifting and lining unit, telescopic shift-ing, additional lifting, shoulder compactor)

• Modificationof the lining trolley to linearguidance

• Repairofthetampingunits• InstallationofadigitalDRPrecorderanda

SmartALc• Paintworkinlinewiththenew Plasser & Theurer machine design

Delivery in August 2019In August 2019, the upgraded Unimat 08-475/4S left the Leverkusen-Opladen plant following extensive testing, and travelled straight to the next worksite. The machine has been in continuous operation since then. Subject to the maintenance regulations being met, this is expected to continue for years to come.

In August the Unimat 08-475/4S left our works in a new design, technically upgraded and with the approval still in place.

10 DP UPDATE

In summer 2018, a freight train crashes into two stationary machines operated by Schweerbau. The Unimat 09-16/4S

Tamping Machine and the SSP 110 SW Ballast Plough suffer considerable damage. Shortly after the accident both machines arrive in Opladen, where they are to be given a new lease of life.

Two machines back in shape

rEPAIr AND rETrOFIT AFTEr rEAr-END cOLLISION

UnIMAT 09-16/4S WITh TRAIlER. In early November 2019, progress in the repair of the damaged machine is evident. In February 2020 the machine is expected to be back in service.

DP UPDATE 11

After the accident, Schweerbau originally wanted to scrap or pos-sibly sell the 21-year-old Unimat 09-16/4S as quickly as possible.

but in the end the company decided otherwi-se. This was due to the new option to perform a retrofit on the machine. Following success-ful negotiations with the insurance company it was agreed that Deutsche Plasser would repair the machine and at the same time carry out a retrofit. The insurance company would pay for the cost of the repair, Schweerbau would pay for the retrofit.

Retaining approval at any rate!To retain the approval for the machine, we consulted with Plasser & Theurer in Linz to find out what retrofit measures could be taken in this instance. Not an easy task, especially since in this case the control system needed to be updated. Work on the Unimat 09-16/4S in Opladen has been under way since may 2019. completion is scheduled for February 2020.

Repair and upgrade of the SSP 110 SW already completed successfully

right from the start things were different for the SSP 110 SW ballast plough. This machine had undergone a complete retrofit eight years ago, and Schweerbau was keen to continue using it. Therefore, the machine stayed in Opladen after the accident. The extensive work that has been carried out on the machine since includes a complete replacement of the frame.

!Overhaul & modernisation

12 DP UPDATE

SSP 110 SW restored

rEPAIr

The investigation into the causes of the fire is still ongoing. The effects of the fire were known a few days later. Over 80% of the machine had been

destroyed. The fire burnt down the whole front part, caused severe damage to the cabin and the drive unit and destroyed large parts of the hydraulics and electrics. The burnt-out SSP 110 SW was examined in our Leverkusen-Opladen maintenance plant on 3rd April. customer representatives, ex-perts from the manufacturer robel and from Deutsche Plasser were present. After another two weeks the customer was provided with the information about what core work need-ed to be carried out to make the machine operational again. From the beginning, the customer wanted this to be done, since the SSP 110 SW is no longer built in this version.

A dynamic projectIn order not to waste any time, our staff in Opladen started to dismantle the machine straight away. Even so, the time it takes to repair a 14-year-old machine only depends to a very small extent on our capacities in Opladen. much more critical factors in such projects are the availability/lead times of the components and vehicle equipment. Some spare parts are no longer available in their original form and need to be specially pro-duced, which can be very time-consuming. In addition, the damage caused by a fire is different from normal wear. This means that the production and some of the design take time and have to be carried out by the people who know the machine technology, i.e. at robel, the manufacturer.

During the night of 29th March 2019, the SSP 110 SW Ballast

Regulator operated by Gleisbau-Busching-Wagner caught fire.

It is still not known what caused it. On 30th March, the damaged vehicle could be moved to our

Leverkusen-Opladen maintenance workshop. The restoration

started on 2nd April ...

Mid October 2019 the repair work on the burnt-down SSP 110 SW from Gleisbau-Busching-Wagner is on schedule. Considerable progress can already be seen on the freshly painted cabin.

DP UPDATE 13

With this in mind, the customer was quoted a project duration that would enable us to reliably carry out all the work. We did point out that this project period would be re- duced if bought-in parts were supplied earlier than predicted.

Work in full progressTo date, the project is on schedule. All key components have been ordered and have arrived at the maintenance workshop for as-sembly. Some of the work has already been completed. All things going well, without any unexpected delays, Gleisbau-busching- Wagner will be able to take the machine back in operation just under a year after the fire.

WORk TO bE CARRIED OUT On ThE SSP 110 SW OF GlEISbAU-bUSChInG-WAGnER

• renew hydraulics and outside connection lines to the standard of the latest fire safety regulation • renew interior cabin lining and flooring • repair control and operator panels inside the cabin• completely recondition vehicle frame• New paintwork

RECOnDITIOnInG OF TAMPInG UnITS

2017 - 2019Reconditioned tamping units

100

120

140

160

Customers served

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15

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2017

2017 2018 2019

2018 2019

Machines

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40

2017 2018 2019

ThE UnIMAT 09-4x4/4S DynAMIC from Budimex was equipped with 3D acceleration sensors for the measurement runs.

14 DP UPDATE

Deutsche Plasser Poland together with Politechnika Wrocławska (Wrocław Technical University) performed vibration measurements to compare the effectiveness

of a DGS 62N and a Unimat 09-4x4/4S Dynamic.

Vibration measurements

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Innovation

DP UPDATE 15

The measurements were carried out to compare the outputs of a DGS 62N with two stabilising units and a Unimat 09-4x4/4S

Dynamic with one tamping unit.

ObjectivesThe measurements should provide conclu-sions on two areas of interest:• acomparisonoftheoutputsofthetwoma-

chines at different speeds and frequencies• anexamination todetermine if thema-

chines can achieve a degree of track stability that would permit trains running on the track at over 100 km/h

For the collection of the required data, 3D acceleration sensors were used to obtain the measurements; the values were then com-pared and analysed.

Implementation of the experimentsThe experiments were carried out in Pila-wa on 31st July and 1st August. machines

operated by budimex were used for the ex-periment and equipped with the necessary sensors beforehand.

ResultsWe are very pleased with the results. The measurement data shows that both the DGS 62N and the Unimat 09-4x4/4S Dynamic achieve a track stability that allows trains running on the track at over 100 km/h.Furthermore, the measurement data indicate that measuring runs with the use of a DrP should be carried our prior to stabilisation. With the data obtained it can be ensured that the track is tamped and stabilised to the best possible quality.

Financing The project was financed using an “innovati-on voucher” from the regional Programme of the European Fund and the European Fund for regional Development.

The other machine deployed for the research project was the DGS 62 N from Budimex.

“The results of the research project are highly welcome, and we are pleased to be able to offer suitable machines for all requirements of track

stabilisation in Poland.”

Wojciech MusialHead of Poland office

„

16 DP UPDATE

NEW OFFIcE

more space for a better service

The address remains the same. The new office is in the same building as the old one but offers about twice as much space. The additional

space provides the best working conditions for our members of staff and, above all, provides more space for customer service.

Workshop area doubledThe workshop area has doubled in size. An area covering over 120 m2 is now available for servicing work. In addition, a new office was set up for our service engineers so they can prepare for and follow up on their call-outs in an ideal environment.The new space also provides a new home for the electronics workshop, which was set up at the beginning of 2019. Here, electro-nic components, e.g. transducers and pen-dulums, can now be serviced and repaired, if necessary, directly on site for our Polish customers. This saves time and cost for the customers’ benefit as these components no longer need to be sent to Germany.

New meeting roomThe new office also houses a meeting room which offers ideal conditions for successful customer care. It is well equipped and has access to the workshop area, which allows customers and prospects to familiarise them-selves with Plasser & Theurer machines and our service offering.In addition, this room is used for continuous professional development of our staff so they have the best possible qualifications for their work.

More human resourcesThe expansion of the Polish service team is a response to the development in the Polish market. Poland is increasingly committing public funds to improve its railway infrastruc-ture. This results in fast upgrades of machines and processes. At the same time, more and more Polish railway construction companies are sub-contracting their servicing work.

In recent years, the Polish office of Deutsche Plasser has seen healthy growth and thus an increase in the number of employees. When the previous office opened we employed two service engineers in Poland. This has increased to nine service engineers today. In order to offer our Polish team optimum working condi-tions, they moved into a bigger office in the summer of 2019.

The new office of Deutsche Plasser in Poland. The workshop area was doubled to more than 120 m2.

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DP UPDATE 17

International experts from academia and practice shared their knowledge with the attendees.

In their talks, internationally acclaimed experts, both academics and practi-tioners, examined different aspects of maintenance.

Comprehensive overviewThe systematic structure of the programme offered a comprehensive overview for the participants, from strategies for perma-nent way maintenance, best practice ex-amples on maintenance technologies and the selection of appropriate machines for the chosen maintenance strategy through to the economically efficient deployment of machines and the huge importance of a service offering over the whole life cycle of a machine.

Service offering as exemplified by Deutsche Plasser

In his talk on services, Wojciech musial, Head of our Polish office, outlined the wide range of possible services, using Deutsche Plasser’s service offering as an example. He emphasised the importance of fol-lowing manufacturers’ recommendations. This ensures that a machine’s availability is as high as it possibly can be.

At the beginning of September 2019, PKP Polskie Linie Kolejowe S.A. in Warsaw held a seminar on the subject of maintenance. Wojciech Musial, Head of our Polish office, represented Deutsche Plasser as a speaker.

Many participants accepted the invitation from PKP Polskie Linie Kolejowe S.A. to attend the seminar.

PkP Seminar on Maintenance

SEmINAr

The new meeting room offers ideal conditions for successful customer care.Part of our team in Poland.

18 DP UPDATE

Over the last few years, Trako has gone from strength to strength. In 2019, over 18,000 visitors and around 700 exhibitors from 30

countries attended the trade fair.For this year’s fair, our Polish office decided to focus on three areas.

Expansion of service offeringWe used this opportunity to present the ex-pansion of our service offering in Poland. In addition to expanding our team of service engineers, we are also very pleased to have a bigger workshop which enables us to carry out considerably more work locally than be-fore. Furthermore, we have taken a big step towards the digitalisation of our processes. All these measures assist us in looking after our customers better and completing the servicing work more quickly and efficiently. This also contributes significantly to a high availability of the machines.

24/7 serviceHand in hand with the expansion of our service capacities we would like to offer our customers a more tailor-made service, going as far as a 24/7 offering. This service solution allows us to respond flexibly to the wishes and needs of our customers, including cus-tomer support 24 hours a day, 7 days a week.

Tamping unit overhaul offerOur third focus at the trade fair was on our proven and comprehensive programme for tamping unit overhauls with four options. No matter which option our customers choose, we will actively support them. We offer fixed prices without subsequent charges (for major overhauls with original spare parts) as well as an extended warranty.

Successful trade fairWe are very pleased with this trade fair. We were able to engage in many informative

Trako 2019TrADE FAIr

xxxxxxxxx xxxxx xxx xxx xxxxxxxx xxx

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At the end of September, Poland’s biggest railway fair, Trako 2019, took place in Danzig. Deutsche Plasser participated again this year and was able to engage in many interesting discussions.

DP UPDATE 19

“For us, Trako was a highly interesting and valuable trade fair. I am delighted

about the positive feedback we received from our customers on our work,

especially on the recent expansion of our service offering for the Polish market.”

Wojciech MusialHead of Poland office

„

ISO 9001:2015 CERTIFICATIOn In POlAnD

In summer 2019, an ISO 9001:2015 audit was carried out in our Polish office in Wroclaw. The audit was completed successfully, and our Wroclaw plant received its ISO 9001:2015 certification in September.The preparations for the audit started at the beginning of the year. In close cooperation with the Quality management department in munich, Deutsche Plasser Poland prepared thoroughly for the certification process.The long-standing experience in munich provided invaluable assistance in streamlining the processes in Poland. Furthermore, defining the processes helped to distinguish between standardised and non-standardised processes. This clear concept provides greater flexibility in the day-to-day business.The audit was completed successfully on 3rd July. The official certificate for the ISO 9001:2015 standard was finally issued on 9th October 2019.

discussions with current and prospective customers and successfully present our three key areas. Personal contact with our Polish customers provided the opportunity to better understand the challenges they face in their day-to-day work. These insights will be utilised in the coming months for developing new and advancing existing solutions.

Ort und Datum:

Zertifizierungsstelle:

Essen, 09. Oktober 2019 DNV GL - Business Assurance

Schnieringshof 14, 45329 Essen, Germany

Thomas Beck Leiter Zertifizierungsstelle

Bei Verstoß gegen die im Zertifizierungsvertrag genannten Bedingungen kann das Zertifikat seine Gültigkeit verlieren.

AKKREDITIERTE STELLE: DNV GL Business Assurance Zertifizierung & Umweltgutachter GmbH, Schnieringshof 14, 45329 Essen, Germany.

TEL:+49 201 7296-555. www.dnvgl.de/assurance

Zertifikat-Nr.: 77623-2010-AQ-GER-DAkkS

Datum der Erstzertifizierung:

10. November 2004

Gültig: 01. November 2019 - 31. Oktober 2022

Hiermit wird bescheinigt, dass das Unternehmen

Deutsche Plasser Bahnbaumaschinen GmbH Friedrich-Eckart-Str. 35, 81929 München, Deutschland

sowie die im Anhang aufgeführten Standorte

ein Qualitäts-Managementsystem in Übereinstimmung mit dem folgenden Standard

eingeführt hat und anwendet:

ISO 9001:2015 Dieses Zertifikat ist gültig für die folgenden Produkt- oder Dienstleistungsbereiche:

Vertrieb, Reparatur, Instandhaltung, Wartung, Inspektion, Begutachtung,

Schulungen und Einweisungen von Bahnbaumaschinen sowie Vertrieb und

Lagerhaltung von entsprechenden Ersatzteilen

20 DP UPDATE

TAmPING UNIT OVErHAUL

International centre of excellenceIf there is a service that has a special link to Deutsche Plasser, it is the reconditioning of tamping units. Ever since we founded

our company, we have gathered a lot of expertise and experience in this area.

In OUR WORkShOP we also deliver training to the employees of our partner companies.

DP UPDATE 21

For decades, our customers have appreciated our competence in this area, and this year we are pleased to report yet another increase in orders.

For our partner companies, too, we are a highly respected contact for anything to do with the reconditioning of tamping units.

Support from Deutsche PlasserWhile for us this has been one of our key services since the beginning, some of our partner companies are only just starting out in this area. As there is a big demand from machine operators to carry out these over-hauls locally, our partners are keen to set up their own departments. based on our excel-lent reputation in this area we are often asked to support them.

Visits to MunichThis support usually starts off with a visit to our workshop in munich. Here, our guests will familiarise themselves with our pro- cesses and our quality requirements, which at the same time are a benchmark for their own efforts.Over the last few years we have welcomed delegations from brazil, India, Australia, South Korea and the USA in munich. Usually, one visit is not enough; usually, subsequent visits by engineers, who will have to recon-dition the tamping units at their premises, will follow.They will spend several weeks in munich and shadow our specialist staff in their daily work. This way all work steps, from the preparatory work through to the test run and the nec-

essary documentation, can be taught thoroughly, and the visiting engineers can gather initial hands-on experience.

Local supportWhen partner companies start to set up their own departments, our support is not con-fined to visits in munich, but we will assist them locally to ensure the best implementa-tion. In July 2019, our experienced engineer Alexander Schneider spent four weeks in the USA with Plasser American to assist them with setting up a department for the overhaul of tamping units.mr Schneider has been with Deutsche Plas-ser for 17 years, has spent the last 15 years in our repair technology department in munich and is regularly deployed for machine repairs in the field. During this time, he has become an expert for Plasser & Theurer tamping units and therefore a competent contact for our partner companies.

Joint kick-off in VirginiaHis stay in Virginia marked the kick-off for tamping unit overhauls in North America. mr Schneider instructed the local members of staff in the basic principles and guided them along the different work steps.Plasser American has ambitious plans. A new workshop will be built for the overhaul of the tamping units, and the responsible team will be expanded. The staff working in this area already had strong basic skills and initial experiences; our member of staff had the task of “finetuning” these in different areas.A deliberate decision was made to cover a wide range of tasks. From preparatory work, such as the organisation of the tools and re-sources or the frame measurement, on to the

Plasser American was very happy with the support from Munich.

Alexander Schneider has been working in our repair technology department in Munich for 15 years and is regularly deployed for machine repairs.

Competence & cooperation

22 DP UPDATE

finishing of individual components and the re-vision of the documentation through to the assembly and testing of the tamping units – nothing was left out.Alexander Schneider and his US colleagues managed to fully overhaul two tamping units in these first four weeks - and to the proven Deutsche Plasser quality.And there is more to come. Within the next year, mr Schneider will travel back to Plasser American to carry out an analysis with the American team of the experience gained thus far. The results will serve as a basis for further training that he will deliver afterwards. Deutsche Plasser continues to remain a close partner for tamping unit overhauls in North America.

Ambitious plans in IndiaPlasser India, too, has ambitious plans. Like in the USA, a new workshop for tamping unit overhauls will be set up in India, and a team of engineers will receive training.Apart from an Indian delegation visiting munich, mr Schneider has already been to India to provide initial training to the envisa-ged team, similar to the USA.

Close cooperation with Plasser & Theurer

Apart from our long-standing experience and vast technical expertise, another building block for our excellent reputation in tamping unit overhauls is the close cooperation with the manufacturer Plasser & Theurer.Our engineers work closely with the experts

in Linz and so have direct access to the latest technologies and insights. All this feeds into our day-to-day work and ensures the high quality of our service.

Renowned globallyIn the USA or India, in Australia, Asia or South America: Deutsche Plasser and its employees are renowned all over the world for their expertise in reconditioning and over-hauling tamping units. Yet, we do not rest on our laurels but always endeavour to do better. We will never lose sight of our ultimate aim: to ensure the best possible availability of tamp-ing machines from Plasser & Theurer.

Delegations of our partner companies, e.g. Plasser India, like to visit our workshop to benefit from our expertise in tamping unit overhauls.

During Mr. Schneider‘s stay in the USA, two units were jointly overhauled with the Plasser American team.

„I am pleased to share my knowledge and experience with colleagues

from our partner companies.“

Alexander SchneiderRepair Technology

„

DP UPDATE 23

VEDO

The new service package

by the time the first major overhaul of a machine is due, every operating company will need to decide how a machine can be brought back

to perfect condition as economically as pos-sible. Our answer to this is VEDO, the new service package that contains all required spare parts and service offerings. VEDO starts off with a machine audit car-ried out by a service engineer. In the second stage, the current condition of the machine is documented comprehensively in an audit report. based on that, we put together a quo-tation listing the measures and spare parts recommended for an efficient overhaul and upgrade. In addition, we will be available to provide support of any kind for carrying out the work.

New overhaul standard with global validity

VEDO is a service package we are offering in cooperation with our global partner com-panies. The machine audits, audit reports and VEDO quotations are prepared using standardised protocols. All processes and services meet Plasser & Theurer’s strict quality criteria.

For your machine overhaul

yOUR bEnEFIT

• Increasedavailability• Establishingfullfunctionality• Machineauditmakinguseofthemanufacturer’sknow-how• Reliableandcomprehensiveauditreport• VEDOquotationforallrequiredsparepartsandmeasures• Adheringtoqualitycriteriaoftheworldmarketleader

Since 1st July 2019, Christian Greifelt has held the position of certified welding engineer in our leverkusen-Opladen Maintenance Work-shop. In addition to that, he is also working in the Quality Manage-ment and Compliance department, where he is responsible for the quality management in the plant.

christian Greifelt studied mechanical engineering and, prior to joining Deutsche Plasser, worked as a design engineer for a reputable German crane manufacturer, where he also held the position of certified welding engineer.

born and bred in Leverkusen, christian Greifelt has known about our Lever-kusen-Opladen maintenance workshop for some time. “In march, when I attended the “Night of Technology, I got to know the workshop and the Plasser & Theurer machines better”. These machines make a mechanical engineer’s heart beat faster. From then on I knew that I wanted to work there.”

Planned expansion of welding competence

christian Greifelt has now been with us since July. He thoroughly enjoys his new workplace, and he already has plans to position the welding compe-tence of the plant even more broadly.

Christian, once again a very warm welcome at Deutsche Plasser and all the best!

24 DP UPDATE

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CERTIFICATIOnS REnEWED

Deutsche Plasser is pleased with the extension of existing certifications. Deutsche bahn confirmed our quality capability as a supplier with the highest rating Q1.In addition, our facilities in munich and our maintenance workshop in Opladen once again received the certifica-tion for the welding of railway vehicles and parts as per EN 15085-2.

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new certified welding engineer in Opladen

“Both aluminium and stainless steel are becoming more and more important for our machines. Therefore, we will try and

expand our welding competence in these areas over the next few years.”

Christian GreifeltCertified Welding Engineer, Deutsche PlasserMaintenance Workshop Leverkusen-Opladen

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The handover was accompanied by our member of staff Ernest malkoc. As usual, he was available for in-structions and any questions arising

in practise to assist the vehicle driver and future operators during the first few shifts. Operating the vehicle, loading the rails and operating the crane were they key tasks. The vehicle is stationed at berlin rummelsburg.

MISS platform

The Track Working Vehicle (GAF) from Plasser & Theurer was based on the mISS platform. mISS stands for “Track Infrastructure multi-functional maintenance Vehicles”. The vehi-cles are intended to be deployed for various tasks on the track but are of similar designs.

Versatile working vehicle

The series 746 track working vehicles have particularly large loading platforms that can be used in many ways. They are even big enough for turnout parts. rails and other long

material of up to 20 m length can be carried along on special supports on the side of the frame.The vehicles can be connected up and used in double-traction mode. braked wagons of up to a total weight of 80 tonnes can be trailed.Depending on the vehicle model, different tools can be attached to the cranes of this series of vehicles, e.g. clamshell grabs, forestry mulchers, branch and hedge clip-pers. Furthermore, the vehicles are designed to attach snow clearing equipment (snow blower, snow plough, snow sweeper).In addition, the GAF has a vibration-decou-pled sound- and heat-insulated cabin with driver’s and pilot’s seat as well as a recreation area with fridge, Wc, heating and air condi-tioning. At the other end of the vehicle is a vibration-decoupled sound- and heat-insula-ted rotating cabin with heating, air conditio-ning, driver’s and operator’s desk for crane operations (= pilot’s seat).

Track Working Vehicle for Db netz

DELIVErY

Service engineer Ernest Malkoc supported the first deployments of the new Track Working Vehicle, which is stationed in Berlin Rummelsburg.

Prior to being handed over to our customer DB Netz AG, the Track Working Vehicle was showcased at the iaf Congress in Münster.

Once the machine had been presented to industry experts at the iaf Congress in Münster in May 2019, it was handed over to DB Netz AG in Berlin on 3rd June. This was number 14 of a total of 28 machines of the Plasser & Theurer 746 series.

DP UPDATE 25

26 DP UPDATE

Veit Tobis and marcus Saalborn from Deutsche Plasser assisted in the delivery, training and machine in-duction. They had taken part in the

training for operators and service engineers in Linz, which gave them an ideal opportunity to familiarise themselves with the machine and the customer team that will be respon-sible for the machine.

Handover and training on site

After completing the training in Linz, the machine was shipped from Linz to the Königsborn site of Db bahnbau group. There the official handover to the customer took place on 29th may 2019.After that, the operators were instructed and the machine commissioned jointly with our staff on site. The operating company is very happy with the machine which is already deployed successfully in normal operation.This machine is Db bahnbau’s third machine of this type stationed in Königsborn. The fourth already supplied machine is stationed in Hanau.

Proven machine type

The USP 2000 c2 is a ballast profiling machine with a 5-cubic-metre hopper for all line categories with one-pass technology. The two-sided shoulder ploughs with auto-matic slew limiters that can be used without affecting the clearance gauge allow for optimum adaptation to any ballast bed edge. The precise level and alignment control of the centre plough ensures gentle treatment of sleepers and fastenings as well as a reduction of the remaining ballast on the bal-last shoulder to a minimum, independent of the working direction. The sweeper unit has a cross and a steep conveyor as well as an electric sweeper brush changeover device. The 5-cubic-metre hopper is used for the needs-based intake of ballast and its recovery.

Deutsche Plasser assisted with the delivery of a USP 2000 C2 Universal Ballast Distribution and Regulating Machine to the DB Bahnbau group. This was the fourth machine of this type that was handed over to the customer.

USP 2000 C2 to Db bahnbau

DELIVErY

Veit Tobis and Marcus Saalborn assisted with the delivery of the machine and managed the training and instruction of the future ope-rators and service engineers.

The USP 2000 C2 of DB Bahnbau group in Linz prior to delivery to Königsborn.

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The good order situation in the cur-rent year and the positive prospects for the coming years ensure that our maintenance workshop in Leverkusen-

Opladen will be working to capacity. To meet the resulting challenges in the usual high quality, we are separating the areas of plant management and technology.Since 18th November 2019, Sven Peters is a Project Engineer for Technology and EbA expert (German Federal railway Office) at our main- tenance workshop. The position of plant manager has been taken over by Thomas ruland, who has extensive experience in the areas of pro-cess optimisation and organisational structuring. mr. ruland is the first point of contact for our customers in all things related to our main- tenance workshop.

Change in management of our maintenance workshop in leverkusen-Opladen

Thomas Ruland is the new plant manager of our maintenance workshop in Leverkusen-Opladen.

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28 DP UPDATEwww.deutsche-plasser.de

Find more information on retrofit here:www.deutsche-plasser.de/retrofit