55%
Reduction in outage days for crossing changeouts
Accelerating Rail Crossing Changeouts: Optimizing Capital Project Delivery and Minimizing Service Disruption
Industry: Transportation, Logistics and Services
Service: Manufacturing
Service: Operations Strategy and Transformation
Our Client
A leading freight rail operator aiming to increase crossing changeout throughput without disrupting revenue service.
The Challenge
The rail operator faced operational and safety challenges in accelerating capital project delivery:
- Service disruption risk: Planned increase in crossing changeouts threatened to take revenue trains out of service.
- Inefficient processes: Crossing replacement workflows were slow and time-consuming.
- Safety concerns: Need to accelerate work without compromising safety standards.
- Limited coordination: Poor alignment between engineering, frontline leadership, and capital delivery crews.
Real Results Achieved Together
EFESO’s collaborative approach enabled faster crossing changeouts, reduced outages, and improved coordination across teams.
17%
Additional improvement enabling faster return of track to revenue service
Transformation Impact
- Streamlined crossing changeout processes to reduce time offline.
- Enhanced cross-functional collaboration between engineering, frontline leaders, and delivery crews.
- Applied Lean and Industrial Engineering tools to identify and eliminate waste.
- Optimized block planning to accelerate project execution while maintaining safety.
- Empowered field teams to implement efficiency improvements directly in their workflows.
Our Approach
EFESO applied a structured, collaborative method to optimize capital project delivery:
Lean Workshops
- Engaged frontline leaders, engineers, and capital crafts to apply Lean and Industrial Engineering principles.
Waste Identification
- Trained field teams to recognize inefficiencies in their own processes for faster, safer execution.
Optimized Block Planning
- Developed streamlined plans with capital delivery crews, minimizing downtime while ensuring safety compliance.
Cross-Functional Alignment
- Fostered improved coordination across engineering, leadership, and delivery teams to reduce handoff delays and non-value-added work.
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Facing Similar Challenges?
- Accelerate maintenance and project execution without disrupting service.
- Strengthen cross-functional collaboration and workflow efficiency.
- Apply Lean and Industrial Engineering principles for faster, safer project delivery.
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