17%
Reduction in Line of Road failures
Enhancing Passenger Car Availability Through Maintenance Excellence
Industry: Transportation, Logistics and Services
Service: Manufacturing
Service: Operations Strategy and Transformation
Our Client
A national rail operator’s Commercial Group needed to increase passenger car availability to support growing demand in a busy region. Following a previous diagnostic, leadership launched an Operational Excellence initiative at a large maintenance center to improve mechanical performance and address key operational bottlenecks.
The Challenge
The rail operator’s Commercial Group was faced with insufficient passenger car availability to meet service demand in a key business corridor, facing key challenges such as:
- Operational inefficiencies in inspection workflows and material handling.
- Delays driven by limited parts availability and inconsistent frontline execution.
- Need for sustainable performance improvement and stronger daily management.
Real Results Achieved Together
Through EFESO's improvement plan, the rail operator optimized maintenance workflows and frontline leadership to boost passenger car availability, reducing failures by 17%.
11%
Decrease in train delays
Transformation Impact
- Reduction in number of cars waiting for materials from 5 to 3
- Increased planning efficiency and optimized workflows
- Improved daily management and ensured sustainable performance
Our Approach
EFESO deployed a structured improvement plan focused on process optimization and frontline leadership development:
Workflow Optimization
- Applied Industrial Engineering methods to streamline inspection activities.
Material Availability Focus
- Launched targeted efforts to ensure timely access to required parts.
Daily Visual Management
- Introduced a “Pulse” process to manage planning, scheduling, and performance in real time.
Frontline Coaching
- Trained and coached supervisors on performance management and sustaining gains on the shop floor.
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Facing Similar Challenges?
- Improve frontline management and ensure sustainable performance.
- Optimize workflows and streamline inspections with Industrial Engineering methods.
- Manage planning, scheduling, and timely access to required materials.
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