Worker Guidance PG Revolutionizes Bogie Assembly and Overhaul at Stadler Rail

CSP GmbH & Co. KG, together with Stadler Rail, has successfully implemented a pioneering project for mobile worker guidance in rail vehicle production.

Mobile quality assurance in accordance with DIN EN 17976 enables error-free documentation for more than 18,000 digitalized work processes in rail vehicle manufacturing.

CSP GmbH & Co. KG, together with Stadler Rail, has successfully implemented a pioneering project for mobile worker guidance in rail vehicle production.
With PG (Process Guidance), over 18,000 work processes in bogie assembly and overhaul are digitally guided and documented.

The manufacturer-independent system enables seamless traceability and supports compliance with the European standard DIN EN 17976 for safe bolting in rail vehicles — all without additional training requirements for employees.

* Stadler Rail: Precision and Quality at Eleven Sites Worldwide

Stadler Rail has been developing and producing rail vehicles since 1942 — from regional trains and trams to custom-built one-off solutions.
The company employs around 7,000 people at eleven sites worldwide. In bogie assembly at the Winterthur site in particular, precise and traceable bolting plays a crucial role in product quality and liability safety.

* The Challenge: Product Liability and Efficiency in Complex Processes

At Stadler, the challenge was to ensure fully traceable and error-free bolt documentation despite a high variety of variants. "For liability reasons, exact inspections and complete documentation are required for bolting processes. Individual bolts must remain traceable even years later,” explains Ronny Böhler, Head of Bogie Assembly, Stadler Winterthur AG.

The previous software from the tool manufacturer could not efficiently handle the data volumes.
“Before PG was introduced, we worked with table-based lists that were hardly manageable. A lot of information was available, but not relevant for daily work,” says Böhler.

* The PG Solution: Mobile, Visually Guided Quality Assurance

In 2015, Stadler opted for the manufacturer-independent PG solution from CSP GmbH & Co. KG.
The system offers:

- Mobile worker guidance via tablets directly at the bogie
- Step-by-step instructions with visual support
- Manufacturer-independent integration of various systems and tools
- Automatic electronic documentation of every work step
- Modular implementation in only four days without production downtime

“The implementation of PG was modular and straightforward. Within a very short time, our workers could operate directly at the bogie step by step — with clear instructions and without additional training,” confirms Ronny Böhler.

“Digital worker guidance allows us to clearly define the production sequence and ensure that best practices are consistently followed.”

“Paper-based documentation has been completely replaced by digital instructions. This saves time and prevents outdated drawings from being used accidentally.”

* Impressive Results

Thanks to the PG implementation, significant improvements in efficiency and quality have been achieved:
- 18,829 work processes digitalized
- 6,960 images integrated into visual instructions
- 487 workstations equipped with PG
- 1,004 active users daily
- Greatly reduced training and onboarding requirements
- Significantly reduced error rates in production and documentation
- Rapid introduction without operational downtime

“Since the introduction of worker guidance, we have significantly reduced the error rate in production and documentation. Visual support increases process reliability and minimizes queries.”

* Reliability and Future-Proofing

The solution operates at Stadler with almost no interruptions and is continuously expanded.
“High flexibility, smooth processes, and full compliance with standards — the system has become indispensable in our daily production,” says Ronny Böhler.

PG is now used not only in bogie assembly in Winterthur but also in other plants and in bogie overhaul.

“The onboarding time for more complex workstations has noticeably decreased due to the step-by-step instructions. New employees can be deployed more quickly without additional training requirements.”

* Conclusion

With PG, Stadler Rail has taken a decisive step toward digital, standards-compliant, and paperless quality assurance.

The combination of manufacturer independence, mobile flexibility, and support for DIN EN 17976 makes PG a pioneering tool in modern rail vehicle production.

PG ensures transparency, safety, and efficiency at Stadler — from assembly to overhaul.