Optimise assembly processes, quality assurance and material flow with scalable solutions Automation for the rail industry
FFT draws on its extensive experience in the field of body-in-white (BIW) from the automotive industry to offer the rail industry turnkey solutions from a single source. In doing so, the company combines overall responsibility for complex projects with proven expertise and a strong track record across numerous individual production areas. The aim is to apply existing know-how specifically to the new challenges facing the rail industry, thereby creating innovative and efficient manufacturing solutions.
The focus is on a holistic approach to turnkey project management and project execution, from analysis through to successful implementation. Production systems are individually tailored to the customer’s requirements and designed to achieve maximum efficiency and flexibility. The intelligent combination of manual, semi-automated and fully automated production cells results in high-performance production concepts that are optimally tailored to the needs of modern rail vehicle manufacturing.
The rail industry is facing a period of profound change Challenges
Rising demand for sustainable mobility is putting increasing pressure on manufacturers to expand production capacity whilst ensuring quality, flexibility and cost-effectiveness.
Higher production volumes
Global demand for rail vehicles is rising as a result of investment in sustainable mobility. Manufacturers need to expand their production capacity flexibly whilst ensuring efficiency and quality.
Quality requirements
Safety-critical components require the highest standards of manufacturing quality and process stability. Automated systems enable precise and repeatable production throughout the entire manufacturing process.
Skills shortage
It is becoming increasingly difficult to find qualified skilled workers in many areas of manufacturing. Automation helps to alleviate resource shortages and safeguard production processes in the long term.
Cost and time pressures
Rising costs and tight project schedules are increasing competitive pressure on manufacturers. Efficient production processes help to ensure that deadlines are met reliably and that resources are used to their full potential.
Holistic planning
FFT also develops comprehensive concepts for factory layouts, building management and logistics in order to create efficient and future-proof production environments. The planning process covers all relevant aspects, from factory planning and layout design through to simulations, ergonomic assessments and MTM analyses. The aim is to optimally coordinate production processes and achieve maximum efficiency across all areas.
Particular emphasis is placed on integrating individual systems into overarching overall structures. These include, amongst others, Manufacturing Execution Systems (MES), logistics systems including fleet management, building management systems, and train control systems. This holistic networking results in intelligent and high-performance production and infrastructure concepts that efficiently interconnect all processes.
FFT's areas of expertise Automation technologies for railway manufacturing
Our solutions combine industrial robotics, intelligent control technology and digital production systems to deliver efficient and future-proof manufacturing in the rail industry.
a testament to our expertise Examples from our portfolio
Our aim is to support companies worldwide in the automation of both small-scale operations (production cells) and large, complex production processes (production lines and plants). Our services range from the design of new production concepts, through the optimisation of existing plants and detailed planning – including virtual commissioning – to the implementation and modernisation of safe processes.
Automation of welding processes
Automated welding of a car body with more than 22,000 weld points, with a production time of just two days per vehicle. Automatic path generation and adaptation to changes in contour ensure maximum accuracy and flexibility.
- 5 stations with a total of 10 robots.
- Over 22,000 visible weld points per car body.
- Welding guns with a working range of over 1.5 m
- Linear axes up to 60 m and rotary tables up to 20 m in length.
Automation of a bogie workshop
Planning and implementation of a fully automated bogie workshop for the rail vehicle sector. A turnkey solution including commissioning of the entire plant, safety approval, and operational and quality acceptance.
- Development of the overall concept (factory planning, layout, simulation, analyses, etc.).
- Integration of individual systems into higher-level systems (MES, logistics systems, fleet and plant management, building automation).
- Supplier management (supplemented by in-house technologies, fixture construction, interface management and occupational safety).
Let us work with you to automate your production. We look forward to getting in touch with you.
Please send us your concept idea, your automation requirements or a description of the production process where we can assist you.
We look forward to presenting our standardised portfolio to you, but also to working with you to develop new solutions.
