CASE STUDY
Train retrofit in the electrical domain
How ALTEN Polska delivers comprehensive rolling stock modernization across Europe?
Electrical retrofit for the railway industry is the process of upgrading existing vehicles to meet new design requirements, quality standards, and customer expectations. In practice, this involves not only replacing components but also integrating new technological solutions that enhance safety, reliability, and passenger comfort. In the era of dynamic changes in public transport, retrofit has become a key element of rolling stock maintenance and development strategies.
ALTEN Polska undertook an electrical retrofit project for a global leader in the railway sector. The project covered modernization of electrical systems in trains both in Poland and across international markets. The scope was extensive: from preparing technical documentation and securing materials to implementing changes at the component, carriage, and full-train level. Each stage required close collaboration between engineering, production, and logistics teams, as well as the use of advanced tools such as SAP, NEO, and Visio.
Challenge
Ensuring compliance with design requirements and ISO standards while maintaining project timelines and process safety.
Solution
- Development of complete electrical retrofit documentation based on design and GAP analysis
- Implementation of procedures ensuring safety and compliance with industry standards
- Material procurement and supply risk management based on Bill of Materials (BOM)
- Execution of changes in a dedicated production hall and on entire trains
- Electrical testing (W2W, reflectometry, continuity) and preparation of compliance reports for the client
Benefits
- Full compliance with design requirements and ISO 9001:2015 and ISO 22163 standards
- Increased safety and reliability of rolling stock
- Positive client feedback and extension of cooperation to future projects
- Development of ALTEN Polska’s expertise in electrical retrofit across Europe
Project Challenges
Retrofit in the railway industry requires not only technical knowledge but also excellent organization and coordination. The greatest difficulties in the electrical domain arose during implementation on entire trains—accessing wiring harnesses required dismantling interior finishing elements, which carried a risk of damage. Each stage had to be executed with the highest precision to ensure structural safety and avoid additional costs. These challenges highlighted the importance of team experience and risk management in large-scale projects.
Tools and Solutions
The project relied on advanced engineering tools:
- NEO – for jig board modifications and routing of electrical harnesses
- SAP – for BOM updates and operation time management
- Visio – for creating detailed production instructions including special processes
These tools enabled efficient management of documentation, materials, and schedules, ensuring timely delivery and high-quality execution.
Benefits for End Users and the Client
Modernizing rolling stock through electrical retrofit provided end users with greater safety and travel comfort. The client received a product fully compliant with design requirements, ready for validation and further operation. Moreover, the project’s success opened the door to additional contracts for ALTEN Polska, including expansion into international markets. Electrical retrofit has become one of the company’s core competencies, confirming its growing position in the railway industry.
