Customer Challenge

Create Assembly Process Plan 


A major rail manufacturer in Europe produces bogies for various product family. On-time shipment of bogies determines delivery of trains to their end customers. 


Challenge is to reduce current TAKT time of XX days to 3 days due to steep increase in demand of trains build rate. Timely resolution of non-conformances is also critical to ensure product integrity and reputation. 


Hence, they are looking for a support partner to come up with engineering solutions to eliminate all the issues. 


  • To reduce TAKT time by defining complete assembly strategy, tooling design, build plan, visual aid creation & sustaining production hours by position


  • Create assembly process plan & condition of supply
  • Optimize the assembly strategy
  • Identify number of assembly tooling requirement
  • Design of assembly tooling and BOM
  • Storage solution for assembly tooling
  • Creation of build book
  • Creation of 3D visualization of assembly process
  • Optimized floor plan layout
  • Precedence chart
  • Line of balance



  • QuEST with its expert capabilities, reviewed the reference assembly design data and developed new feasible concepts with stress analysis. Also verified design solutions by ergonomics simulation
  • Deliverables: detailed & assembly designs & manufacturing drawings, floor plan, build plan, precedence chart, 3D technical instructions
  • Co-ordinated and obtained all mandatory specialist approvals


  • TAKT time to be proved virtually to 3 days
  • Reduced assembly time (data not shared by customer)
  • ‘Fool proof’ wherever necessary (Poka Yoke)
  • Improved quality & reduced production time
  • Standardized operating procedure for family variants
  • Mobile assemblies – Can transport to different locations for assembly & test

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