Bogie Overhaul Service - Unipart Rail

Bogie Overhaul
World-class facility producing
high performance bogie overhauls

Unipart Rail
Bogie Overhaul Service
Unipart Rail provides a complete ‘depot to depot’ bogie overhaul service
to train operators and owners, delivering highly reliable quality bogie
performance across the complete overhaul cycle.
World Class
Facilities and Workforce
Situated at the heart of the UK Rail network, our
world-class facility has the capacity to overhaul over
1200 bogies a year.
In 2010 Unipart Rail overhauled and repaired over
960 bogies. The range of bogies is extensive with
types to present day high speed new era trains.
Our extensive procurement and bogie overhaul
experience enables us to take responsibility for
managing the entire supply chain to ensure the
overhaul programme meets our customers’
availability requirements and are completed on time
within budget.
Experienced engineers work with our customers
to help solve any technical issues that arise during
the programme. They are further able to add
value, by assessing the condition of the assets and
components with a view of extending life and
maintenance periodicity, as well as re-engineering
obsolete components.
Our workforce is the lifeblood of our business and are key to our success, the strong team ethic helps to produce
a product to be proud of. Our workforce fully embraces our company’s continuous improvement culture and are
totally engaged in providing the best possible service and products to our customers.
bogie overhaul.
Collaborative Approach
We have the capacity to overhaul all bogie types
working to the exacting standards and engineering
We believe that the relationship we develop
with our customers should be based on effective
communication, close collaboration and co-operation.
At Unipart Rail we understand that every customer’s
requirements can be different. It is only by working
collaboratively that we can fully understand their
maintenance needs and respond with a creative solution
An integrated partnership approach provides the biggest
jointly agree business aims and projects that will provide
the desired breakthrough of improvements.
Our highly experienced project managers will work
with you to ensure that all your requirements are met.
Our project managers will communicate with you every
step of the way ensuring any issues are resolved in a
proactive, structured and responsive manner allowing
the knowledge that your project is in capable hands.

Key elements of the Bogie Overhaul Process
Wash
Oil, grease and soil are removed using two high
pressure, hot water, 1detergent mix pressure
washers enabling two bogies to be cleaned at
once. The working environment is controlled
by ventilation providing sixty air changes per
for settlement of solids and via a separator to
collect hydrocarbons.
Dismantle
Raised rails facilitate a comfortable effective
working height. Bogies are stripped into
component parts using 2mechanical and hydraulic
pullers to maintain component integrity. All
components are sorted and are placed directly
into appropriate containers eliminating the need
for re-handling and minimising lead-time and
Shot Blast
Components are blasted 3in our purpose-built
shot blast facility. Two bogie frames can be
processed simultaneously. G17 chilled cast iron
recycled during operation enabling a continuous
shot blasting process.
Manipulators
mounting various bogie types. Manipulators lift
and lower bogie frames to enable the inspection.
Repair and assembly to be carried out safely and
4
5
Secondary Suspension Air
Bag Tester
6
later assembly stages.
Bracket Alignment
Axle box pivot brackets can be aligned on the
bogie frame to tight tolerances to eliminate axial
load in wheel bearings.
Bolster Jig
7
We use specially designed handling equipment, including the
bolster jig, to ensure that bogie parts travel smoothly through
the process to further protect component integrity.
Dispatch and Delivery
Prior to despatch all bogies are inspected,
strapped and
12
sheeted to prevent damage during
transit. All relevant documentation are provided
in a pack for the convenience of our customers.
Our logistic partner, works in with us to deliver
bogies to our customers’ schedules, ensuring a
Bogie Press and Wheel
Weighting
The bogie press comprises a twin ram hydraulic
max load.
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A twin ram and four identical wheel load cells
are used to accurately set the wheel load
distribution and enable the bogie height to be
set to the individual vehicle type.
Assembly
Equipped with
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a manipulator, raised rails and
a Faro Arm to complete the alignment process,
dedicated tools. Materials are provided as
kits to reduce the amount of movement and
transportation required during the assembly
process.
Spray Booths
Used for both paint 9application and curing with a
low bake mode, the air assisted paint application
system achieves high volume controlled spraying
with Copon water-based paint. This produces a
and low environmental impact.
Spring Tester
This equipment is designed 8to measure both
Chevron and Coil springs. With a maximum load
of six tonnes, the force applied is displayed in
kN on a digital readout to accurately determine
spring integrity and packing heights.

Main Features
Scope of Work
In-house engineering support
Provison of specialist support
services
Component Overhaul
We will work with you from the outset; agreeing
the scope of work in line with your maintenance
requirements.
Our production process is designed to be tailoured
to your requirements. We offer a quick turnaround
of bogies to enable you to minimise the downtime
requirements.
you to improve it. If you need to extend your overhaul
periodicity, we will work with you to do so effectively
Our engineering support teams are able to solve any
technical issues that arise during the programme. They
are further able to add value by assessing the condition
of the assets and components with a view of extending
life, as well as re-engineering obsolete components.
Our Engineers have many years experience working
in the rail industry. This experience as we seek to
implement improvements to the design that increase
reliability, extend maintenance periodicities and extend
the design life; without compromising safety.
We have the skills base to offer any heavy engineering
We have a large and highly trained workforce and
we have invested in a structured apprentice training
program to ensure new talent is brought into the
business.
Our extensive rail industry experience and
comprehensive network of approved suppliers ensures
that the components are overhauled to the latest
industry standards, delivering trouble free and reliable
performance throughout the component life cycle.
Our engineers also make improvements to the design
of components and systems to prevent future failure.
Re-engineering of obsolete
components
Access to a global supply base
A continuous improvement and
Lean philosophy
Integrated depot to depot bogie
transport service
Components that are used in locomotives can rapidly
go out of production or become obsolete (sometimes
Our specialist in-house engineering team is able to
work with you to identify the origin of a particular part,
even where this is not immediately obvious. We can
work with our specialist supply base to re-engineer
a component, for example if the production of a
particular component has been made obsolete or the
original manufacturer no longer exists.
Our procurement teams source items required to
experts have many years’ experience dealing with
major international suppliers building long-standing
relationships.
In many instances where we re-source a component
from a supplier, it is not just a case of ensuring
improvements in technology to improve both the
materials and the service to our customers.
Every business needs a set of principles that guides it.
Ours is called The Unipart Way.
It is more than a set of tools and techniques – it is
a way of working that engages our and your people,
committing them to world-class performance and a
culture of sustained continuous improvement.
Using the ‘Lean’ and continuous improvement expertise,
our bogie overhaul process is designed to place quality
and on-time delivery at the heart of its objectives. This
enables us to supply on time, every time.
Working in partnership with our logistics partner we
offer a full range of integrated bogie transport services.
We help our clients to cut costs, drive year-on-year
continuous improvement, focus on carbon reduction
and create supply chain visibility.
latest technology providing you with instant visibility of
delivery progress.

About Unipart
Unipart Group is a leading third party logistics provider and a consultant in operational excellence. Operating across
a range of market sectors including automotive, leisure, marine, manufacturing, mobile telecoms, rail, retail and
technology, Unipart offers a breadth of services from third party logistics to expert consultancy worldwide.
At the heart of our culture is The Unipart Way, our company philosophy.
Walk into any Unipart global facility and the difference is clear. In every aspect of our business, teams of people are
using a consistent, integrated Lean toolkit aligned within The Unipart Way culture that empowers them to deliver
more for their customers.
Contact us:
For Traction & Rolling Stock information:
Unipart Rail
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Balby Carr Bank, Doncaster, DN4 5JQ
For information on
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Unipart Rail
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Crewe
Cheshire, CW2 6EH
Unipart Rail
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York
North Yorkshire, YO26 4ZD
enquiries@unipartrail.com
Unipart
Sudfeld 7A
59174 Kamen
Deutschland
informationen@unipartrail.de
www.unipartrail.de
Unipart Rail
1 Tyrone Place
Erskine Park NSW 1790
Postal Address
St. Marys NSW 1790
209/1 Asoke Road
Klongtoey Nua
Wattana
Bangkok 10110
Thailand
Bath
Ontario
K0H 1G0
Canada
For information on LED
Signalling & Lighting:
Unipart Dorman
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Southport
Merseyside, PR9 7TN
dorman.info@uni[partdorman.co.uk
www.unipartdorman.co.uk
Rivval
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Carrickasedge
Carrickmacross
Co. Monaghan
Ireland
Unipart Rail
Chancheng District
Foshan
Guangdong
Email: trsenquiries@unipartrail.co.uk
UK website: www.unipartrail.co.m
Copyright © Unipart Rail
Issue 1 September 2012
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