New train introduction - how difficult can it really be? PART FOUR: COVID-19

This is part four of a series I’m writing on the challenges of introducing new trains onto the UK rail network.

·     Part One: Training

·     Part Two: Stabling & Cascade

·     Part Three: Infrastructure

·     Part Four: COVID-19

·     Part Five: Functionality & reliability

·     Part Six: Assurance & testing

·     Part 7: Authorisation and reliability growth

To quote my last article written in October 19’

“there’s an unprecedented amounts of new rolling stock on order in the UK, resulting in the UK fleet size increasing by an estimated 50%”

Although this is still true, I’m sure, like me, you will be happy to never hear that word again!

The theme of my series is explaining why introducing new trains into passenger service is a lot more complicated than it might appear. I felt I had to include an unexpected extra chapter into this story to explain how COVID-19 has added unforeseen complexity.

The build

The manufacturing process for building a new train is reliant on a great deal of manual work requiring people to be working in close proximity. Bombardier’s manufacturing site in Derby pre-COVID-19 had in excess of 500 staff working on trains each week, having visited the build line for a number of fleets I consider it a masterclass in lean manufacturing.

All train manufacturers will need to adapt quickly to the constantly evolving government guidelines to maintain their pre-COVID-19 productivity rate.  

This time-lapse of a Crossrail class 345 build demonstrates the number of people who work on a train build line and how many jobs involve working in close proximity

Train manufacturers are also vulnerable to their complex global supply chain’s ability to adapt and recover to deliver the equipment and components needed to keep their production lines flowing efficiently.   

Another consideration is the reliance on a global workforce and suppliers for materials adds an element of uncertainty being outside of the UK government’s policy and jurisdiction.

The Introduction

Once the train is built, the impact of COVID-19 on train operating companies (TOCs) becomes a factor. Training is often on the critical path to the introduction of any new train into passenger service. TOCs may have to rethink the method or PPE required to deliver training to comply with government guidelines.

If this involves having fewer trainees on a training course to limit proximity in the cab or class room it may lead to a slower rates of reaching the required critical mass of trained drivers to allow new trains to be introduced on a particular route or service. Just putting on more courses to compensate may not be an option as other constraints such as competent trainers, training paths and access to training units & simulators are often already limiting factors to the number of courses that can be run in parallel.  

At the point of writing this, ASLEF’s COVID-19 guidance version 1.2 states that “all non-essential driver training should cease”, meaning that any TOC wanting to conduct traction training for a new fleet would need to demonstrate that it was essential.

The future

Any complex project such as new train introduction has its risks and I commend any psychic project manager that had  pandemic on their risk register. Most projects are going to encounter new risks such as volatile absence levels, budget cuts and changing guidelines.

Who knows what the short and long-term impacts are going to look like for the future of rail and its passengers. But I hope, in an industry not famed for its dynamism, we can get through this challenging time, we can find new ways to innovate at pace, we can adapt to unconventional working practices, we can embrace Zoom as the new normal. Finally and most importantly that we must ensure the physical and mental welfare of all our friends, family, passengers and colleagues is our top priority.

Charlotte Hughes

Associate Director – Rolling Stock

CPC Systems  

I write these articles because I’m passionate about the industry and sharing my experience and lessons learned. So if you read and enjoy my articles please like, share or leave a comment.  

For obvious reasons this is a slightly different article to my previous ones but if you found this interesting here are links to my previous articles