Box-build of door control units for rail vehicles
Electromechanical assembly and functional test of door control units for a rail systems supplier, with full serial-number traceability per unit.
- Delivery geography
- Italy
- Annual volume
- ~1,800 units/year
- Batch size
- ~150 per month
- Variants in scope
- 4 variants
- Program duration
- Fourth program year
- Responsibility level
- Subsystem
- Standards applied
- EN 45545 material requirements · Customer-run type testing
What the delivered system actually does.
A rail vehicle door control unit is what decides whether a door may open, and it has to make that decision correctly for decades, in a vehicle that vibrates, in temperatures from a Nordic winter to a Mediterranean summer. It is a small box carrying a large responsibility.
GANI performs the box build: the electromechanical assembly of the unit, the wiring and the mechanical integration, and then the functional test that proves the assembled unit behaves as the customer specification requires before it is closed and shipped.
Every unit carries full serial-number traceability. For a rail systems supplier that is not paperwork — it is the ability, years into service, to identify which units carry a given component revision, which is what makes a targeted fleet action possible instead of a fleet-wide one.
A rail systems supplier needed a partner for a door control unit combining a controller board, wiring, relays and an enclosure, delivered against project milestones with documentation their end customer could audit. Traceability had to reach from unit serial down to component lot.
STARTING CONDITIONA released design with BOM and assembly drawings existed from the supplier’s engineering team; production had not yet started anywhere.
- Released BOM, assembly drawings and wiring schedules
- Functional test specification for the unit
- Project delivery schedule per vehicle batch
- Traceability and documentation requirements from the end customer
- NPI run with build feedback and agreed documentation updates
- Electromechanical assembly and internal wiring of the units
- Test fixture build and 100% functional testing
- Serial-number traceability from component lot to test record
- Batch deliveries against the vehicle project schedule
What the program delivers.
- Golden sample approved after joint review with the supplier
- Deliveries tracked the vehicle batch schedule across the project
- Audit by the end customer passed on the traceability records
- Follow-on vehicle option exercised on the same unit
