Annual review 2021 – Outlook for 2022

More digital, more automated and more efficient

We are continuously developing the processes in our depots and trying out the latest technologies for their potential. Innovative, practical digitalisation and automation solutions are used in our depots to make our processes faster, more efficient and more transparent - for us and our customers. At the Krefeld depot, for example, for the first time we tested a robot this year that can perform testing and preparatory work independently. Two further robots were successfully tested at the Paderborn depot, where they move particularly heavy bearing housings. The use of robots not only makes work faster, but also improves ergonomics in the workplace. Smaller digital helpers also further optimise our processes. For example, all depots have been using a cloud-based app for internal transport since this year. Among other things, the system calculates the fastest routes between storage zones, halls, workshops and work stands. This saves valuable time.

New Cottbus depot: Faster than planned

These and other innovative technologies will be used for the first time in bundled form at our new depot in Cottbus. This year, we developed a new two-stage concept for the construction of Deutsche Bahn's most modern and environmentally friendly depot. The result: as early as 2024 - two years earlier than planned - we will be able to service the first ICE trains in a new double-track building. We are thus creating the first 500 of a total of 1,200 new jobs in the region affected by the coal phase-out. We have already concluded a cooperation agreement with LEAG, the company that operates the power plants in Lusatia, to take on employees. We will start training them as early as next year and gradually integrate the career changers into DB Fahrzeuginstandhaltung.

The Cottbus depot will be the centre of expertise for heavy maintenance of electric multiple units and hybrid vehicles. The ground-breaking ceremony for the second hall will take place next year so that we can put it into operation in 2026. 2022 will also see the opening of the information centre at Cottbus main station, which we have been building since October this year. On 150 square metres, we show interested parties, among other things, the current planning status of the new depot and inform them about the progress of the construction work.

Greener vehicles, more sustainable production

Environmentally friendly vehicles with hybrid and alternative drives are already being maintained and further developed by us today. Our centre of expertise for diesel engines and drive systems in Bremen is constantly expanding its range of services. This year, for example, alternative fuels for DB Long Distance that are compatible with conventional diesel engines were tested here. As DB Fahrzeuginstandhaltung, we see it as our social responsibility to support and drive forward the development of environmentally friendly technologies with our expertise. In addition, as a company we have developed a detailed plan to make our own operations as sustainable as possible. This year, for example, we began the gradual switch to green electricity. We are also completing the process of making our locations a "paperless factory".

Redesign: More passenger comfort and longer life cycle

Of course, as a maintenance provider, we contribute to sustainability by definition. However, we not only ensure that components and vehicles last long and reliably but also that even older passenger trains do not differ from new stock in terms of customer comfort and attractiveness. The redesign of the ICE 1 is a prime example of this: this year, just in time for the 30th anniversary of the trains, the starting signal was given for the refurbishment of the entire fleet in our Neumünster, Krefeld, Nuremberg and Dessau depots. The appearance of the ICE 1 is optimally adapted to that of the more recent train generations. In this way, we guarantee passengers a consistent travel experience – whatever train they are on.

We have also created more comfort for passengers on local transport. At the end of the year, we were able to successfully complete Deutsche Bahn's largest modernisation project to date after three years of intensive work: 238 S-Bahn Munich commuter trains were extensively refurbished in Nuremberg and Krefeld/Hagen. A total of 34,000 seat cushions were replaced, more than 750 kilometres of cables were laid and 83,000 square metres of vehicle exterior and 23,000 square metres of interior panelling were repainted.

World premiere for highly automated S-Bahn Hamburg

Also in December, we completed the redesign project for the Hamburg S-Bahn in Neumünster as planned. 111 electric railcars are now newly painted and with a modern interior for passengers as they travel. A special highlight was the “IdeasTrain", which we were able to complete on schedule in just three months – equipped with newly designed seats, a standing lounge, a work counter with connections for power, USB and Wi-Fi and a large number of clear displays with real-time passenger information.

We also equipped four Hamburg S-Bahn trains with the necessary technology for highly automated operation. They celebrated their world premiere at the "Intelligent Transport System World Congress" in October 2021. It took our team only four to six weeks per vehicle to retrofit the required ATO and ETCS systems and equip the trains with the appropriate computers, radio channels, radars and balise antennas. The highly automated control of the trains enables a tighter timetable. This way, more suburban trains can be used – without building new tracks.

Equipped for upcoming orders

For the coming year, numerous projects that have already been started as well as new projects are on the agenda. The Bundeswehr has contracted us for maintenance work on 280 heavy-duty flat wagons for another four years. We won an EU-wide tender from Arriva Danmark. We have received an order from our Slovakian partner ŽOS Zvolen for the overhaul of diesel railcars of the Czech state railway. At the end of the year, the starting signal was given for the vehicle overhaul of the Hessische Landesbahn; and in January 2022, the redesign of the tilting technology vehicles for DB Regio Südost will start at the Kassel depot.

To meet increasing demand, we are expanding our production capacities and investing in optimal material supplies. This year, we expanded and modernised the warehouse capacities in Munich and Fulda. In our central electronics plant in Munich, a new automated small parts warehouse provides more space than before and optimum capacity utilisation. In Fulda, we have created an additional 10,000 square metres of space. We mainly store old parts there, which we recondition into new parts – an important procedure because many manufacturers are gradually discontinuing their components. The global supply bottlenecks of recent months have also clearly shown that our flexibility and smart storage concepts are more important than ever.

Raw material shortages, climate protection and the ongoing Covid pandemic – 2021 was marked by challenges and changes. Against this background, it is all the more gratifying that we were able to master the tasks of this year together, made important investments in the future of our company and continue to work together on innovative ideas and solutions for the rail transport of tomorrow.

On behalf of DB Fahrzeuginstandhaltung, I would like to thank all our customers and partners for their trust and cooperation. I would definitely like to extend my personal thanks to the entire DB Fahrzeuginstandhaltung team. Happy Holidays to you all and a healthy, prosperous New Year! Stay safe.

Yours sincerely,

Gorden Falk