Contexte and challenges

From its Zaragoza Centre of Excellence in Spain, SEGULA leverages its manufacturing engineering expertise to coordinate eight production facilities across Europe, the United States, and Mexico. The primary challenge lies in guaranteeing absolute technical consistency across all pilot and satellite plants.

To secure these large-scale programmes, manufacturing operations must address three major types of industrial challenges:

• Industrial Transfers: Launching a model at a pilot plant, then transferring its production to a satellite facility (e.g. trams for Rome and Montpellier).
• Parallel Manufacturing: Synchronising two plants simultaneously on the same production run to meet demanding delivery rates (e.g. trams for Budapest and Marseille).
• Distributed Integration: Manufacturing modular subassemblies (electrical cabinets, cabling) across several plants prior to final on-site integration directly at the operator’s depot (e.g. Medellín metro in Colombia, KiwiRail network modernisation in New Zealand).

Our mission

SEGULA Technologies bridges the gap between engineering design and shop-floor execution. The teams model the assembly process by adapting guidelines to on-the-ground constraints and local realities:

• Transforming bills of materials and parts lists into detailed shop-floor instructions.
• Defining manufacturing processes, selecting tooling, and balancing assembly cycle times.
• Assessing and factoring in plant-specific variables (technical capabilities, factory layout, local supplier networks).
• Delivering cross-functional support for both new rolling stock (Urbos range) and mid-life refurbishments of legacy fleets (Cairo and Athens metros).

Our added value

• Unified Digital Governance: Centralised utilisation of SAP to reflect every engineering modification across all worldwide workshops in real time.
• End-to-End Traceability: Rigorous monitoring of work-in-progress and quality control at every stage of the manufacturing cycle.
• Multi-Site Agility: Seamless coordination between primary design facilities and manufacturing subsidiaries.
• Retrofit Expertise: Proven capability in integrating modern systems into decades-old rolling stock while strictly adhering to original engineering baselines.

Key figures

• 8 global production sites coordinated (Europe, United States, Mexico).
• 31 railway projects managed simultaneously.
• Nearly 10,000 modification requests managed via SAP over the 2024–2025 period.

Client benefits

• Consistent Quality: An identical benchmark of excellence guaranteed from plant to plant, regardless of the country of assembly.
• Schedule Reliability: Smoother industrial handovers and faster ramp-ups through parallel manufacturing.
• Operational Continuity: Instantaneous alignment of production workshops when engineering updates occur, enabled by digital SAP governance.
• Extended Fleet Lifespan: Increased service life for legacy rolling stock through rigorous industrial methodologies applied to heavy overhauls.