Challenge
A leading player in the rolling stock industry was grappling with a recurring field failure in their HVAC systems for their locomotives. Cracks had developed in the housing base sheet near the motor mount, leading to water ingress in driver cabins. Over 80% of the units produced at their manufacturing facility were failing in under 200 days, putting service reliability and operational budgets at risk. Replacements were being handled on the ground, but the scale of the issue strained inventory, warehouse space, and manpower. The client needed a lasting solution that could meet the 20-year field life requirement without compromising performance.
Solution
Quest Global tackled the issue with end-to-end design and engineering support:
Conducted root cause analysis and generated multiple design concepts
Developed 3D parametric models and 2D drawings using Creo 4.0
Ran FEA interactions and coordinated trial fitments with suppliers
Participated in cross-functional design reviews to finalize housing redesign
Results – At A Glance
Helped resolve a high-impact field issue affecting service uptime
Designed a technically and economically viable solution that was easy to implement on-site
Delivered over 25 concepts and built 20+ new components from scratch
Released 100+ detailed drawings on time, with 100% accuracy
Enabled integration of the new design across additional rolling stock platforms
