Quality assurance for rail vehicles and parts
(List of rolling stock products subject to quality inspection)
Our lists of products subject to quality inspection describe the most important quality requirements for products that we procure. The current versions are available to registered suppliers here.
More information for new and registered suppliers
- Auditing new and active suppliers
- Manufacturer-related product qualification for specific manufacturing processes
- Supplier development
- Special, job-based qualifications for welding
- Special, job-based qualifications for adhesive bonding
- First article inspection
- Quality gates
- In-process inspection for rail vehicles
- How we conduct contractual acceptance tests on rail vehicles
- Quality-dependent supplier monitoring for suppliers that deliver vehicle parts
- Order the above QA services here
- Quality engineering in the manufacturing process for rail vehicles for Deutsche Bahn AG
- Development support
- Design review
- Software development
- Type testing
Auditing new and active suppliers
We need to determine suppliers' quality capability before they can deliver safety-critical products to us. This assessment includes a detailed assessment of opportunities and risks and development of measures before and during order processing to minimize risks for both parties. The assessment also includes a forecast of performance and may be supplemented with capacity assessments. We use questionnaires for auditing. They are available to registered suppliers in German and English. Our auditors customize these questionnaires for your company and structures. You can provide us with your current IRIS audit reports. Depending on the results, this may reduce the number of questions.
Additional qualifications are required for products with special manufacturing processes, such as forging and casting. See the next section on HPQ. Additional qualifications may be required for welding and adhesive bonding depending on the job.
We cooperate with other railroads in the auditing process. More information is available here: cross-acceptance-of-supplier-audits
Manufacturer-related product qualification (HPQ) for specific manufacturing processes
Do you manufacturer safety-critical rail vehicle parts that are subject to HPQ and want to supply them directly or indirectly (first-tier supplier or similar) to Deutsche Bahn AG? More information about what HPQ is, how it is carried out and its scope is available on the HPQ information sheet. You can conveniently submit an application by e-mail to HPQ-SFZ@deutschebahn.com and we will then send you an offer.
Please use one of the three applications below depending on the product you are offering:
More information is available in our HPQ information sheet.
The HPQ test specification is available here.
Supplier development
Establishing and maintaining long-term contractual and supplier relationships based on partnership is important to us. We can provide you with tailored support to help you achieve your and our quality targets. We offer this if you are registered with us or already have a contractual relationship with us and want to offer new products or services. This joint approach also helps us to minimize risks to both parties when entering into relationships with suppliers and service providers. If you would like to take advantage of this support, please contact your DB buyer.
Special, job-based qualifications for welding
Are you a manufacturer or supplier of welded parts for rail vehicles and would like to supply them to Deutsche Bahn AG directly or indirectly (e.g. via a first-tier supplier)? Or would you like to provide welding maintenance services for Deutsche Bahn AG? Testing of welded structures (STBP) parts 1 and 2 is one of the key prerequisites that must be met first. The following documents (in German) provide more information on the framework and contact details if you have any questions.
Leaflet on DB AG requirements in accordance with DB Guideline 951.0010 (in German)
Leaflet on testing of welded structures by DB AG in accordance with DB Guideline 951.0010 (in German)
List of production sites for welded components and assemblies for rail vehicles for DB jobs (in German)
Terms of Reference for welded rail vehicle parts (in German)
Leaflet on requirements for welding repair of DB rail vehicles outside DB AG (in German)
Leaflet on requirements for welding repair of DB rail vehicles (in German)
Special, job-based qualifications for adhesive bonding
Are you a manufacturer or supplier of rail vehicle parts with bonded joints within the meaning of DIN 6700 or of rail vehicle parts that are intended for bonding in accordance with DIN 6700, and would you like to supply them to Deutsche Bahn AG directly or indirectly (e.g. through a first-tier supplier)? Or would you like to provide maintenance services involving adhesive bonding for Deutsche Bahn AG?
Testing of adhesive-bonded structures, which consists of testing of adhesive-bonded structure design (KKP) and testing of the construction process for adhesive-bonded structures (KFP), is one of the key prerequisites that must be met first.
The following documents (in German) provide more information on the framework and contact details if you have any questions.
Leaflet on DB AG requirements for adhesive bonding in rolling stock construction in accordance with DB Guideline 951.0040 (in German)
Leaflet on testing of adhesive-bonded structures by DB AG in accordance with DB Guideline 951.0040 (in German)
Terms of Reference for rail vehicle parts with adhesive-bonded joints (in German)
Leaflet on requirements for adhesive bonding repair of DB rail vehicles outside DB AG (in German)
First article inspection
DB AG expects suppliers of certain safety-critical rail vehicle parts to carry out first article inspections (FAI, "EMP" in German). Which rail vehicle parts require this depends on the specific contract. FAI is usually performed on the first product manufactured under series conditions. It is intended to demonstrate that the quality requirements set out in drawings, specifications and purchase orders are being fulfilled. You inspect the first articles you produce, proving to us that you have mastered the production and inspection processes.
Quality gates
If you supply rail vehicles to us, we will usually set up a project. The quality gates are important synchronization points during these projects when the progress is measured and evaluated by a specific group of participants based on criteria set in advance. This allows you and us to identify risks in time and take countermeasures. Quality gates are an essential tool for us to ensure projects are successful. Quality gates are designed in accordance with the project requirements and arranged with you in the contract. Our staff will help you use them.
In-process inspection for rail vehicles
Would you like to manufacture rail vehicles for DB AG? As a provider of rail vehicles, you will undergo quality-dependent in-process inspection. Quality-dependent in-process inspection includes checks to test specified stopping and signaling points and variable, process-oriented inspections as part of in-process inspection for the entire production process. Inspections are contractually arranged with you. Qualified DB AG test engineers carry out, document and monitor the inspection results at your premises.
How we conduct contractual acceptance testing on rail vehicles.
Contractual acceptance of rail vehicles involves checking whether the vehicle meets the requirements set out in the contract. Testing can include various components, for example, to determine that the vehicle documentation and vehicle functioning comply with contractual requirements. We use the VDB's list of defects as a guide when conducting acceptance testing.
Quality-dependent supplier monitoring for suppliers that deliver vehicle parts
Quality-dependent supplier monitoring is a tool that DB AG uses with suppliers of certain safety-critical rail vehicle parts. Which rail vehicle parts require this depends on the specific contract. DB AG quality inspection engineers must inspect your product and production processes for the specific parts before they can be supplied. If the inspections are passed, delivery will be approved for these parts for a specific period of time.
Production and inspection information
Order the above QA services here
Would you like to request an inspection service, such as first article inspection or welded structure testing, from DB AG's quality assurance organization? Please use our QSL Form to order quality assurance services. Please see the instructions and the relevant contract terms, which are located in the Supplementary contractual terms of DB AG and its affiliated companies for quality assurance in procurement.
QSL Form (German and English)
Instructions for filling out the QSL Order Form
Please e-mail your order to AS-SFK@deutschebahn.com
Quality engineering in the manufacturing process for rail vehicles for Deutsche Bahn AG
Quality engineering is an important component of our quality assurance for the procurement of rail vehicles. We use our own methods and use the VDB guidelines as a guide. The following methods are part of the supply contracts and cannot be ordered separately.
Development support
Our development support ensures that operational experience and rail-specific interface knowledge are incorporated at an early stage in the development of your project.
A joint review process, software development support and type testing are essential tools in this process. The intensity of development support is ideally based on the degree of maturity of the product and its components, which we will determine using the maturity level model we developed with the VDB and Round Table Rail (RTR, an initiative of vehicle and component manufacturers and European rail companies).
Design review
Design review involves evaluating all key aspects of the main technical concepts with you based on the essential requirements of the specifications and the relevant standards and TSI. The process has three to five stages, from assessing the high-level design to the final design, and aims to create a functional specification coordinated with both parties.
Software development
We provide support during vehicle software development and testing to ensure that everything happens on schedule and meets quality standards. Our first step is to consult with you on the software release and development plan you developed and on planned quality assurance measures.
Then, over the course of the project, we regularly monitor the progress of software development and the implementation and effectiveness of the quality assurance measures.
Type testing
We conduct type tests at the component and system level to ensure that the results of technical development and designs that were created during design review are in compliance before production begins.
If type test results from previous projects and tests are already available, they can be recognized if product conformity is confirmed to avoid unnecessary expenses for new tests.
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