Smart Tech, Smarter Trains: How Downer is Transforming Rail Maintenance

17/10/2025

Downer Rail & Transit Systems is reshaping the future of rollingstock maintenance through intelligent diagnostics and smart technology that deliver faster fault detection, real-time insights, and improved fleet performance.

But this transformation hasn’t come off the shelf. Like many maintainers and operators, our team faced the limitations of OEM-supplied systems including diagnostic tools that lacked the detail engineers needed, fragmented data locked behind proprietary systems, and maintenance practices that relied heavily on specialist interpretation. 

Recognising these constraints, our team set out to design a smarter solution, one that puts practical tools in the hands of the people maintaining some of Australia’s largest train fleets.

“When the tools we needed didn’t exist, we built them,” says Keith Lee, ICT and Integration Engineering Discipline Manager. “We wanted something that worked on the ground, in real time, and gave our teams instant access to the insights that matter.”

The result is a suite of intelligent diagnostic and maintenance tools now embedded across Downer’s rollingstock operations. 

“We have a host of tools that help us perform maintenance tasks, that we call our farm suite of tools based on the names,” Keith laughed as he explained the tools. 

“We have the CAT, or Camera Alignment Tool which provides a connection that overlays a template for ease of use on any mobile device.

“We have the DOG, or Digital Onboard Gateway which allows us to download specific logs and detailed information to troubleshoot issues.

“We have the COW, or Configuration Over Wireless which is a detailed configuration audit tool that gives us a detailed snapshot of every subsystem configuration.”

With this suite of tools, technicians can troubleshoot faults directly onboard the train, supported by smart devices that provide real-time fault detection and instant corrective action prompts.

“Our teams are now benefitting from the tools created by our SMEs which help them resolve faults quicker and proactively,” Keith explained. 

That shift has had a tangible impact across the fleets Downer maintains. 

Faults are being identified and resolved faster, downtime has been reduced, and fleet availability has improved. By removing manual steps and simplifying complex diagnostics, the tools also allow engineers and technicians to focus on higher-value tasks, driving greater efficiency and better outcomes for customers.

“This is about empowering our people,” Keith says. “The easier we make it for them to do their best work, the better our fleets perform, and the better experience we deliver to passengers.”

What started as a solution to Downer’s own operational challenge is now available to the global rail industry. Through our Engineering Consulting Services offering, these tools—and the expertise behind them - are helping operators build smarter, more connected maintenance regimes.

“We’ve proven these tools on the ground, every day, across some of the most complex rail networks in the country,” Keith says. “And we’re just getting started. Smart, engineer-led innovation is the future of rail maintenance, and we’re proud to be leading the way.”

To learn more about Downer’s Rail Engineering Consulting Services offering, click here.

To learn more about Downer’s Rail & Transit Systems visit Rail.