Accelerating Track Renewal Through Optimized Capital Delivery

Client Context

A major national railroad corporation launched a $30 billion infrastructure initiative and needed to more than double annual productivity of its Track Laying System (TLS) to meet aggressive capital improvement targets.

Key Challenges

• Existing TLS output was insufficient to meet delivery goals.

• Prolonged scheduled outages and inefficient workflows hindered throughput.

• Fragmented coordination across planning, operations, and support teams.

• Lack of real-time KPIs and daily performance management.

Approach & Key Success Factors

EFESO deployed a cross-functional improvement model to maximize productivity and reduce delays:

• Field Waste & Root Cause Analysis: Observed field operations and analyzed sources of inefficiency.

• Optimized Block Planning: Aligned capital planning, field crews, transportation, and dispatch to streamline handoffs and reduce waste.

• KPI Development & Tracking: Created in-process metrics and visual trackers to monitor performance.

• Daily Leadership Pulse: Launched fact-based daily reviews to reinforce execution rigor and frontline accountability.

Results

46%

Increase in tie and rail replacement productivity

70%

Reduction in scheduled outage time per block

38%

Reduction in production delays

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