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Plasser & Theurer, Export of railroad construction machinery, Gesellschaft m.b.H.
Success Story

Digitalized QM with Testify enables more efficient processes for cross-location production at Plasser & Theurer.

Customer
Plasser & Theurer, Export of railroad construction machinery, Gesellschaft m.b.H.
Date
13. June 2025
Success Story

Plasser & Theurer is the global market leader in the manufacture of track maintenance machines and associated maintenance vehicles. The company is a full-service provider and unique within the industry, as it has focused on the development, production and servicing of special vehicles and custom-made products. Plasser & Theurer relies on continuous improvement through innovation while retaining the tried and tested, thereby revolutionizing the offerings within the industry. It currently holds up to 2,000 patents that have been created through this dynamic corporate philosophy.

The digitization success story of Plasser & Theurer Linz.

When production is spread across different locations, coordinated processes and cooperation in quality management are crucial. Plasser & Theurer Linz has digitalized these processes, saving up to one worker per vehicle. Digital quality control during production is also possible for the customer.

Initial situation at Plasser & Theurer Linz.

At the main plant in Linz, the machines and testing processes have to be specially adapted for individualized customer orders. Plasser & Theurer attaches great importance to close coordination with the customer. In order to further develop the processes and make them even more efficient, the main plant decided to use Testify as a digital tool after a test phase in order to master the current challenges.

Standardized documentation and rapid coordination required.

Before Testify, quality acceptance was carried out in a time-consuming process with paper, pen and photo documentation. Differences in the level of detail in documentation and paper-based records slow down processes and collaboration, especially when different production sites are involved.

 

Control by the customer desired.

For a special customer order, the customer requests an inspection during production. This requires quick updates and comprehensible representations of the current production status and the involvement of the customer in the quality acceptance process.

 

Testify integration explained step by step

Proof of concept in a small circle

A team from the QM department at the main plant in Linz experimented with Testify for 3 months. Other employees were gradually integrated. In the PoC package, there is a close exchange with Testify in order to adapt the service to the specific requirements of Plasser & Theurer Linz and actively incorporate customer feedback. Testify can be adapted to individual processes and is constantly developing its services based on customer feedback. This enables the Testify (Web)Appsitiv to be individually optimized for the organization.

The foundation stone for the digital infrastructure is laid.

After the training workshop, Plasser & Theurer Linz equipped its employees with smartphones and tablets. Defects can now be digitally documented directly when inspecting the machines. The QM team entered the tried-and-tested processes and quality checks into the easy-to-use Testify (web) app. The entirety of the individual processes is now visible. The view of the big picture offers potential to add fine-tuning between the individual checks, build up categories of quality checks and continuously improve the processes.

Efficient collaboration.

Sets of checklists and defect categories are now available to employees in production. These are used to process the quality tests and simultaneously document them in a structured manner via the Testify app. This standardizes the documentation of acceptance tests and saves time, as it is no longer necessary to create individual reports by hand. Employees distribute the automatically generated reports and lists of defects to be rectified among themselves and assign individual tasks via the app. This allows work steps to be quickly coordinated and the current status can be viewed by all employees in the Testify Task Cockpit on their smartphones.
Plasser & Theurer produces across multiple locations. Employees now only need to take their smartphones with them when approving products at the plant in France to view all logs and reports at a glance.

Integration of the customer in the value creation process.

The reports and logs are shared with the customer by e-mail. In this way, customers are quickly and easily integrated with clearly prepared documents on current events in production. However, this does not represent any additional effort, as the reports are generated automatically as soon as the employees complete the quality checks assigned to the customer product and thus note the current status.

Awareness of quality management has been created.

Testify has become an integral part of the work processes of Plasser & Theurer employees. “More cooperation has developed,” says Peter Ruff, Head of Quality Assurance.

Next steps at Plasser & Theurer.

Testify has established itself as an integral part of quality management workflows. The next step is to carry out audit logging with Testify. Plasser & Theurer Linz has already successfully tested the first trials and the processes for the actual audit are currently being developed. In addition, further protocols are to be converted to completely digital processes.
Other areas of development include customer access to the Testify app, which allows quality inspections during production to be tracked in real time. This promotes the further integration of customers into the production processes and enables even closer exchange and collaboration in real time.

Not only has handling become extremely simple – we no longer have to enter a single log manually – but employees have also become more aware of the quality and safety of our products and actively exchange information about them. This has brought them closer together.

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