In the field of the production of safety electronic devices specific to the railway sector, the IRIS (International Railway Industry Standard) certification represents an international quality management standard. Developed by UNIFE (Union of European Railway Industries), the IRIS certification is globally recognized and ensures that suppliers operate according to the highest standards of quality and safety, with a focus on continuous optimization of production processes, from design to maintenance.
Design process
The design process in Elemaster is oriented towards risk reduction, working particularly on project simplification, while maintaining a high level of customization according to Customers’ needs. This design is done with a methodical approach that involves the identification and mitigation of potential risks at an early stage of the project, including the use of advanced modelling and simulation tools to predict and solve problems before the prototyping phase. In addition, the involvement of internal multidisciplinary teams allows for the integration of different skills, ensuring a complete view of the project.
Sustainability in design
Elemaster takes a sustainable approach to the design of its products, focusing on recyclable components and eco-friendly materials to significantly reduce environmental impact and promote more efficient use of resources. The design aims at durability, ensuring a longer life cycle and reducing the need for frequent replacements, improving product reliability and reducing electronic waste. Another key aspect is upgradability: devices are developed to be easily updated and adapted to new technologies, further extending their life cycle and contributing to a more circular economy.
The after-sales reconditioning of Elemaster products
Elemaster is committed to ensuring that equipment remains active and operational in the long term through effective after-sales reconditioning. This commitment implies the management of any request for maintenance, return or modification of installed devices even after 15 years of operation. The ability to keep equipment operational for such a long period is made possible by careful design and availability of compatible spare parts, ensuring that products can be easily repaired and upgraded, minimising downtime and extending their use.
Prototyping with excellent design
During prototype development, methodologies such as Design for Testability (DFT), Design for Manufacturability (DFM) and Design to Cost (DTC) are applied, practices that allow the optimization of product design for production, reducing costs and improving quality.
Each methodology has a specific focus:
- DFT ensures that the product is easily testable during production and use.
- DFM ensures that the product can be manufactured efficiently and without defects.
- DTC focuses on cost optimization throughout the product lifecycle.
Elemaster maintains constant communication with the Customer during the prototype production phase, responding to their requests as quickly as possible. To reduce time to market, Elemaster has created a division dedicated exclusively to rapid prototyping, equipped with advanced technologies that allow the development process to be accelerated, ensuring short lead times and high quality of prototypes. New Product Introduction (NPI) is an essential part of the service portfolio, with the aim of achieving a reliable and repeatable process to put products on the market quickly, meeting quality, technical and cost competitiveness requirements. The process includes product specification analysis, using methods such as Zero Design Defect (ZDD), Manufacturing Rules Checks (MRC) and Reliability Stress Screening (RSS) to eliminate defects early on and validate the assembly and testing process.
Prototype testing and verification
To identify hidden defects and ensure the quality of internal connections, Elemaster uses 3D X-RAY inspection machines to perform inspections on sample welds, ensuring that components are properly welded. In addition, Eletest automatic platforms ensure that each device meets the quality and safety requirements through rigorous testing, which includes verification of functionality, reliability and product resistance under different operating conditions. The combination of these advanced testing techniques ensures that only products meeting the highest standards reach the market.
Evaluation and pre-production modifications
Prior to mass production, Elemaster performs a product and process audit (FAI – First Article Inspection) to document the full picture of the project, making any necessary changes before starting large-scale production. This is a crucial step in identifying and resolving potential problems, ensuring that the final product meets all technical specifications and regulatory requirements. The audit includes a series of detailed tests and inspections that verify the prototype’s compliance with design and production standards.
The IRIS certification in mass production
After sample validation, production follows strictly controlled processes to maintain compliance with IRIS standards. Sourcing compliant materials, using certified machinery and adopting manufacturing methodologies that minimize defects are essential to maintain compliance with IRIS standards. Another key point underlying quality and compliance management is continuous staff training, regular audits and a constant review of processes.
A Future of Innovation and Quality
With a commitment to excellence in design and manufacturing, Elemaster continues to set new standards in the railway electronics industry. International certifications and the adoption of cutting-edge methodologies ensure that each product not only meets Customer requirements but exceeds expectations in terms of quality and reliability. Thanks to an integrated and sustainable approach, the company can easily face the challenges of the global market, promoting a future where innovation and quality are the heart of every production process. With a clear vision and a constant commitment to sustainability and product updateability, Elemaster is ready to lead the industry towards new technological frontiers, always maintaining a strong focus on customer satisfaction and operational excellence.