KR Engineering Brochure 6pageD

A strong tradition
of engineering
provides the
foundation of expertise
that exists in our
workshops today
Hillside
and Hutt
Workshops
– a track record
of engineering
excellence
KIWIRAIL MECHANICAL
0800 801 070, Option 0
HUTT WORKSHOPS
HILLSIDE WORKSHOPS
Elizabeth Street
300 Hillside Road
Moera, Lower Hutt
South Dunedin
New Zealand 5010
New Zealand 9044
PO Box 36005
PO Box 2146
Wellington Mail Centre
South Dunedin 9044
Lower Hutt 5045
Ph: +64 3 479 3470
Ph: +64 4 587 1800
Fax: +64 3 479 3209
Fax: +64 4 587 1736
• Overhaul • Refurbish • Rebuild • Components • Test • Inspection • Manufacture • Design • Inventory • Fabrication • Foundry • Machining • Traction Systems •
A track record
of engineering
excellence
Hillside Workshops
Hutt Workshops
This site has manufactured rolling stock for the
New Zealand rail industry since 1875, and more
recently it has expanded its unique skills base and
heavyweight capability to all engineering
applications.
The Hutt Workshops site has a long history of rail
engineering, having been established in 1929-30
as a locomotive manufacturing and maintenance
facility. Today, as a KiwiRail-owned facility, it
continues to provide a range of engineering services,
notably around component manufacture and
locomotive overhauls.
Hillside Workshops is one of Dunedin’s best-known
landmarks with eight hectares of open yard and
nearly three hectares of covered floor space
including on site foundry, machining,
assembly, paint and finishing facilities.
KiwiRail has manufactured and assembled rolling stock in
New Zealand since the inception of the railways in the late 1800s.
We have a strong tradition of engineering that has provided the
foundation of expertise that exists in our workshops today.
The KiwiRail Mechanical business provides mechanical support to
the New Zealand rail industry and other markets. Wide-ranging
knowledge and experience in the New Zealand rail industry’s
regulatory and statutory framework includes commissioning and
type testing of new vehicles, together with extensive capability in
design, manufacture, maintenance and overhaul. Skills and resources
are concentrated at two sites, Hutt Workshops in Wellington and
Hillside Workshops in Dunedin, with both sites benefitting from
excellent road and mainline rail connections. Hillside has developed
a depth of fabrication expertise around passenger carriage and
freight wagon builds, while Hutt Workshop’s focus is on component
manufacture, electric motors and heavy locomotive overhauls /
rebuilds.
Engineering capabilities are also being used by customers outside
the rail industry, from power generation and shipping, mining and
Products and Services
• Specialised welding process
capability
• New rail rolling stock
manufacture
• Steel components
manufacture for rail
• Civil structure manufacture
and refurbishment
• Refurbishment of rail wagons
• Rebuild of freight, passenger
and locomotive bogies
• Locomotive refurbishment and
upgrade programmes
• Steel and iron castings
• Rail componentry and
inventory
• Smelter industry components
• Mining industry components
• Stainless steel valve bodies
• Heat-resistant castings.
Projects
• C class flat-deck wagons
• CE class coal hopper wagons
• YJ class ballast hopper wagons
• SA and SD class passenger
carriages for Auckland
• SW, SWS and SWG class
passenger carriages for the
Wellington-Wairarapa service
• AK scenic carriages for tourism
experience trains
• GT class car carrier wagons
• Locomotive bogie process
improvements
• YJ class wagon controls fit-out
• High quality passenger bogie
refurbishment – one million
kilometres before overhaul
• ZH class box wagons
refurbishment
• Refurbishment of DSG shunt
locomotive
• Supplier of stainless steel valve
body castings
forestry, to irrigation and decorative castings. KiwiRail’s workshops
• Research and development of
are a major force in New Zealand engineering, with 400 staff across
• Turbine casings for power
two sites including electrical engineers, mechanical engineers, trade
qualified employees (maintenance and diagnostic), fitters, fabricators,
a range of semi-skilled workers, engineering support and registered
engineers.
Modern efficiency and quality standards are used across everything
we do, including the the “5S” principles, which provide the basis for
continuous improvement and maintain workplace efficiency in
production environments. Both sites are ISO accredited.
high temperature materials
stations.
WINNER – Otago Chamber of
Commerce Westpac Business of
the Year Supreme Excellence
Award 2004
WINNER – NZ Casting of
the Year Award 2002
Major Resources
• NZ’s largest heavy engineering
facility
• 10,500m2 floor area in two
workshops
• 100 tonne overhead crane
• 18 metre bed profile cutting
machine – plasma and oxyacetylene processes
• Internal fit-out of passenger
carriages
• Large capacity grit blast and
paint booths
• 5 tonne arc furnace
• 2 tonne hot heel induction
furnace
• 500kg high frequency
induction furnace
• Heat treatment and
spectrometer capability
• Materials testing laboratory
• Machining facility with CNC
machines and various
specialist machines
• Butler Plano mill (9m bed)
• 3D modelling software.
IPENZ – Excellence Award
for Mechanical and
Manufacture 2005
Testing & Inspection Services
• IANZ accreditation since 1991
• Destructive and nondestructive testing
• Mechanical testing equipment
for strength, toughness and
hardness
• Radiographic (x-ray) testing
• Surface methods (cracks
testing) equipment
• Weld testing and inspection
• Lloyds accredited foundry.
In recent years, Hutt Workshops’ main focus has
been on overhaul programmes and refurbishment
projects, of which many are extensive and require
the facility’s specialist skills, capabilities, plant
and tooling.
Products and Services
• Major rolling stock overhaul
• Heavy maintenance and
overhaul of locomotives (diesel
and electric)
• Heavy maintenance and
overhaul of passenger fleets
• Maintenance and overhaul of
freight rolling stock
• Refurbishment of rolling stock
• Diesel engine overhaul – strip
down, rebuild, remanufacture
• Fabrication
• Electrical systems
maintenance and overhaul
• Wheelset, axles and brake disc
production
• Refurbishment of rail wagons
• Rebuild of freight, passenger
and locomotive bogies
• Locomotive refurbishment and
upgrade programmes
• Steel and iron castings
• Rail componentry and
inventory.
Projects
• EO class locomotive
refurbishment
• Freight wagon overhaul and
refurbishment
• Diesel engine overhauls
• Electric traction system
overhaul
• DX class locomotive rebuild
and upgrade.
The Hutt workshops’ site also houses KiwiRail’s
electrical equipment facility that carries out overhaul
and refurbishment of electrical systems including
traction motors and alternators for heavy
applications.
The wide ranging inventory warehouse facilities at
Hutt Workshops are also the national logistics
centre, including an inventory of spares and
consumables for operations around the country.
Major Resources
• High stud engineering facility
• 40,000m2 floor area
• 100 tonne overhead crane
• Electrical systems unit
• Traction motor test bay
• Wheelset production.
Testing & Inspection Services
• “5S” Continuous Improvement
• ISO9002 accreditation
• Traction motor electrical load
testing
• Brake component test facility
• Locomotive load banking
facility
• Woodward governor testing.