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A rail operator sought to reduce manual-handling risk during overhaul activities by introducing a lifting device to remove door engines weighing over 20kg, located beneath saloon seating. There was concern that the device might overstress the saloon fixing points, particularly around the window frame.

INTERFAIC carried out a structured engineering assessment, including free-body force estimation, load-cell validation testing and Finite Element Analysis (FEA) of the critical fixing interface. Results demonstrated that stresses remained well below material yield with minimal deformation, providing clear assurance that the lifting method was safe.

Outcome: approval was granted for deployment of the lifting device fleet-wide. Delivering reduced injury risk and improved maintenance efficiency, supported by evidence-based engineering analysis.