In this Q&A with Rail Business Daily, TRB Lightweight Structure’s lead engineer- rail, Lyndon Newman, shares insights from a long and varied career – during which he has manufactured panels for the TDI Revolution Very Light Rail vehicle, been involved in the introduction of the Hitachi Class 800 Fleet and helped to develop detrainment systems for the global marketplace.
How did you get started as an engineer?
I decided to pursue engineering at an early age, as I was always curious about how things worked.
After studying Mechanical and Production Engineering, I joined Hawker Siddeley as a trainee engineer, where I worked on components for the Harrier Jump Jet and Concorde – a coup for an aircraft enthusiast!
Later, I was invited to join one of the leading composite material and panel suppliers of the day. There, I worked on projects like the Fokker fleet of aircraft and the Jaguar XJ220.
After being made redundant from a smaller composite company in 1996, I joined TRB as a project engineer, and quickly became production manager. Soon, I was working on tram floors for Strasbourg via Adtranz (now Alstom Derby) and floors for the Juniper vehicles. My first major project as projects manager was the Alstom Class 390 Pendolino interiors for all 57 vehicles.
And, since becoming lead engineer, it’s been rail all the way!
How has the rail industry changed since you first started?
In the early days, the use of composite and bonded materials was limited, and the industry was still biased towards heavy fabrication and steelwork.
As trains have developed and rail has tried to become ‘greener’, it’s coming around to the advantages of using composites and bonded honeycomb assemblies in certain areas of a vehicle to reduce mass.
A good example of this is the TDI Revolution Very Light Rail vehicle, whose chassis sides doesn’t consist of the usual welded aluminium profiles. Instead, 10 Carbon PFA composite panels form the structure of the train.
The panels were manufactured at TRB, so I’ve had first-hand experience of providing revolutionary materials for a revolutionary vehicle with a significantly reduced mass.
What qualities are necessary to succeed as an engineer in the rail industry?
Good working knowledge of rail industry standards is key, especially in the repair field.
It’s not just about understanding how to manufacture a component; you must design and produce it so that it performs structurally and meets other performance requirements.
Being willing to ask questions also helps – as an engineer, you can’t be expected to know everything. In my current role, I talk to customer engineers, sub-contract engineers, test house engineers and technicians, and learn a lot from them.
How has your experience helped you adapt to changes in the industry, and what advice would you give to someone starting out?
I’m fortunate to have worked either with or alongside some very experienced people over the years. They’ve taught me a lot about processes, new materials and even specifications and applications, as things are constantly evolving.
Good engineers never stop learning. Every project is different, and determination is key – as is sharing the challenges you’re facing. Issues often arise when an individual tries to do everything themselves – ‘a problem shared is a problem halved’. Don’t be afraid to ask questions and occasionally admit that you don’t know everything.
What do you think the future holds for the rail industry, and what role do you see yourself playing in it?
The industry is in a strange place, particularly for engineers working at SME level. The pandemic slowed things down, and the big projects for new mainline trains are rapidly approaching completion. It feels like the rolling stock SMEs are waiting for HS2 to kick off.
As well as looking for new and exciting manufacturing opportunities, I’d like to mentor young engineers as they join the industry, helping them to learn the trade and understand the products.
What do you think are the biggest opportunities for innovation and growth in the rail industry?
I think the future seems to be reliant on alternative forms of energy.
It was great to be involved with the Revolution VLR vehicle and the Hitachi Class 800 fleet of Bi Modes, because of their green credentials. I’d love to develop more lightweight, fuel-efficient vehicles, combining TRB’s technologies with new propulsion methods and providing greener transport opportunities.
I hope this approach will help to bring the cost of running these vehicles down, bringing more people back to rail.
What do you love most about working as an engineer in the rail industry?
The people, projects, and opportunities to visit depots and train manufacturers, both in the UK and worldwide.
I’ve visited manufacturers across the globe, from Hitachi in Japan to Siemens in California, along with a large number in Mainland Europe. Wherever you go, people are passionate about the industry and proud of what they produce.
What are some of the most exciting projects or initiatives you’ve worked on in your career?
Probably the Hitachi Class 800 fleet or the IEP (Intercity Express Programme). I visited the Hitachi plant in Kasado, Japan, and worked with its Japanese team, even seeing the Shinkansen (bullet train) in production.
In terms of initiatives, it’s got to be the work I’m involved in now – developing detrainment systems for the global marketplace. TRB already designs, validates and manufactures detrainment doors; now, we’re taking that capability and focussing it on other markets where the hinged door and stairs (common to the UK) are replaced by flip-up doors and ramps. It’s fascinating!
What advice would you give to young people considering a career in engineering, and what can the industry do to attract and retain talent?
The rail industry is like an extended family. It’s also multi-faceted, and you can specialise in anything from interiors and doors to bogeys, electronics, engines and even toilets!
There’s also freight, and the support industry that provides the network’s infrastructure, as well as hundreds of SMEs specialising in bespoke product solutions and services.
I believe that an apprenticeship, with hands-on experience, is the best way to learn – although engineering qualifications are also important.
If an apprenticeship isn’t possible, we could incentivise young engineers via programmes that offer continual training. Making it interesting and challenging is key; they need to feel like they’re contributing. Exposing them to a variety of scenarios will also help them to learn and mature.
What do you see as the biggest challenges facing the rail industry, and how can they be addressed?
The biggest challenge is the cost-of-living crisis coupled with the rising cost of travel, and we need to make train travel more attractive.
We must also promote and invest in greener technologies, encouraging people to travel by rail because it’s good for the environment.
It’s down to governments to address these challenges. They need to consider how they support their national rail industry, allowing it to grow, employ people, and hopefully create new jobs.
Doing so will also enable the next generation of engineers to embark on a journey like mine.
Anyone considering a career in rail should get on board and enjoy the ride. The journey, while challenging at times, is interesting, rewarding and fun.
