Manufactory

Introducing WITT Solutions Manufaktur

Our manufacturing facility in Brandenburg is at the heart of WITT Solutions: this is where everything our customers need for the monitoring and qualification of their DC systems is produced – from the initial idea right through to the tested, ready-to-ship unit. We have made a conscious decision not to rely on suppliers from around the world, but to manufacture everything ourselves: warehousing, mechanical engineering, component manufacturing, electromechanics, commissioning, quality assurance and dispatch are all under one roof. This gives us the flexibility to produce one-off items and small batches, as well as test and inspection systems, cost-effectively in accordance with customer-specific requirements – and gives our customers the assurance that every component comes from a single source and is fully traceable.

For those who work here, this means one thing above all else: variety. No two days are the same, because hardly any two orders are alike. And what is created in our workshop is more than just an off-the-shelf product – our systems monitor and protect DC railway systems on which thousands of passengers rely every day. In many places, trains simply wouldn’t run without the equipment from our workshop. Anyone working in one of our seven departments makes a direct contribution to something of great social importance through their work.

Warehouse

Before we can manufacture or repair a piece of equipment, we need to have the right component to hand – even if it has long since been discontinued on the market. Our warehouse stocks not only current, approved components, but also parts that have not been produced for decades. This is precisely what enables us to reliably repair even very old assemblies for our customers, rather than immediately replacing entire systems. For our customers, this means long-term security of supply, even for devices that have been in use for twenty years or more. For our team, the warehouse acts as the link to all other departments – and sometimes involves a bit of detective work when a component from the nineties is needed.

Mechanical manufacturing

We do not produce off-the-shelf housings, sub-assembly racks and mechanical components; instead, we manufacture them to fit each application precisely – whether for DC rail systems or battery buffer systems. State-of-the-art machinery is combined here with decades of experience in tool and jig making. For our customers, this means: bespoke variants without having to go through external suppliers – everything from a single source. For our team, it means versatility – every production run presents new challenges in terms of materials, tolerances and machining, and no two components are exactly alike.

Electromechanics

This is where we bring together items from the warehouse and from component production: sub-assemblies, printed circuit board assemblies and mechanical parts are wired and assembled into complete systems here – from individual components right through to ready-to-use devices in our Classic and WITT Bridge product ranges. As our devices operate in safety-critical railway systems, every connection counts. For our customers, this means traceable, high-quality manufacturing in accordance with clearly documented test procedures. For our team, electromechanics is the interface where, for the first time, a complete device is formed from many individual parts

Component manufacturing

Our component manufacturing facility produces the measurement, control and regulation assemblies for our products – such as the components of the WITT Bridge series. Printed circuit boards (PCBs) are assembled and soldered, and the finished printed circuit board assemblies (PCBAs) are fitted into the housing and tested individually. For our customers, this forms the basis for reliable electronics manufactured in-house, rather than purchasing off-the-shelf components. For our team, it involves precision work on a small scale – a steady hand, a keen eye and the satisfaction of holding a fully functional, tested assembly in their hands at the end of the process.

Commissioning

Before a device leaves our factory, it is tested under realistic conditions. Using our digital twin, we simulate the behaviour of DC systems with up to 3,000 VDC and up to 128 signal channels – this allows us to replicate even complex fault scenarios in the laboratory before the device is deployed in live railway operations. For our customers, this means devices that can be integrated immediately and seamlessly into existing systems. For our team, commissioning is the moment when theory and the real-world system come together – this is where each device is powered up for the very first time.

Quality assurance

Our systems monitor installations where, in the worst-case scenario, a failure could endanger the lives and safety of passengers – which is why quality assurance is not an afterthought for us, but a consistent priority. An automated test system with 128 channels, reference measurement cards from National Instruments and our own signal generators reliably tests even complex scenarios, as part of our ISO 9001-certified processes. For our customers, this means documented, traceable quality that goes far beyond statutory requirements. For our team, it is the certainty that their work contributes directly to safety in rail transport.

We look forward to receiving your assignments.