Quality Assurance

With our quality assurance services, your assets will undergo thorough validation to meet the quality standards and requirements set by all relevant stakeholder groups.

Quality assurance involves working closely with operating companies, regulators, industry stakeholders, and manufacturers. Drawing upon our extensive experience in navigating these complexities combined with our focus on improvement, innovation and quality enables us to address challenges efficiently, ensuring a reliable and efficient system.

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Sub supplier reviews

Our team has significant experience in undertaking a first article inspection (FAI) – a fundamental step in ensuring the quality and compliance of a manufactured product.

We will establish a comprehensive understanding of the product requirements by thoroughly reviewing the engineering drawings, specifications, and any relevant documentation, and develop a detailed inspection plan, outlining the key characteristics and critical features to be examined during the inspection.

During the physical inspection, we will meticulously examine and measure each component and, where applicable, test against the established criteria. Any differences will be documented and analysed to determine their impact on product functionality and compliance.

We will then compile an FAI report, summarising the inspection findings and providing a clear overview of the product’s quality status.

If required, we can also carry out a subsystem quality review and provide a more in-depth examination of a specific item, assessing their individual performance and integration within the larger system.

Our comprehensive approach ensures that the product not only meets the specified requirements but also operates seamlessly within its intended context, promoting overall system reliability and performance.

Our services include:

  • First Article Inspection (FAI) reviews
  • Attendance at FAIs

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  • Follow up and report write ups of FAIs
  • Sub system quality reviews


We can conduct comprehensive audits across the following processes in manufacturing, quality, test, and management plans. Such audits enable organisations to uphold operational excellence and consistently deliver high-quality products or services.

  • Process audits. With many years of experience conducting process audits, we can undertake detailed examinations of workflows, procedures, and operational protocols to ensure efficiency and adherence to best practices.
  • Manufacturing audits. When conducting manufacturing audits, we will focus on the production floor, scrutinising equipment, materials and workmanship to guarantee compliance with design specifications and quality standards.
  • Quality audits. When undertaking a quality audit, we will thoroughly inspect your quality control processes, product inspections, and adherence to established quality management systems.
  • Test audits. As part of our test audits, we will evaluate the effectiveness of testing procedures and protocols to confirm that products meet or exceed performance expectations.
  • Management plan audits. As part of our management plan audits, we will assess leadership strategies, communication channels, and overall organisational effectiveness.

A holistic approach to these audits ensures that every facet of the business aligns with established standards, promoting continuous improvement and sustainable success. Regular and systematic audits play a pivotal role in identifying areas for enhancement, mitigating risks, and fostering a culture of quality and excellence within your organisation.

Our services include:

  • Process audits
  • Manufacturing audits
  • Production audits
  • Quality audits

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  • Test audits
  • Safety audits
  • Quality management plan audits

Manufacturer reviews

When conducting a manufacturing review, we perform a comprehensive evaluation and in-depth assessment of the processes and activities involved to gauge the efficiency, effectiveness, and overall performance of your manufacturing operations.

Our objective is to identify areas for improvement, ensure quality control, and optimise the production process. Our team will assess the quality of the products being manufactured, ensuring they meet the required standards and specifications.

We will assess the efficiency of manufacturing processes to identify bottlenecks, streamline operations, and improve overall productivity. Additionally, we ensure that your manufacturing processes adhere to industry regulations, safety standards, and environmental guidelines.

We evaluate the skills and training of the manufacturing workforce, ensuring they are well-equipped to handle their responsibilities effectively and only undertake tasks for which they are competent.

Our services include:

  • Reviewing and agreement of glass case sample standards
  • Managing of glass case standard samples
  • Creation of quality standards

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  • Unit production inspections
  • Final asset inspections, verifications and close out
  • Asset quality inspections


Encompass Engineering has played a crucial role in our endeavours at West Midlands Trains, particularly during the implementation of our new Cl 196 fleet. Their unwavering support has proven invaluable, encompassing critical aspects such as technical assistance through modification reviews, testing witnessing, wayside engineering, and proficient project management to facilitate the integration of the units into passenger service. Their contribution has not only assisted us in overcoming challenges but has also significantly enhanced the depth of our capabilities when it mattered most.

— John Doughty, Engineering Director, West Midlands Trains

Encompass contributed towards the speedy review and feedback of design and maintenance information that has helped move the project forward.

— Rachel Turner, Head of New Trains, East Midlands Rail

Case Studies

Enhancing Asset Management for Rock Rail’s Class 717 Fleet

Rock Rail owns a fleet of 25 Class 717 units that has been serving passengers since 2019.

To protect their assets, Rock Rail wanted an independent specialist team to conduct inspections on these Siemens units - from both the physical unit and maintenance perspective. The project would provide insight into whether or not agreed-upon maintenance procedures were being adhered to.

Frequently Asked Questions

Quality assurance is vital in rail services to enhance safety, maintain customer satisfaction, meet regulatory requirements, minimise disruptions, and uphold the reputation of rail operators.
Quality assurance services offer several benefits in the rail industry, including: Enhanced Safety: Rigorous safety protocols and inspections help prevent accidents and ensure the well-being of passengers, staff, and the public. Improved Reliability: Regular maintenance, monitoring, and adherence to quality standards contribute to the reliability and punctuality of rail services, reducing delays and disruptions. Increased Customer Satisfaction: Providing safe, reliable, and comfortable transportation services enhances customer satisfaction and loyalty, leading to positive experiences and repeat business. Compliance with Regulations: Quality assurance ensures compliance with regulatory requirements, avoiding fines, penalties, and legal issues associated with non-compliance. Cost Savings: Investing in quality assurance services can lead to long-term cost savings by minimising the need for repairs, reducing downtime, and optimising operational efficiency. Enhanced Reputation: Delivering high-quality rail services builds trust and credibility with passengers, stakeholders, and the broader community, enhancing the reputation and brand image of rail operators. Risk Mitigation: Quality assurance helps identify and mitigate risks associated with equipment failure, service interruptions, and safety hazards, safeguarding the interests of both rail operators and passengers. Continuous Improvement: Implementing quality assurance processes fosters a culture of continuous improvement, encouraging innovation, efficiency gains, and the adoption of best practices to enhance rail services over time.
Rail operators can integrate quality assurance into their operations effectively by establishing clear quality objectives, implementing robust processes and procedures, providing comprehensive training for staff, conducting regular audits and inspections, and fostering a culture of accountability and continuous improvement throughout the organisation.

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