Championing Change with Prevu3D: Success, Innovation, and Vision

A Q&A with Matthew Mardres, Digital Experience Designer, Amsted Rail

Q: For those unfamiliar with Amsted Rail, can you give us a brief overview of your company and role?

A: Amsted Rail is a 147-year-old leader in rail car components manufacturing. If you’ve seen a train, chances are we made the wheels, side frames, or entire bogie assemblies. We operate 60 facilities in 20 countries, making us a global, but often under-the-radar, company. My role as a Digital Experience Designer on the Emerging Technologies team focuses on leveraging cutting-edge tools like Prevu3D to modernize and optimize our operations.

Q: How did Amsted Rail begin experimenting with digital twins and reality capture?

A: Our journey started in 2019 when we explored XR technologies like virtual and augmented reality. Initially, we tested them for training and visualizing IoT data. While useful, we realized they weren’t the right fit for all applications. This led us to explore digital twin technology to bring spatial context to operational data.

Since then, we’ve gone from having no digital footprint to scanning over 3.5 million square feet across six countries. Prevu3D has become a critical tool in our change management, planning, and operational processes.

Q: How did you secure executive buy-in for adopting Prevu3D and investing in scanners?

A: We focused on clear, practical use cases. For example, when relocating a massive piece of equipment from Monterrey, Mexico, to North Carolina, we used Prevu3D to validate feasibility. It prevented costly mistakes like discovering too late that the equipment would breach the destination building’s ceiling.

We also proposed in-house scanning as a cost-effective alternative to external vendors. By purchasing our own scanners and upskilling our team, we reduced scanning costs significantly—sometimes by 90%. This helped us build a strong business case for leadership support.

Q: What are some innovative use cases for digital twins at Amsted Rail?

A: Facility planning is a major one. We’ve used Prevu3D to design new facilities, relocate equipment, and plan automation workflows. For example, in Monterrey, we digitized an empty facility and an existing one, allowing stakeholders to “play Sims” with layouts and ensure compatibility before implementation.

Beyond planning, we’re exploring health and safety applications. One initiative involves training new hires in virtual environments to familiarize them with hazards and workflows before stepping onto the shop floor. We’re also using digital twins for crisis management, like active shooter and fire safety planning, enabling us to simulate and refine emergency responses.

Q: How has digital twin technology influenced cultural change within the organization?

A: Cultural change is a challenge, especially when transitioning from hands-on, manual processes to digital-first approaches. The key has been making the technology engaging and accessible. We’ve emphasized “What’s in it for me?” to highlight how these tools solve practical problems for frontline workers and decision-makers.

Building trust has also been critical. By working closely with stakeholders, demonstrating results, and positioning them as champions of change, we’ve fostered widespread adoption.

Q: What are your long-term goals for digital twins at Amsted Rail?

A: Our vision is to create a “visual faceplate” for all systems, integrating IoT, ERP, and safety data into a dynamic, two-way digital twin interface. This will enable real-time monitoring, remote collaboration, and predictive insights.

We’re particularly focused on using AI to enhance decision-making and support our aging workforce. By creating user-friendly, interactive tools, we aim to capture institutional knowledge and enable seasoned employees to contribute remotely, extending their careers while training the next generation.

Q: How has Prevu3D helped Amsted Rail stay ahead in innovation?

A: Prevu3D has made complex processes like equipment relocation, facility planning, and safety training significantly more efficient. Its flexibility allows us to plan proactively by scanning environments ahead of specific projects, ensuring data is readily available for future use.

For example, we once avoided a costly mistake when moving a three-story-tall piece of equipment by using Prevu3D to identify structural issues in the destination facility before the move. This proactive approach is now embedded in our operations, saving time, money, and resources.

Q: What’s next for Amsted Rail and Prevu3D?

A: We’re excited about features that keep digital twins dynamic and up-to-date, like integrating drones for rapid updates and enabling real-time data overlays. We’re also looking forward to XR applications that allow frontline workers to visualize critical IoT data in their immediate environment.

Our ultimate goal is to create an immersive, interactive digital ecosystem that empowers our workforce, enhances safety, and drives operational excellence.

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About Amsted Rail

Amsted Rail is the world’s leading provider of undercarriage and end-of-car railcar components with facilities spanning more than 40 locations across 6 continents. Through our state-of-the-art manufacturing processes, Amsted Rail is providing our customers worldwide with unmatched performance and reliability for the long haul. Amsted Rail is part of Amsted Industries Incorporated, a diversified global manufacturer of highly engineered industrial components. Amsted Industries is privately held and employee-owned, giving employees a stake in its present and future successes.