RS Report highlights challenges facing rail engineers

Engineers and maintainers working in a variety of industries will be facing challenges caused by dwindling labour resources, skills shortages, ageing assets, and availability and accessibility of maintenance products. But for those working in the rail industry, there are many more challenges atop these: extreme weather, pressure to be more sustainable and ever-growing demand on the services.

This year marks the bicentenary of rail in the UK, with the steam-powered Locomotion No.1 train journey by George Stephenson in September 1825 cited as the start of the railway network. Much has changed over the last two centuries, although in some places, the infrastructure built in the early decades of the network is what the service still operates on today. This means engineers are tackling ageing assets and trying to adapt them to the rigours of the modern world. 

It’s no mean feat when, alongside the challenges, complexities within the industry and the number of stakeholders causing fragmentation means the landscape is even more difficult to navigate.

RS’ recently launched report ‘UK Rail - An Industry Review’ presents a current snapshot of the state of play of the rail industry. And it offers some solutions to how engineers can make the railways fit for the growing and evolving demand. The report references key industry information and data from sources including Rail Industry Association (RIA), the Rail Delivery Group (RDG), and the Office of Rail and Road (ORR).

Ageing infrastructure presents a significant pain point for engineers

Ageing assets are highlighted in RS’ rail report as an acute challenge for the railway industry, as much of the UK’s railway infrastructure is very old and some of it dates back to the mid-18th century. 

This requires an ongoing maintenance programme, but in the face of growing extreme weather events, this is challenging. When adding in fewer labour and financial resources, and lead time to get hold of maintenance products, it becomes even harder.

Mike Gregson, industry sector manager at RS UK

Mike Gregson, industry sector manager at RS UK & I, said: “Thinking about the management of assets in a holistic way is vital. Implementing condition-based approaches to maintenance as opposed to reactive drives greater efficiency and minimises downtime. Rail companies can partner with trusted suppliers too. RS supports a rail customer with oil condition monitoring and it sees this as an important part of its maintenance programme and an opportunity to ensure assets remain in the best condition possible. 

More broadly, businesses need partners to support them with offerings that aren’t part of their core objectives, but can improve the longevity of parts, reduce downtime and help them to achieve their goals.”

Engineers should embrace digital technology that ensures availability of parts

Technologies can help optimise supply chains and offer advantages for managing maintenance, repair and operations (MRO) procurement. This can greatly assist rail engineers and maintainers in achieving the economies of scale that can reduce costs, improve the reliability of assets and minimise downtime.

Managing ageing assets often means a higher risk of breakdown and difficulties in maintaining equipment, as a result of obsolete parts or items with a long lead time. Technologies like vendor-managed inventory services that provide easy access to essential low-cost parts, enable engineers to have improved accessibility and availability of maintenance products needed. This increases efficiency, productivity and optimises inventory to reduce carrying costs by stocking only what’s needed. 

Gregson added: “In the rail industry, with different infrastructure in various parts of the network, you may need a wide range of sets of spares and obsolescence can be a factor. Supply chain reliability is, therefore, foremost. You need a supplier who can ensure the availability of spares so you can get the fix done quickly and keep downtime to a minimum.

“You also need suppliers you can trust to provide critical parts but nurture a more holistic view of what you need from them too. Build relationships with suppliers that have industry knowledge and expertise, and you’ll gain access to the added value and innovations a partner can offer.”

Recruitment is an ongoing challenge

Recruitment and retention are challenges facing most industries now, as unveiled in a recent RS and Institution of Mechanical Engineering (IMechE) report as a major issue, with half of respondents listing these as prominent concerns. This is highlighted in the RS rail report as one facing the rail industry as well.

Rail today supports around 710,000 UK jobs, from high-skilled positions to apprenticeships. For every 1,000 people employed in the rail network, a further 4,300 jobs are supported across the UK economy.

Rail holds significant green credentials

Rail engineers and maintainers must get a grip on maintenance to help keep the network moving and growing, as, along with economic benefits, the green potential of rail is huge. Membership organisation Rail Delivery Group states for every mile a person travels, passenger trains produce only around a fifth of the greenhouse gas emissions from the average petrol car. Therefore, a 40 per cent growth in rail use by 2035 would result in a greenhouse gas emissions reduction per year that is greater than all domestic aviation emissions in 2019. And while the realism of a 40 per cent growth might be queried, Railway Industry Association (RIA) states rail passenger numbers are likely to grow between 37-97 per cent by 2050, while Office for National Statistics projections show that the UK population will grow by 10 per cent to almost 74m by 2036. 

This will unequivocally mean a greater demand on the rail service and many more journeys, and lead to a reduction in vehicles on the road, reducing carbon emissions and congestion.

In February 2025, the Department for Transport launched a consultation to inform the forthcoming Railways Bill, which will establish Great British Railways. The proposed reform aims to address some of the current industry challenges facing the industry and facilitate a better relationship with rail’s supply chain.

RS’ report concluded that while major reform is coming down the tracks, the need for reliable railway systems throughout the UK remains as important as ever, making a vital contribution to the national economy, and to the objective of achieving a sustainable, low-carbon future.

Innovation and the use of digital technology, combined with strategic maintenance programmes and a robust, efficient supply chain, remain key to overcoming challenges and obstacles. Collaboration with trusted partners, including suppliers, can help companies across the rail sector to make the most of these opportunities without having to figure out all the options on their own.

Click here to download the RS ‘UK Rail – An Industry Review’ report