Behind the Scenes: Development and Installation Stories
We highlight two of our representative products - the “Derailment Prevention Guard for Shinkansen” and the “PC Sleeper Turnouts,” sharing the journey from development to commercialisation and the stories behind their introduction *Department affiliations are as of the end of March 2025.
Derailment Prevention Guard for Shinkansen
K.O | Technical Section, Technical Department.
- Profile
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After studying mechanical engineering at both undergraduate and graduate level, he joined Yamato Trackwork
System in 2014.
In his third year at the company, he assumed responsibility for developing derailment prevention guards for Shinkansen high-speed trains following the transfer of his predecessor. Since then, he has been continuously engaged in the product’s development.
Developed in Response to a Shinkansen Derailment Triggered by an Earthquake
The Shinkansen derailment prevention guard is a device designed to prevent trains from derailing or veering
off the tracks. It was developed in response to the derailment of the Joetsu Shinkansen during the 2004
Niigata Chuetsu Earthquake.
A general purpose guard for standard track sections had already been developed before I joined the Company.
However, there are cases where conventional products cannot be used, such as areas where rails expand and
contract due to temperature changes or where guard installation space is limited. Since taking over the
development of guards in my third year at the Company, I have been responsible for the development and design
of specialized products for such special sections.
When we receive information from our customers, a railway operator, about areas that cannot be addressed with
standard shapes, we use CAD to examine the necessary product adjustment. After that, we consider and apply
testing methods to evaluate various factors, including strength, and pursue practical application through
repeated evaluations and refinement.
High Load Capacity and Excellent Maintainability
Derailment prevention guards are also available from other companies, but our guards were developed
specifically for Shinkansen trains use during earthquakes and feature extremely high load-bearing capacity.
Conventional derailment prevention guards typically have a load capacity of around 3 tons. However, when a
Shinkansen derails due to an earthquake, the guards are subjected to a load of approximately 17 tons. We have
conducted strength tests and confirmed that our derailment guards can withstand loads of 17 tons or more.
Another feature is its high maintainability. There is ballast (crushed stone) surrounding the sleepers that
hold the rails in place. The ballast is compacted to improve the stability of the tracks and the comfort of
the ride. While compacting the work, the derailment prevention guard is positioned on the inside of the rails,
which acts as an obstacle. Our design solves this issue: by simply removing the bolts, the guard to be easily
rotated and detached. When developing new products, we design the structure taking into consideration the ease
of maintenance and use of tools. Our Company actively applies for patents for our proprietary technologies and
continues to pursue further innovation.
End-to-End Solutions: From Design to Product Evaluation and Manufacturing
We value speed in development. As a person in charge of the process, I am aware of the need for a fast
response.
We have also established an environment where we can make new custom-made designs and perform in-house
testing.
Our strength lies in our ability to offer one-stop service solution - from design to testing and
manufacturing.
I believe it is important to have a broad perspective without being restrained by conventional methods, and
to be able to find, consider, and integrate available technologies and methods. In our new designs, we are
exploring various methods using approaches that were not possible in the past. In addition, to better
understand our current products and improve future products, we assemble products we have designed ourselves,
conduct strength tests, and evaluate their usability and structure. We aim to develop products that satisfy
not only our customers but that we can be proud of as well.
PC Sleeper Turnouts
Y.A | Osaka Branch, Sales Department
- Profile
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Since joining the Company in 2010, he has been in charge of railway companies in the Tokai region.
Over the years, he has introduced a range of original products tailored to meet customer requirements, including PC sleeper turnouts.
Enhancing Track Quality Through Rigidity and Stability
There are sleepers made of wood and resin for railroad tracks, but PC (prestressed concrete) sleepers are
becoming mainstream due to their superior durability compared to wooden and resin sleepers. Due to the
concrete material, the product is heavy, offering several advantages such as extended sleeper lifespan,
improved track stability (including elevation and alignment), lower sleeper costs, and reduced maintenance
expenses.
At our company, we incorporate these PC sleepers into turnouts and offer them in customized forms to meet
the specific needs of our customers.
Group Company Integration Driving Better Lead Times and Cost Control
One example of the circumstances that led to the adoption of PC sleeper turnouts involves a section of
track where the customer’s line that I manage, runs parallel to the line of another railway company. We were
informed that this other company had already actively introduced PC sleeper turnouts, which sparked our
interest. Although we have been promoting this product for some time and have understood the benefits of
installing it, we were asked to show how it is actually installed, since PC sleepers are heavier than those
made of wooden or resin . Therefore, I consulted with railway companies that had already adopted the product
and conducted on-site visits. By helping them understand not only the post-installation track conditions but
also the entire process leading to installation, we were able to secure regular orders. Railway companies
that have actually adopted this product commented that “The track condition has improved after
installation,” and “Even after more than ten years, it requires almost no maintenance compared to previous
turnouts.”
While the quality of our products is one of our key strength, another distinguishing advantage of our
company is our close collaboration with all of our group companies. For certain components, we source
materials from Yamato Steel, a group company, which gives us a significant edge in both cost and lead time.
Additionally, we have been ahead of the curve in automating and mechanizing our manufacturing facilities.
This allows us to operate equipment automatically even during long weekends and holidays, enabling us to
meet short delivery schedules. In some cases, our lead times have been nearly half of those offered by
competitors.
Connecting Teams Through Effective Communication
As a salesperson, I am committed to providing quick responses and communicating with sincerity. I make a point to coordinate with technical staff rather than holding up the customer requests myself, and I strive to relay the customer's message as accurately as possible. In particular, I pay close attention to technical details to avoid any miscommunication, as even a small misunderstanding could lead to conveying something that differs from the customer’s true intent.. We regularly check in with our customers so that they feel comfortable reaching out to us anytime they encounter any problems. We are highly recognized for our custom orders, so please don’t hesitate to consult us if you have any specific needs or challenges.
For Product Details on PC Sleeper Turnouts
