Re-engineering freight rail with HCLTech’s RailTwin
Overview
Operating one of North America’s largest Class 1 freight rail networks, our client transports hundreds of thousands of railcars daily across a complex, multi-state infrastructure. Precision and efficiency are essential, requiring advanced capabilities to manage dynamic operations across tracks, yards and interchanges.
Building upon a strong strategic partnership, HCLTech implemented RailTwin — our innovative Cognitive Digital Twin platform for rail infrastructure management and operations. By seamlessly integrating real-time data streams, high-fidelity simulation and AI-driven analytics, HCLTech RailTwin creates a living, data-rich representation of the entire rail ecosystem. This solution transforms the client's operational approach from reactive decision-making to proactive, predictive planning and execution, enabling smarter decisions, enhanced resilience and significant efficiency breakthroughs.
The Challenge
Modernizing operations under rising pressure
Our client faced surging freight demand, operational bottlenecks and the constraints of legacy systems.
As their network scaled in size and complexity, the limitations became increasingly clear:
- Zero real-time visibility into asset health, infrastructure status and network flow
- Manual trip planning and yard operations that throttled throughput
- No sandbox to simulate "what-if" scenarios for capital projects or disruption response
- Reactive maintenance that led to service delays and inflated costs
- Disconnected systems hindering scalability and strategic foresight
These challenges not only choked capacity and agility, but also impacted customer satisfaction and increased vulnerability to inefficiencies and unplanned disruptions.
The Objective
Engineering a cognitive, scalable rail twin
The client set a bold goal: to engineer a dynamic, data-driven replica of its entire rail ecosystem — spanning mainlines, yards, rolling stock and wayside assets. This cognitive digital twin would serve as a real-time mirror of operations, enabling:
- Predictive visibility into network health, asset performance and emerging disruptions
- Simulation of operational and strategic scenarios to guide both long-term planning and real-time decision-making
- Dynamic optimization of schedules, resources and maintenance windows
- Enhanced throughput, efficiency and infrastructure performance
- A scalable digital foundation to support future growth, innovation and resilience
The Solution
A cognitive digital twin for intelligent rail operations
HCLTech deployed RailTwin, a next-generation digital twin platform built to tackle the complexity of freight rail operations. Acting as the network's intelligence core, RailTwin unifies infrastructure, systems and AI, within a cloud-native architecture that mirrors and optimizes operations in real time.
Core capabilities include:
- Real-time simulation: Accurate, high-fidelity models of trains, yards, signaling and infrastructure
- Live data integration: Continuous syncing with IoT sensors, SCADA systems, GIS and control towers
- AI-powered prediction: Early detection of congestion, weather impacts and asset issues
- Scenario planning studio: Simulates timetables, crew plans and capital projects before rollout
- SmartOps modules: Out-of-the-box tools for optimizing cargo prioritization, train slotting, yard sequencing and capacity
With web and mobile access enabled through a modular, microservices architecture, RailTwin empowers dispatchers, planners and maintenance teams to make faster, smarter decisions at every level of the network.
The Impact
From fragmented operations to a responsive rail network
With RailTwin, HCLTech delivered measurable improvements across the client’s operational ecosystem:
- 15% boost in capacity utilization through optimized train and station management
- 10% reduction in delays via improved train availability and predictive maintenance
- ~20% uplift in network performance through dynamic rescheduling and intelligent routing
- 25% enhancement in traffic and route planning accuracy
- Scalable performance across diverse geographies through integrated GIS and asset intelligence.
By combining domain expertise with digital engineering, HCLTech helped the client transform into a data-augmented rail enterprise equipped for future mobility demands.
Looking Ahead
Driving the future of predictive rail
HCLTech remains a strategic partner in the client’s journey toward intelligent operations and digital infrastructure resilience. Our roadmap includes enhanced AI models, broader use case expansion and deep integration with enterprise decision-making systems.
As we continue to evolve RailTwin, we’re not just solving today’s challenges, we’re shaping the railroads of tomorrow. Together, we’re moving from trackside visibility to system-wide intelligence, unlocking a new era of operational foresight, agility and network excellence.
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