How Merz RailServices reliably secures capacities despite bottlenecks
The shortage of skilled labour is no longer an abstract future scenario, but an operational reality in many technical sectors. This is particularly evident in rail vehicle maintenance and servicing. Operators, vehicle owners and workshops are increasingly faced with the challenge of finding and retaining qualified personnel for safety-critical, technology-intensive maintenance work.
At the same time, demand is growing: fleets are getting larger, vehicle technologies are becoming more complex and availability requirements are increasing. If you don't have a resilient HR strategy today, you risk limited operational performance tomorrow.
However, a shortage of skilled labour does not necessarily mean a lack of capacity. Specialist external providers such as Merz RailServices show that systematic qualification, specialisation and structured personnel programmes can build up reliable maintenance resources even in a tight labour market.
Is there a shortage of skilled labour in rail vehicle maintenance?
The short answer is yes, and it is structural.
In Austria, Germany and Switzerland, there is an increasing shortage of qualified technical specialists in railway workshops. This affects traditional metal and electrical engineering professions as well as modern mechatronic, air conditioning and IT-related qualifications. Industry studies and labour market analyses show a high number of vacancies in the rail industry, long backfilling times and growing competition for experienced workshop personnel.
Rail vehicle maintenance is particularly sensitive in this respect:
It combines safety-relevant processes, manufacturer-specific technologies and regulatory qualifications. Specialists cannot be replaced or „trained“ at short notice. New employees often take months to become fully operational.
Which specialist areas are particularly affected?
The bottleneck does not affect all trades equally. The following are particularly critical:
Electrical and mechatronics specialists
Modern vehicles contain complex power electronics, control software, sensors and diagnostic systems. The need for qualifications has clearly shifted from classic mechanics to mechatronic system competences.
HVAC / refrigeration and air conditioning technician
Air conditioning systems are one of the most frequent causes of failure in passenger transport. At the same time, the labour market for refrigeration and air conditioning technology is already tight across all sectors. Additional rail specialisation is exacerbating the bottleneck.
Diagnostics and software specialists
Digital vehicle control systems, condition monitoring and remote diagnostics require specialists with interface expertise between mechanics, electrics and IT.
High-voltage and new drive technologies
Battery and hydrogen vehicles are creating new qualification profiles for which only a limited number of trained personnel are available.
What are the causes of the skills shortage?
The staff shortage is not the result of a single factor, but the interplay of several structural developments.
Demographic change
A significant proportion of today's workshop staff will reach retirement age in the coming years. The number of new recruits will not be sufficient to fully compensate for these retirements.
Fleet growth
Another driver of the shortage of skilled labour is the continuous growth of rail vehicle fleets. With every newly purchased multiple unit, wagon or additional locomotive, the need for maintenance increases faster than new qualified specialists can be trained.
Increasing technological complexity
Vehicles are developing faster than traditional training systems. Qualification profiles are shifting towards electronics, software and system diagnostics.
Limited appeal for young talent
Workshop professions compete with automotive, industrial and IT employers. Shift work and physical labour are often less attractive to young target groups.
Long certification and approval processes
Safety-related activities require formal certificates, manufacturer training and internal authorisations. New employees only become productive after a long familiarisation period.
Small external labour market
Railway-specific experience is rare. International recruitment is additionally limited by language, standardisation and safety requirements.
What impact does the shortage of skilled labour have?
Reduced workshop capacities
Unfilled positions lead directly to lower maintenance performance. Maintenance programmes are delayed and modernisations are postponed.
Decreasing vehicle availability
Longer downtimes in workshops reduce the operational availability of the fleet. This has direct consequences for service quality and reliability in operation.
Rising lifecycle costs
Reactive rather than preventive maintenance increases wear, susceptibility to faults and spare parts costs. External contracts become more expensive.
Burden on existing staff
Overtime and additional shifts increase sickness rates and staff turnover, which in turn exacerbates the shortage.
Delayed innovation projects
A lack of qualifications is slowing down the introduction of new diagnostic tools, digital assistance systems or alternative drive technologies.
Safety and quality risks
Understaffing increases the pressure on audit processes and increases regulatory risks.
What solutions are there?
The industry is reacting, but with varying speed and consistency.
Expansion of own qualification programmes
Internal training workshops, digital learning platforms and accelerated programmes for career changers create new talent pipelines.
Knowledge management
Digital fault databases, standardised repair instructions and mentoring programmes ensure that experience is available.
More attractive working models
Plannable shifts, modern working environments and clear development paths improve retention and recruitment.
International recruitment
Targeted programmes with language and standards training open up additional talent markets.
Digital assistance systems
AR-supported maintenance support and AI diagnostics reduce the need for many years of experience per deployment.
Standardisation of maintenance processes
Modular replacement systems reduce dependence on highly specialised individual repairs.
Why external service providers can provide staff despite a shortage of skilled labour
This is a key success factor for modern maintenance strategies.
Systematic qualification modelsSpecialised service providers consistently invest in their own training and certification programmes. They build up specialised staff in a targeted manner instead of recruiting exclusively from the market.
Focused specialisationInstead of covering the entire range of products for a train or several fleets, external partners concentrate on defined system areas (e.g. air conditioning systems, couplings, doors, brakes, etc.) or vehicle fleets. This creates in-depth expertise with a high repetition rate.
Standardised tools and processesDigital diagnostic tools, structured repair kits and documented work processes shorten familiarisation times and increase productivity.
Attractive project and deployment modelsVaried projects, predictable rotation and modern working time models appeal to target groups who avoid traditional workshop structures.
International talent sourcesStructured recruitment channels open up additional labour markets.
Merz RailServices as a reliable partner for maintenance capacities
Merz RailServices has specialised in precisely this challenge. Our approach is based on three pillars:
Targeted development of skilled labour
Internal training programmes, manufacturer-specific training and structured induction paths ensure a high level of qualification, even for lateral entrants.
Technical specialisation
Focus on clearly defined vehicle systems enables in-depth expertise, short lead times and reproducible quality.
Flexible deployment models
Scalable service capacities support operators precisely where bottlenecks occur, at short notice and predictably.
This enables us to create stable maintenance resources. Even in a tight labour market.
Conclusion
The shortage of skilled labour in rail vehicle maintenance is real, structural and will become even more acute in the medium term. At the same time, new solution models are emerging: Those who invest in qualification, specialisation and process standardisation at an early stage will be able to provide reliable maintenance capacities in the future.
Merz RailServices stands for precisely this approach: qualified specialists, structured processes and reliable service, regardless of market bottlenecks.
Do you also have bottlenecks in the maintenance of your rail vehicles?
Talk to our experts. We will show you how external service capacities can support your workshop and ensure sustainable fleet availability.
Sources and further information
ÖBB Press (10.10.2025): Expansion of TS Innsbruck, new jobs, increasing demand, specialists wanted
Kurier (28.01.2025): ÖBB needs tens of thousands of employees by 2030 (skilled labour requirement)