Downer Group has reinforced its commitment to a workforce-centred approach to automation, announcing an expanded partnership with Australian robotics company Future Maintenance Technologies (FMT), aimed at growing the use of robotic rail maintenance systems across Australia and overseas. Downer is one of the largest providers of rail and infrastructure services in Australia and New Zealand.

The agreement marks the next stage in a collaboration that has seen the two companies pilot autonomous inspection technologies within operational rail environments, with a focus on improving safety, efficiency and maintenance outcomes. The partnership backs a practical approach to automation that keeps skilled people at the centre of maintenance operations rather than substituting them with robots.

Downer says its experience has shown that the most effective maintenance strategies combine advanced robotics with experienced technicians, not replacing one with the other.

The partnership is being delivered through XDNA, Downer’s digital asset management business, which works with FMT to introduce robotic technologies capable of undertaking inspections in challenging rail maintenance environments.

“We have never believed the version of the automation story that goes ‘robots in, people out’,” says XDNA Executive General Manager Darren Hungerford.

“What really works – what our customers want and what we have proven on the ground with FMT – is robots and humans in harmony. The robots take on the jobs that are repetitive, hazardous or simply impossible to do consistently at scale, and our skilled people get to spend their time on the higher-value engineering work that keeps fleets running,” he explains.

FMT’s Rail Facility Drones (RFD) and Train Robotic Examination System (TRES) are already deployed within live Australian rail environments, where they perform physically demanding inspection tasks that traditionally require workers to access confined spaces, operate beneath rail carriages or work at height.

The systems collect detailed inspection data that is processed using artificial intelligence before being reviewed by human experts. This approach aims to provide more consistent inspections, richer asset data and earlier fault detection while reducing the amount of time workers spend in potentially hazardous locations.

Unlike traditional automated industrial systems that require strict separation between machinery and personnel, the robots have been designed to operate alongside maintenance crews. Multiple onboard sensors continuously monitor nearby activity, allowing the machines to slow down or stop if people or objects enter designated operating zones. This enables technicians to focus on diagnosis, planning and higher‑value engineering work.

The technology was initially trialled at Downer’s depots in Auburn (NSW) and Pakenham (Victoria), where its Rail & Transit Systems team worked with FMT engineers to test autonomous inspection systems on the Waratah and HCMT fleets.

As FMT’s first major industry partner, Downer played a key role in validating the technology in live operational environments. The latest agreement formalises a relationship that has evolved from pilot programs through live deployment to commercial scale‑up.

With more than 155 years of rail industry experience, Downer believes the partnership aligns closely with the future direction of maintenance operations.

“We backed FMT early because we could see the tangible benefits for our customers, safer inspections, better data and more effective use of our workforce,” Hungerford says. “This next phase is about taking what we’ve proven together and delivering it for more customers, in more markets.”

FMT Chief Executive Officer, Loic Ayoul credits the partnership with helping the company transition from development to real-world deployment.

“Downer gave us the opportunity to demonstrate our technology in a live operational setting at the Pakenham depot,” Ayoul says. “They’ve worked alongside us at every stage, and that partnership has been very valuable in supporting our progress to date.”

The companies are now targeting broader adoption of the technology, both domestically and internationally. The United Kingdom has emerged as a priority market due to similarities with Australia, including ageing rail fleets, shortage of skilled resources and rising expectations around reliability and asset performance.

Downer and FMT are currently engaging with rail operators across the UK and the wider Asia-Pacific region as they seek to expand the reach of their joint offering.

“The rail industry has talked about the future of maintenance for a long time,” Hungerford adds. “With FMT, we’re delivering it, practically, safely and with our people at the centre.”

Images: Supplied

Architecture News & Editorial Desk

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