Driving safety and innovation: Norfolk Southern Mechanical’s standout 2025

By Brett Willi, Senior Communications Manager

A year of meaningful progress across safety, reliability and technology

Norfolk Southern’s Mechanical team made exceptional progress in 2025, delivering measurable improvements that strengthened safety, enhanced fleet reliability and advanced the use of smart technology across our network. The team deployed new tools, refined daily operational execution and aligned their efforts to build a stronger, more resilient and more efficient railroad.

“This year’s results reflect accountability, strong collaboration and a commitment to doing things the right way,” said Brian Barr, Vice President and Chief Mechanical Officer. “We’ve continued to accelerate innovation while maintaining exceptional accuracy across our operations. I’m grateful for the dedication and discipline our Mechanical team brings to safety and precision every day.”

2025 Mechanical accomplishments:

Advancing safety outcomes

• 35% improvement in Federal Railroad Administration (FRA) reportable injuries
• 48% improvement across Rule Violation Derailment (RVD), Rule Violation Injury (RVI) and Run-Through-Switch (RTS)
• 7% reduction in mechanical-caused derailments

Enabling wayside performance

• 31.1% fewer wayside train stops while inspecting 4.2% more axles, demonstrating how improved operational execution and technology deployment are driving positive results
• Zero wrung journals recorded
• 53 damaged, broken, or cracked wheels proactively identified by machine vision
• Three additional Digital Train Inspection (DTI) portals installed, bringing total to 10 in service
• New double-track wheel integrity system installed in Burns Harbor, Ind.

Strengthening car maintenance operations

• 4.5% reduction in total freight car bad orders
• 4.6% decrease in running repairs
• 8.8% decrease in non-running repair bad orders
• 18.4% fewer home shop cars
• 13.2% reduction in wreck-damage cars

Delivering locomotive reliability

• Industry-leading 94.23% locomotive availability (up 43 bps)
• Average daily mechanical failures reduced to 5.11, a 4.5% improvement
• Industry-leading fly rate: 1.14 mechanical failures for locomotive in a year 
• 14.5% improvement in locomotive failure unusual occurrences

Maintaining cost discipline focus

• Significantly reduced rental-related costs by actively managing foreign End-of-Train-Devices (EOTDs) — equipment owned by other railroads — and improving monthly liability exception oversight

Sustaining momentum at Norfolk Pier

• 20% improvement in reliability with resiliency projects
• Zero craft employee vehicle incidents
• Zero reportable accidents

As NS’ Mechanical team continues advancing technology and efficiency, these achievements support the company’s long‑term commitment to sustainable freight transportation and delivering reliable service to customers and communities.

Brett Willi leads internal communications for Norfolk Southern, focusing on safety, compliance, operational excellence and employee engagement. He also oversees communications for Engineering and Mechanical. Brett joined NS in 2025, with 20 years of strategic communications, digital content and analytics expertise.