On Friday, Alstom granted The Courier unprecedented access to its Ballarat workshop to document the production line responsible for manufacturing the popular trains that transport of tens of thousands of Melbourne commuters daily.

The month long, 10-step process involving more than 60 local workers eventually sees an empty shell shipped from Poland converted into one of the most reliable trains on the metro network.

Crucially, the production of each carriage requires significant input from local suppliers, with 57 businesses in and around Ballarat providing various parts and services to the cause.

Alstom Ballarat production manager Michael Selby said it will be a “significant” milestone when the 500^th X’Trapolis carriage is completed.

“To have 500 rail cars produced here in Ballarat is a really great achievement,” he said.

“It’s built by local people with their expertise and these vehicles are running around Melbourne.

“(They’re) an extremely reliable vehicle that move millions of people.”

A key to Alstom’s success is its policy in using ‘technology transfer’ from sister workshops in France and Italy.

Peter Walls, Alstom Ballarat’s project supervisor, is responsible for learning new skills overseas and teaching them to Ballarat’s staff.

“I think without the technology transfer, it would be a lot harder for us to build the trains,” he said.

“Over there – they are the master builders in France.

“The way they do things over there with how they implement their tools (is groundbreaking). To see that over there and bring it here helps Ballarat so much. It’s a good thing.”

Alstom purchased the Ballarat site from the state government in 1999 and began manufacturing X’Trapolis trains in 2002.

Since that time, the company has been awarded seven contracts from the state government for 92 trains.

The current order made in May last year is due for completion in August.

The latest order, a $105.2 million state budget commitment in April, will see the manufacturer build five new X’Trapolis trains and secure work for locals until early in 2018.

Alstom is shortlisted for a massive tender of 65 high capacity trains ordered by the Labor government, with the successful bidder to be announced later this year.

To see Alstom Ballarat’s production process, go to the http://www.thecourier.com.au/story/4062364/key-milestone-for-alstom/?cs=62 link.