CEPM Comprehensive Equipment Performance Monitoring Project AAR Component ID (CID) Development and Use
CEPM Comprehensive Equipment Performance Monitoring Project
AAR Component ID (CID) Development and Use
Agenda
CEPM Overview
Objectives, Benefits, Requirements
Bar Codes, CID
Registration, Association
Data Flow Summary
Key Documents, Standards, Rules, Timeline
Next Component – Reusable Framework
CEPM Project Systems and Data Flow Detail
Formats
User Interface Walk-Through
Registration/Retrieval, Association/Retrieval, Reports
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What is the CEPM Project?
Comprehensive Equipment Performance Monitoring
=
CEPM
=
Component Tracking
=
Use of Component Barcodes and UMLER Expansion
(including mileage)
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CEPM Task Force
CEPM Project Deliverables are being developed in
coordination with representatives from across the Industry;
• Equipment Owners
• Shops
• Repair Shops
• Manufacturers
• Railroads
• Software Providers
• Industry Committees
• TTCI
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Implementation via AAR Circular Process
History of Industry Equipment Information
For over 50 years, industry tracking of owner reported
equipment characteristics was accomplished via the
legacy Umler System.
In 2009, Railinc, in coordination with the industry,
re-designed Umler to create a new platform that could
support increasing requirements for tracking and
communicating equipment level information.
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CEPM - Extension of UMLER to expand Component Details
Expanding Equipment Information Details
The industry has taken another step in a multi-year program to
track more detailed information.
Manufacturer, Shop, and other critical reported details will
support safety, operations, planning, and performance
analysis.
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Critical components, Dynamic/Wayside, Machine Vision
CEPM Component Tracking Objectives
• Support Recall of Components identified with safety
issues – EW/MA process
• E.g. Wheels, Castings, Brake Valves
• Support equipment owners with details of
components on their equipment
• Capability to track performance of components
related to component life, failure rates, and
history of the components.
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Automation, Prioritization, Optimization
Efficient Recall is a major benefit
Railinc will maintain a central database of Component details
and the association of those components to equipment.
Combined with derailment history and component details and
history, safety and defect trends can be more quickly
identified.
Benefits
1. Reduce time between issue id and recall ↑Safety
2. Provide more targeted recalls ↓Cost
3. Design and Quality of components ↑Safety + ↓Cost
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Performance Measurement is a major benefit
Performance Examples
Bearing OEM/Reconditioner
Bearing cage, backing ring, …
Wheel Heat/Batch
Wheelshop
Mileage
Future
Castings
Knuckles, Couplers
Side Frames, Bolsters, Truck Type
Braking System Components
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Industry Requirements Set Forth
10
• Establish industry rules and standards for reporting component
details and application to equipment
• Develop a re-usable framework that can support the entire list
of priorities for tracking: wheelsets, castings, valves, PTC, GPS
devices, brakes, cushioning, traction motors, etc.
• Maintain Confidentiality of reported data dictated by possession
• Support Bar Code and RFID standards
• Automation, data integrity, inventory management
CID Definition
AAR Component ID (CID) – e.g. ABCD1234567890
Combination of:
#1) AAR Component ID Company Code - Code
assigned by AAR/Railinc which identifies the parent
company
#2) AAR Component ID Number - The number used in
union with the AAR Component ID Company Code for
the purpose of creating a unique identification of the
component or assembly. This number is generated
and assigned by the Parent Company in #1.
**CID is used as the KEY to store and retrieve all detail**
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CID = Standard, Unique ID methodology for any and all components
CID Example
Parent Company = ABCD makes wheels and castings
ABCD Wheel Mfg = WWWW
ABCD Castings Mfg = CCCC
Parent Company = DEFG makes wheelsets and castings
DEFG Wheel Shop1 = WSWS
DEFG Wheel Shop2 = SSSS
DEFG Castings Mfg = KKKK
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Wheel Casting
Serial Number 123456 A1A2A3
CID ABCD 0000000123 ABCD 9000000123
Wheelset1 Wheelset2 Casting
Serial Number K1K2K3
CID DEFG 0000000123 DEFG 0000000124 DEFG 000000125
Bar Codes, RFID primer
BarCode: 1D BarCode
ABCD1234567890 =
Used for AAR Component Identification, Little Data
BarCode: 2D BarCode or Bar Code Matrix
ABCD1234567890 =
Used for Carrying much data, with redundancy
RFID: Example: AEI
Used for Carrying much data, wireless/remote
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Costs, Equipment/Reliability, Longevity – Wheelsets: Survive until application
Railcar Component Tracking
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Priority #1 - Wheelsets
Wheelset Component Tracking
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New Wheel Data (not all fields required in some cases)
AAR Facility Code
Design Code
Finger Gauge Reading
Stamped Month
Stamped year
Manufactured Timestamp
New or Turned
Nominal Diameter
Rim Thickness Side Scale Reading
Stamped Class
Stamped Mfg Code
Stamped Serial Number
Tape Size
…
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Data Sent Via Bar Code to Wheelshop
Bar Code contains all required data
Some readable data is also printed on label
Turned Wheel Data
AAR Facility Code
Design Code
Finger Gauge Reading
Stamped Month
Stamped year
Manufactured Timestamp
New or Turned
Nominal Diameter
Rim Thickness Side Scale Reading
Stamped Class
Stamped Mfg Code
Stamped Serial Number
Tape Size
…
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Data Captured at Wheelshop
Bar Code contains all required data
Some readable data is also printed on label
Bearing Data (New or Reconditioned)
Reconditioned Classification
AAR OEM/Recon Facility Code
Backing Ring Type
Cage Type
Grease Type
Seal Type
Certificate #
Cup Stamped Month
Cup Stamped year
Manufactured Timestamp
New or Reconditioned
Nominal Diameter, Nominal Length
Cup Serial #
…
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Data Sent Via Bar Code to Wheelshop
Bar Code contains all required data
Some readable data is also printed on label
Axle Data (New, Converted)
AAR Condition Code
AAR OEM/Recon Facility Code
AAR Type
Body Design
Classification
Converter AAR Facility Code
Converter Timestamp
Manufactured Timestamp
Nominal Diameter
Nominal Length
Plating
S# and Heat ID
…
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Data Sent Via Bar Code to Wheelshop
Bar Code contains all required data
Some readable data is also printed on label
Secondhand Axle Data
AAR Condition Code
AAR OEM/Recon Facility Code
AAR Type
Body Design
Classification
Converter AAR Facility Code
Converter Timestamp
Manufactured Timestamp
Nominal Diameter
Nominal Length
Plating
S# and Heat ID
…
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Data Generated at Wheelshop
Bar Code contains all required data
Some readable data is also printed on label
Wheelset Registration Data
Bar Code
Component ID Company Code
Component ID Number
Wheelset Specific Data (Database)
Component AAR Facility Code
Component Assembly Timestamp
Compiled Wheel, Axle, and Bearing Data (Database)
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Data Sent Electronically to Railinc (REGISTER)
Bar Code on wheelset contains ONLY the CID
Some readable data is also printed on label
Data Accessible via Web/UI using CID
Umler
Component
Register
3.
REGISTER
Component
Details
With
Railinc
CEPM-Wheelset Process Flow
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Railroads
Car Owners
Shops
7. Confidential
Reporting
Note:
Only high level processes
displayed
Component
Repairs
5. Report Repair via CRB or EHMS
- ASSOCIATE
Wheel Shop
2. Assemble Components
And Tag Wheelset
4. Ship
Component
To Repair
Shop with
Tag
Repair Shop (incl RIP Tracks)
AAR Early
Warning
6. Update
Component
Status
Manufacturer
1. Mfg, Tag, & Ship Components
REGISTER ASSOCIATE
Key Contributions/Contributors for Success
Manufacturers –
Communicate Detail to Shops via 2D barcode
Wheel Shops –
Data Compilation and Entry to register wheelset details
Repair Shops –
Report wheelset application to equipment using 1D barcode
Railinc –
Data processing and Integration
Railroads –
Event reporting to accumulate mileage
TTCI –
Standards, Analysis
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Key Benefits of CEPM
Manufacturers – Measure Quality and Fewer,Smaller Recalls
Shops – Inventory of Wheelsets (ability to determine performance)
Repair Shops – Comprehensive Maintenance Planning
Railinc – Increased Safety and Value for the industry
Railroads – Safety, Reduced Rail and Property Damage
TTCI – Strategic Research Initiative Support
Equipment Owners – Safety, Equipment and Component
Mileage for Planning, Component Details and History,
Improved Purchasing Decisions, Reduced Change outs,
Billing Validation, In-Kind Repair Quality, Home Shop
Maintenance Planning
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Agenda Checkpoint
CEPM Overview
Objectives, Benefits, Requirements
Bar Codes, CID
Registration, Association
Data Flow Summary
Key Documents, Standards, Rules, Timeline
Reusable Framework - Next Component
CEPM Project Systems and Data Flow Detail
Formats
User Interface Walk-Throughs
Registration/Retrieval, Association/Retrieval, Reports
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Key Documents and Standards
NEW DOCUMENTS
1) AAR Component ID Wheelset Data Glossary
2) AAR Component ID Bar Code Specification
www.railinc.com/CEPM (with support docs)
www.railinc.com/reference (long term)
EXISTING STANDARDS
1) MSRP Section G, G-II, H, H-II (Existing)
2) Field Manual of the AAR (Addition of CID reporting)
Rule 44 – Wheelsets –CRB requirements
Rule 88 – Mechanical Requirements for Acceptance
• All Wheelset Installations/Repairs
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CEPM Tentative Industry Timeline
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-Registration of
Wheelsets
(Optional)
-Report
Component ID
via CRB
(Optional)
-Report
Component ID
via EHMS
(Optional)
-OEMs provide
required data to
Shops (Mandatory)
-Wheelset
Registration by
Wheel Shops
(Mandatory)
-Shops provided
informational
notice in CRB for
missing Wheelset
Component IDs in
Field 327-340 on
changes
-All Wheelset
changes must
be reported
with
Component ID
(Mandatory)
-CRB rejected
for missing
Component ID
AAR Component ID Wheelset Data Glossary
Spreadsheet Handout-
Technical Detail for What is Required for each component:
In Dataset, On Bar Code, Format
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AAR Component ID Wheelset Data Glossary
Wheelset
Wheel 1 and 2
Bearing 1 and 2
Axle
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CIRCULAR
Comments
AAR Component ID Bar Code Specification
Document Handout-
Physical Bar Code Requirements (Prior RP-021, MSRP L)
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AAR Component ID Bar Code Specification
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CIRCULAR Comments
2 1 3 4 5
6 7 8 9 10
Wheelset Wheel Axle Bearing
Development Model – Next Component
Reusable Framework
Data Definition Spreadsheet
AAR Rules/Standards Compliance, Additions
Railinc Involvement
Physical Barcode Specification – Added Sections
Vetting with Domain Experts/Vendors/Users
Implementation Schedule
Responsible AAR Committee Review(s)
CRB and Umler Modifications
Circular Process
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Truck System
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Agenda Checkpoint
CEPM Overview
Objectives, Benefits, Requirements
Bar Codes, CID
Registration, Association
Data Flow Summary
Key Documents, Standards, Rules, Timeline
Next Component – Reusable Framework
CEPM Project Systems
Data Flow Detail, Formats
Walk Throughs
Registration/Retrieval, Association/Retrieval, Reports
© ASSOCIATION OF AMERICAN RAILROADS PAGE 34
Industry Systems affected
• Equipment Characteristics
• Store confidential component details and association to equipment
Umler
• Equipment Health
• Report Component TAG ID through EHMS
EHMS
• Repair Billing
• Submit application/repair details via CRB CRB
35
XML Format (Tagged: Extended Markup Language)
Wheel Blank Example:
Elements C101 to C118
(from spreadsheet)
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<Wheel>
<C101></C101>
<C102></C102>
<C103>GRFI</C103 >
<C104>2/1/2011 18:55:12</C104 >
<C105>11</C105 >
<C106>01</C106 >
<C107>GK</C107 >
<C108>D</C108 >
<C109>22</C109 >
<C110>0</C110 >
<C111>1231</C111 >
<C112>1234abcd</C112 >
<C113>36</C113 >
<C114>CH</C114 >
<C115>CrvS</C115 >
<C116>241.25</C116 >
<C117>N</C117 >
<C118>AMST1234</C118>
</Wheel>
Encoded into Bar Code
XML Format (Tagged: Extended Markup Language)
Wheel Blank Example (Same thing):
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<Wheel><C101></C101><C102></C102><C103>GRFI</C103 ><C104>2/1/2011
18:55:12</C104 ><C105>11</C105 ><C106>01</C106 ><C107>GK</C107 >
<C108>D</C108 ><C109>22</C109 ><C110>0</C110 ><C111>1231</C111 >
<C112>1234abcd</C112 <C113>36</C113 ><C114>CH</C114 ><C115>CrvS</C1
15> <C116>241.25</C116 ><C117>N</C117> <C118>AMST1234</C118></Wheel>
International Standard:
XML 1.0, 5th ed, 2008, Nov 26 –
http://www.w3.org/TR/2008/REC-xml-20081126/
XML Format (Tagged: Extended Markup Language)
Wheelset Registration Example:
Sample Elements: CID and C003(Wheelshop Facility Code-QA Code)
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<!-- Wheelset's CID -->
<r202:componentId>
<r202:companyCode>SHOP</r202:companyCode>
<r202:idNumber>1234567890</r202:idNumber>
</r202:componentId>
<r202:componentType>WHEELSET</r202:componentType>
<r202:elements>
<!-- Wheelset's AAR Facility Code -->
<r202:element>
<r202:elementId>C003</r202:elementId>
<r202:elementValue>GRBT</r202:elementValue>
</r202:element>
Sent to Railinc to Register Wheelset prior to shipping
CRB Format
500 byte
New CRB process
McGinn - Pricemaster?
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CEPM Systems – Data Entry
Umler
Equipment Registry – changes will include links
in the equipment record to the component details
Component Registry - new Component Registry
will provide access similar to the equipment
registry customers are familiar with
CRB/BRC/EHMS/LRB – UI changes to include
component Tag ID with repairs
Web Services – Integration for registering and
applying components to equipment
Batch/File Uploads (Historical Data, New Cars)
© ASSOCIATION OF AMERICAN RAILROADS PAGE 40
Car
ABT
Date, Performer
Wheelset
CID
WheelSerial # WheelShop Axle Type Bearing
Reconditioner
…
User Interface (UI) and Web Services and Legacy Uploads/Backfill
CEPM – Data Access & Integration
User Interface – Web Page
Retrieval Using CID, Car Mark/Number
Retrieval Using Detail – e.g. Wheel Stamped Serial #
Web Services – Computer Messaging / Requests using XML
Real time transactional integration will allow companies to
integrate information into their own systems to enhance the
processing of component information on equipment
© ASSOCIATION OF AMERICAN RAILROADS PAGE 41
Process Flow Chart Section
From Standpoint of:
OEM
WheelShop
Car Shop (Repair, Builders, …)
Car Owner
© ASSOCIATION OF AMERICAN RAILROADS PAGE 42
OEM / Reconditioner
*Additional Detail Required for Bearings, Wheels, and Axles
1) Capture Required Data (database)
2) Encode into 2D Bar Code Matrix and Print
3) Apply to Wheel, Bearing, or Axle and Ship
Future Option ?
1) Capture Required Data
2) Create CID for Wheel, Bearing, or Axle
3) Apply 1D CID Bar Code Label
4) Electronically Register component with RailInc and Ship
Note: Wheelshop would have to retrieve any necessary data from Railinc
© ASSOCIATION OF AMERICAN RAILROADS PAGE 43
Wheelshop - Registration
1) Track Wheelset through facility (using CID barcode?)
2) Capture Necessary Data
a) (from Barcodes or Manually)
b) Assemble Dataset for all subcomponents
c) Link with CID
3) Ensure CID Bar Code is applied to wheel plate
4) Register with Railinc and ship wheelset
a) UI for small quantities
b) Web Service Message (XML) for bulk
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Car Shop - UI Association
© ASSOCIATION OF AMERICAN RAILROADS PAGE 45
Wheelset has AAR CID
YES
NO
Report Car Mark/Nbr,
Location on Car, CID via
EHMS, Umler, or CRB UI
Use Umler UI
to retrieve CID
using wheel S#
Car Shop - CRB Association
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Wheelset has AAR CID
YES
NO
Report CRB 500 byte
format to Railinc with CID
in position 327-340 on
Wheelset line (Rule 44)
Use Umler UI
to retrieve CID
using wheel S#
CRB 500 Byte format:
Railinc is building a web service
that accepts the 500 byte
format and reconciles billing for
single car messages. July 2012
Car Shop - Batch Association
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Wheelset has AAR CID
YES
NO
Report Car Mark/Nbr,
Location on Car, CID
in .csv file sent via FTP
Use Umler UI
to retrieve CID
using wheel S#
Car Shop Repair Sample Process
Web Service Data Retrieval
CRB or Web Service Association
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Car Owner
CCH
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Agenda Checkpoint
CEPM Overview
Objectives, Benefits, Requirements
Bar Codes, CID
Registration, Association
Data Flow Summary
Key Documents, Standards, Rules, Timeline
Next Component – Reusable Framework
CEPM Project Systems and Data Flow Detail
Formats
Walk Throughs
Registration/Retrieval, Association/Retrieval, Reports
© ASSOCIATION OF AMERICAN RAILROADS PAGE 50
Info & Walk-Throughs
1) Circulars – Mike Fore ([email protected])
2) Railinc – Ron Tsolis, Program Manager
1) [email protected] – Mailbox for anything CEPM
related
2) www.railinc.com/cepm
1) All current information for CEPM project
2) Current Project Documents
1) Bar Code Specification
2) Data Glossary Specification
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Railinc Test Environment
wwwtst.railinc.com
© ASSOCIATION OF AMERICAN RAILROADS PAGE 52
Create
your own
SSO ID
Request Permissions in Test
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Permission Request
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Enter your 4 character
Company ID assigned by
Railinc
Railinc Launch Pad
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Umler Home Page
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Component Registry menu
- Add / Modify components
- Associate to Equipment
Register New Component
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Add New Component
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Company Code is assigned by
Railinc and is associated to
your SSO ID Component ID Number is
assigned & managed by Wheel
Shop
Component Type will be used
when adding future
components
Add Component Details
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Existing Wheelset Data
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Associate Component to Equipment
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Position from B end
based off of Umler
record
Component ID in Umler
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Managing Component Details
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Need More Information
[email protected] -email
www.railinc.com/cepm - project website
You Survived the AAR Town Hall on the CEPM Project
Tuesday July 12th, 9am-4:30pm
Westin Hotel, Chicago (Rosemont) (see the project website for more details)
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Questions?
Thank you for the opportunity to discuss this significant
project with the industry.
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