THE MAINTAINABILITY APPROACH AT ALSTOM … · Freightliner Direct Rail Service English, Welsh & Scottish Freightliner Direct Rail Service Freight Owners /Operators Freight Owners

1

Transport Service

THE MAINTAINABILITY APPROACH

AT ALSTOM TRANSPORT

Yves DURANDTechnical Director

November 2001November 2001

2

• INTRODUCTION

– Maintainability approached with pragmatism for measurableperformances

– How to build maintainability ?• Why the selected approach ?

• Contents of the development programme

• Changes in the new build projects objectives

Transport Service

3

A new logic emerges

Operators SuppliersSuppliers

DESIGN MANUFACTURE MARKET FINANCE OPERATE MAINTAIN

Suppliers OperatorsNew Players Suppliers

Suppliers Operators Suppliers

Transport Service

Market dynamicsTraditionnellement

OperatorsSuppliers

4

Cross Country TrainsCross Country Trains

West Coast TrainsWest Coast Trains

RailpartRailpart

RailcareRailcare

Serco Metrolink(Manchester) Tramlink(Croydon) Stagecoach Supertram(Sheffield) Blackpool Transport Services

Serco Metrolink(Manchester) Tramlink(Croydon) Stagecoach Supertram(Sheffield) Blackpool Transport Services

Travel WestMidlandsDocklands LightRailwayNottinghamExpress TransitBirmingham

Travel WestMidlandsDocklands LightRailwayNottinghamExpress TransitBirmingham

Light RailLight Rail

English, Welsh &Scottish

Freightliner

Direct Rail Service

English, Welsh &Scottish

Freightliner

Direct Rail Service

FreightOwners

/Operators

FreightOwners

/Operators

Chiltern RailwaysChiltern Railways

ScotrailScotrail

ThamesTrains

ThamesTrains

Connex SouthEastern

Connex SouthEastern

First NorthWestern

First GreatWestern

First NorthWestern

First GreatWestern

MerseyrailElectricsNorthern Spirit

MerseyrailElectricsNorthern Spirit

Cardiff RailwayCompany

Wales & West

LTS Rail

Cardiff RailwayCompany

Wales & West

LTS Rail

AngliaRailways

AngliaRailways

First GreatEastern

First GreatEastern

West Anglia GreatNorthern

West Anglia GreatNorthern

Great NorthEastern Railway

Great NorthEastern Railway

GatwickExpress

GatwickExpress

ScotrailSilverlink

ScotrailSilverlink

MidlandMainline

MidlandMainline

Central TrainsCentral Trains

Island LineIsland Line

Midland MainlineMidland Mainline

Connex South CentralConnex South Central

Thameslink RailThameslink Rail

South West

Trains

South West

Trains

British

Rail

British

Rail

Who are our customers ?

UK 1990 UK 2001

FreightMetros

Light Rail Sea ContainersSea Containers

NationalExpress

NationalExpress

GB RailwaysGB Railways

M40 TrainsM40 Trains

Go-AheadGo-Ahead

FirstGroupFirstGroup

MTL RailMTL Rail

Prism RailPrism Rail

Connex RailConnex Rail

GOVIAGOVIA

StagecoachStagecoach

ARRIVAMendip Rail

Renaissance Rail

ARRIVAMendip Rail

Renaissance Rail

VirginVirgin

LondonUnderground

LondonUnderground

Glasgow

Underground

Glasgow

Underground

EurostarEurostar

HSBC

AbbeyNational

Angel

Rolling Stock OwnersOperator Owners

Operators

Where customers put a new focus on their core competencies,new opportunities have arisen

Transport Service

4

5

Standard product lines

Coradia Prima

X’trapolisMetropolis Citadis

TGV

Urban & Suburban Trains

Main Line & High Speed Trains Locomotives

6

€ 1.9 billion

93/94

Rolling Stock82%

Signaling14%

Services4%

€ 3.5 billion

98/99

Rolling Stock61% Signaling

16%

Services23%

€ 5 billion

02/03

Rolling Stock50%

Signaling20%

Services30%

Transport Service

Service market share is increasing

7Services for the complete life cycle

>30 yearsALSTOM or non-ALSTOM

MANUFACTURE MARKETDESIGN

ALSTOMNew Products

CommissioningWarranty

FINANCE OPERATE MAINTAIN

MaintenanceTransit - Freight - Equipment - Track

RenovationTransit - Freight - Equipment - Track

Parts and Replacement Units

Transport Service

7

Transport Service

8

Bringing innovative

solutions through R&D

9R&D addresses the complete life cycle

Design & Build Operate & Maintain LCPC

Renovations

FRACAS

TrainTracer /CLAMP

e-Maintenance

Condition Monitoring Reliability Ce ntred Maintenance

Corrective Maintenance

Corrective Maintenance

Preventive Maintenance

Preventive Maintenance

Predictive Maintenance

Predictive Maintenance

Transport Service

9

10

The programme architecture

Parts specification Logistic supportdata

Customercontract

Internalagreement

Contracts

LCPC data& calculations

RCManalysis

Depot basicdesign

Manpower planProcurement plan

Documentation Inventory& stores

Equippedworkshops

Depot equipment packCondition monitoring tools

Training Feedback & managementsystems

Logistic supportproducts

Logistic supportengineering

Core data

11

Parts specification & identification

Parts specificationCLAMP

Logistic supportdata

Core data

Electrical Part Example

CUSTOMERSNCF : 10-5171302

DTR PARTNUMBERDTR00251135AEU

TECHNICAL ATTRIBUTESBox Type: Square Flange Type 10Contact Type: MaleNominal Voltage: 220 voltNominal Current: 13 ampsNumber of Contacts: 11Tightness: IP66Case Protection: Black AnodizedCase Encoding: NCoupling Type: BayonetConnector Type: HE302Temperature Range: -55 ºC to +200 ºC

GEOMETRY

SUPPLIERSFramatome: 8525-10R-18B11-PNHLDeutsch: FDBA 50-18.11-PNK

STANDARDSUTE C93422

ALSTOM SPECIFICATIONCUSTOMER SPECIFICATION

COMMERCIAL PARTS

PARTSPart numberDescription

Management datasPart status

…….

PARTSPart numberDescription

Management datasPart status

…….

SUPPLIER/MANUFACTURER

REFERENCE

CUSTOMER

MANUFACTUREDPARTS

PROTECTION

STANDARD

ALSTOM DRAWING

MATERIAL

UNIT

REFERENCEREFERENCE

UNITPARTNUMB

ER

PROJECT

PART MASTER

FAMILYTechnical characteristics

FILE

FILE

FILE

FILE

FILE

FILEOne part = one number

One number = one part

12

"LBS" breakdown

Parts specification Logistic supportdata

LBS / TrainTracer / LCPC

Core data

PBS

Parts

LBSGenericVersion

LBSCode

LBSProject

Application

PartNumber

LRUCode

Zoningcode

LBS FUNCTION

CODE

01

0101 I-----------

0102 I-----------

02

0201 I-----------

0202 I-----------

03

0301 I-----------

0302 I-----------

0303 I-----------

0304 I-----------

0305 I-----------

0306 I-----------

04

0401 I-----------

TRAILER BOGIE

DRIVER INTERFACE

DRIVER CONTROLS

ON-BOARD SIGNALLING

CAB COMMUNICATIONS

DIAGNOSTICS & RECORDING EQUIPMENT

EXTERNAL SECURITY SYSTEM

BODY-BODY DAMPER

ACTIVE TILTING DEVICE

MOTOR BOGIE

DYNAMIC BEHAVIOUR

BOGIES & SUSPENSION

"SYSTEM & EQUIPMENT"

LOGISTIC BREAKDOWN STRUCTURE (LBS)GENERIC VERSION FOR VEHICLE MAINTENANCE

DRIVER ENVIRONMENT

THERMAL & AUTONOMOUS TRACTION

DIESEL ENGINE

13

TrainTracer & LCPC

Parts specification Logistic supportdata

LBS / TrainTracer / LCPC

Core data

PRODUCTION DATA MANAGEMENT PUBLICATION / EXPORT

Descriptionunder neutralformat

Datamanagementarchitecture

Publishingmodels

paper

Digital medium

Neutral format

Publishing

Data integritycontrol

S&E, LRU, or EC=

Node n

Operation description

iDrawings (sizes) .....iDrawings (details and ident.)

Assembly drawing

parts list

servicing procedureremove/install procedure

............

Categories of modules

MDF Modules

MG Modules

MR Modules

MP Modules

Node n : relatedmodules

Modules metadata

Breakdown of the equipmentNode

Module

Module name

Module unique number

Task description

Tools needed

Material needed

Skills required

Task parameters

14

LCCCompetence Centre

RCM analysis

Depot basicdesign

Manpowerplan

Logistic supportengineering

Methodology

15

Documentation Inventory& Stores

Equippedworkshops

DDDDeeeeppppooootttt EEEEqqqquuuuiiiippppmmmmeeeennnntttt PPPPaaaacccckkkkCCCCoooonnnnddddiiiittttiiiioooonnnn mmmmoooonnnniiiittttoooorrrriiiinnnngggg ttttoooooooollllssss

Training FFFFeeeeeeeeddddbbbbaaaacccckkkk &&&& MMMMaaaannnnaaaaggggeeeemmmmeeeennnnttttssssyyyysssstttteeeemmmmssss

Logistic supportproducts

Logistic support products

16

Diagnosis, troubleshooting, repair

CommunicationCommunication

DocumentationDocumentation

DiagnosisDiagnosis

Event attributes

17

Return of experience

FRACAS System

EventsDefect

LoggingDefect

VerificationRepairs

Third PartyReportingPackage

Third PartyReliabilityPackage

Third PartyLCC Package

External Data

CorrectiveAction

18

Condition monitoring of equipment

Vision Cracks Vibration

19

Maintenance information system

Documentation Inventory& Stores

Equippedworkshops

Special toolsCondition monitoring tools

Training FFFFeeeeeeeeddddbbbbaaaacccckkkk &&&& MMMMaaaannnnaaaaggggeeeemmmmeeeennnnttttssssyyyysssstttteeeemmmmssss

Logistic supportproducts

20

"New build" and "Service" relationship

Design Process Phase A Design Process Phase B

GR DRDR DR DR DR

PR PR PR PR PR PR

GR

PR PR PR PR

SER contribution to projects Contribution to the gate reviews

21

CONCLUSION

The maintainability approach to become thecommon working practice throughout the company

To provide the most innovative, cost effective andcomprehensive quality service to the railtransportation industry around the world

Our mission

Requires

for Customer satisfaction.

22