FLEET OPTIMISATION
LONDON CONVENTION MEETING
Christian DANIEL
SNCF
ROLLING STOCK COMPANY
January 22rd/23rd 2013
SNCF : Organisation
SNCF is built with
5 Business Units
3 Functional units
Rolling Stock Company
Driver Organisation
SNCF GEODIS
1 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Controller Organisation
Organisation of SNCF Rolling Stock Company
The Rolling Stock Company:
Depot
40 sites distributed over region
Maintenance 2nd an 3rd Levels
Industrial Workshops
12 sites
Maintenance : 4th and 5th Level for vehicles
Maintenance : 4th and 5th Level for rotating assets
Main Mission : MRO :
Maintain Repair and Overhaul of the Rolling Stock of the EPIC SNCF
2 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
The Management of Assets
•
Vehicles
Over than 500 TGV
Over than 5000 coaches (CORAIL , TEOZ …)
Over than 100 000 wagons
Over than 20 000 locomotives and train sets
•
Rotating Assets : Management of LRU / SRU
Rotating Assets are shared in 2 families :
LRU : Line Replaceable Unit (Dismount in Depot)
SRU : Shop Replaceable Unit (Dismount in Industrial Workshop)
Over than 2 Millions mounted on our vehicles
more than 15 000 references of LRU/SRU
Mechanical
Electronics
HVAC
…..
Over than 500 000 Wheelsets
3 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
OPTIMISING MAINTENANCE PLAN
TO EXTEND SERVICE
4
ROLLING STOCK
JAN 22/23 2013
COMPANY
CONTENTS
Building a Strategy for Maintenance Plan
Fleet Monitoring to Feed-Back Maintenance Plan
Building a consistent Maintenance Plan
Maintenance Plan : From Block to Elementary
LCC Estimation
5 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
CONCEPT: A simple approach to a complex problem
Who
What has to be analyzed (in a nutshell)?
Repairs, maintains, inspects, …?
What
Equipments, components, systems, … are concerned?
Why
What is the justifying event for the maintenance task?
Which
Resources are required?
Where
Do you perform the maintenance task (maintenance level and location)?
How
Do you perform the maintenance task?
6 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Building a Strategy for Maintenance Plan 1/4
How to give more trains to Train Operators in the Rush hours ?
Reducing the Maintenance Footprint on the fleet in depot !
Typical approach for
commuter trains based on
daily time frame.
High demand during rush
hours ; Medium demand
between rush hours ; Low
demand before and after
rush hours ; Null at night
How adapt the Maintenance
Plan to gain more trains at
rush hours ?
Reduce Preventive
Maintenance unavaibility
Industrialize Corrective
Maintenance
7 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Building a Strategy for Maintenance Plan 2/4
Time Frame is not
always based on daily
frequency !
High Speed frame is
mostly based on
weekly time Frame
Freight wagons are
following a more
“opportunistic”
approach
So Strong Relations
are needed to
establish
Maintenance
Production Plan with
the stakeholders
8 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Building a Strategy for Maintenance Plan 3/4
Reduce the
Maintenance footprint
By reallocating tasks
between Preventive
Maintenance Task
(longer than Rush
intervals !)
Strong Coordination
with Fleet Managers to
get the Train in the
Depot at the forecast
date/time !
Lean management to
increase efficiency on
the complete route of
rolling stock (see next
slide)
9 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Building a Strategy for Maintenance Plan 4/4
How to adapt the Maintenance « Time Shift » according to Maintenance Task duration ?
10 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Fleet Monitoring to Feed-Back Maintenance Plan
Build Optimised Business Dashboards
For Fleet Manager to monitor in real-time the behaviour of the fleet (Faults)
For Engineering Department to feed-back the real behaviour of rolling Stock
11 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Building a consistent Maintenance Plan 1/3
As seen by the operator ; we could find 4 types/natures of Work Orders :
On Maintenance Items (Preventive or Corrective)
On Configuration Items (Issued for safety or condition Monitoring on LRU)
For Replenishment (Fuel , Sand , screen wash , grease )
For Engineering Order (Technical Redesign)
Maintenance Plan is consisting of
Preventive Maintenance
• With cyclic triggering
• Each X miles , Y hours , Z Months
• Without cyclic triggering on special events
• Before Each Winter / If temperature is greater 35°C
Corrective Maintenance
• For standard repair Procedures (Wheelsets , Engine , Couplers ….)
• For fault finding (fault management with monitoring system…)
• For Casualty repair
The Maintenance Plan is a major output from an Engineering Process held
either by the Manufacturer either the Entity of Charge of Maintenance.
12 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Building a consistent Maintenance Plan 2/3
13 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Building a consistent Maintenance Plan 3/3
Maintenance Plan is the Success Key for Maintenance . It’s a
Master Document that have to be store in a safe !
It is dedicated to a fleet with the following data's
Maintenance Item on Breakdown Product ( e.g : EN15380-2)
Limits ( With Trigger and Tolerance)
Quantity of Maintenance Item on the branch
Reviewing Maintenance Plan could be analysed with CSM
A readable organisation has to be settled to manage the MP.
Each review has to be evaluated on impacts.
14 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Maintenance Plan : From Block to Elementary 1/3
Dividing Scheduled Block Maintenance Tasks as be
organised in a global project.
Conditions of success has be readable
Impact on planning Business Process has to be evaluated
Limits on Block Maintenance Task is always an
compromise !
15 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Maintenance Plan : From Block to Elementary 2/3
16 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Maintenance Plan : From Block to Elementary 3/3
17 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Monitoring & Proactive Maintenance 1/2
Facing the challenge of Proactive Maintenance :
Optimising the fleet Availability
Increasing the cost of the Realized Maintenance Tasks
Pushing to the affordable limits for Maintenance Tasks:
Avoid “Block” Maintenance Task triggering many Macro Tasks (Lower the
extra Cost)
Adapt for each macro task the optimal trigger (Block Maintenance Task
Trigger is always a comprise)
Adapt records sampling frequency for units to perform best monitoring
(many points recorded for a Maintenance Period)
Place Automatic records for units to increase sampling frequency
• Sideway
• Real-Time Monitoring
Planned with optimising planner your maintenance work orders
Estimate and calculate “Tolerance “ for maintenance tasks
18 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Monitoring & Proactive Maintenance 2/2
19 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
LCC Estimation 1/2
LCC or Life Cycle Cost is an precise tools which requires « Fine input data’s ».
But LCC Calculation needs a strong organisation to maintain and update the
data’s and to make them realistic.
LCC shall take into account
Preventive Maintenance Task
Corrective Maintenance Task
• Major Items Mount/Dismount Frequencies
Logistic Support Records
• Materials and Expandable (BOM)
• Human Labour (Duration and Costing) / Training
• Tools (Generic and specific) / Testing (Faults Finding) / Installation
• Material Logistics
LCC is based on Train Operators Data’s
Fleet
Transport Plan
Windows of Analysis
Company Business Model
20 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
LCC Estimation 2/2
LCC Data Mining could focus on
Cost Per Month/year and per operation
Shared Cost between material and Labour
Cost Driver
Feed Back on real data
Each result detailed per Product breakdown
€
30 Years Life Cycle Cost
Each Bar is a month
21 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Challenging Train Manufacturers
New Train Performances are mainly focused on 3 topics
a) Maturity of the design
b) Respect of the Preventive Maintenance Plan
c) Operational reliability
Level of maturity in the purchase contract between Train
Manufacturer and Train Operating Company:
1) Pure Component Warranty
2) System Reliability (Up to XX faulty missions per Mkms, Up to YY
minutes delay,…..). System includes all sub system and subsystem
3) System “LCC” : Set LCC Target in preset conditions.
22 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Conclusion : Optimising Maintenance Plans
« Maintenance Plan » has to be considered
as the backbone of any Maintenance
Organisation.
It’s a fine mechanical system
invest few : you will get basic outputs with
coarse triggering task
Invest more : you will have reliable tools with
precise monitoring
• (sometimes simplicity hides fine gear trains !)
23 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
OPTIMISING EXAMINATION PLAN
INTRODUCTION TO LSA
24 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22/23 2013
CONTENTS
Standardised Engineering of Maintenance Plan
Fleet Engineering Standard
Product Life Cycle Support
Business Process : LSA
Items
Analysis
Technical Publication
Material
25 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Standardised Engineering of Maintenance Plan
•
Engineering Business Process for establishing Maintenance Plan are
existing for Aerospace and Defence
26 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Fleet Engineering standards : S Series
27 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Fleet Engineering Standards : History & Origin
28 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Product Life Cycle Support :
Integration of S SERIES into the ILS (Integrated Logistic Support) Concept
29 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Business Process to support a Fleet Management
LSA data’s
Equipment
identification
Tasks
Material Data’s
Admin.
of
Order
Design Data
Data’s Definition
Technical
Publications
Training
Module
30
SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Logs mat
and data
IETP
LSA data’s
Contents DM
Systems Definition &
Support Equipments
Breakdown
Logistic
Support
Analysis
Task
Materials
Maintenance
Plan
LSA data’s
COMPUTER AIDED MAINTENANCE
MANAGEMENT
SYSTEM
Others Supports
Train Operating & Maintenance
Feedback on Maintenance Operational data’s
Focus on Logistic Support Analysis
LSA is an Engineering Business Process
having the following data’s:
-
-
31 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
INPUT :
-
Product Breakdown
-
Design Data
OUTPUT :
-
Reliable and Maintainable Products
-
Cost Efficient Support
-
Logistics Product Data’s
-
ILS Support Products
Logistic Support Items
from S3000L
Scrapped
Products
Packaging
Handling
Storage
Transport
Materials ,
(Parts
& expandable)
Operating
& Maintenance
Skills
Tools and Test
Equipment
Training
Maintenance
Plan
The 9 items
from Logistic Support
IT Support
Maintenance
Infrastructure
32 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Technical
Publication
Business Process of Logistic Support Analysis
S3000L :
•
•
•
•
•
•
•
•
Establishment of Product Usage Data
Establishment of Product Design & Performance Data
Establishment of Breakdown according to agreed rules
Candidate Items Selection (Maintenance Items)
Analysis activities for candidate items
Customer Involvement
LSA Review
ILS Product
33 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
List of Technical / Logistic Analysis Activities
List of Potential Analysis
System Breakdown and Product Configuration
RAMTS (Reliability), Availability, Maintainability , Testability and Safety Analysis
LSA FMEA (Failure Mode and Effects Analysis)
Special Event Analysis
Scheduled Maintenance Analysis (S4000M , MSG-3 , RCM )
Operations Analysis (PHST :Packaging, Handling. Storage, Transport)
Software Support Analysis (SSA)
Level of Repair Analysis (LORA)
Maintenance Task Analysis (MTA)
All data’s are records in a database (LSAR : LSA Records)
34 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Are these standards relevant to Railway ?
Manufacturor
Started
LSA in call
to tender
LSA in
product life
PROJECT
Yes
Yes
Regio2N
Yes
Yes
Regiolis
Yes
Yes
NAT
Yes
Yes
TTAB
No
Yes
AGC
2013
2013
2008
2007
2004
35 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22/23 2013
Focus on the Technical Publication
Technical Publication is a whole
documentation Business Process
bases on “S SERIES”.
S1000D supports the Technical
Publication.
Authoring is based on “Write Once” et
“Read Many”.
Issuing Publication on different media :
36 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
•
Paper
•
Interactive on tough book / PDA
•
Interactive on computer
•
PDF
•
Training
Are the LSA Records visible by Operators ?
Parts Catalog
Corrective Manual
Preventive Manual
Breakdown Illustrated
37 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22/23 2013
Breakdown Treeview
Parts Data’s
Focus on Material Management
Material Management is a standard diary
for Material.
Data are exchanged trough DEX (Data
Exchange) protocols from parts
manufacturer to the train operator
company.
90 data’s are specified.
This standard is an opportunity to reduce
Engineering Cost !
38 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22d/23rd 2013
Material Management
Great Opportunity to standardise
39 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22/23 2013
-
Bill of Material
-
Illustrated Parts Catalogue
-
Costing
-
Forescast
-
….
Conclusion on LSA 1/2
LSA is an global ,standard and written methodology to support Fleet Engineering along the life cycle
from design phases to end of life.
LSA supports process to update standardized data’s to settle up Engineering methodologies :
Maintainability
Availability
Reliability
Life Cycle Cost
Material Management
….
LSA can elaborate key figures for operational processes and shorten any complementary analyses
by issuing updated input values.
40 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22/23 2013
Conclusion on LSA 2/2
In the EUROSPEC initiative for
standard components
In the Raildex
Euro
EuroSpec
SNCF Rolling Stock Company is contributing to expand LSA in the Railway Industry
www.raildex.com
The RAILDEX initiative is launched to standardize the exchange of maintenance documentation
in the railway industry between all actors: OEM, Integrators and Operators
41 SNCF – Christian DANIEL
ROLLING STOCK COMPANY
JAN 22/23 2013