November 2001

Transport Service
THE MAINTAINABILITY APPROACH AT ALSTOM TRANSPORT

Yves DURAND Technical Director

1

Transport Service INTRODUCTION

Maintainability approached with pragmatism for measurable performances How to build maintainability ?
Why the selected approach ? Contents of the development programme Changes in the new build projects objectives

Transport Service Market dynamics

Traditionnellement A new logic emerges
MARKET FINANCE OPERATE MAINTAIN

DESIGN

MANUFACTURE

Suppliers Suppliers Suppliers Suppliers

Operators Operators New Players Operators Operators Suppliers Suppliers Suppliers

Transport Service Who are our customers ?

UK 1990
Rolling Stock Owners Operator Owners
Operators
Thameslink Rail Stagecoach Island Line ARRIVA Mendip Rail Renaissance Rail South West Trains MTL Rail Connex South Central Midland Mainline Chiltern Railways

UK 2001
Connex South Eastern Cardiff Railway Company Wales & West LTS Rail Thames Trains Prism Rail Scotrail Merseyrail Electrics Northern Spirit

GOVIA

Connex Rail

M40 Trains

Abbey National Freight Metros Light Rail

London Underground

Angel

First North Western First Great Western Go-Ahead

British
Rail

FirstGroup Freight Owners /Operators First Great Eastern Sea Containers Anglia Railways Eurostar National Express

English, Welsh & Scottish Freightliner Direct Rail Service

HSBC

Great North Eastern Railway

Travel West Midlands Docklands Light Railway Nottingham Express Transit Birmingham

Glasgow Underground Light Rail Virgin GB Railways Gatwick Express

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

Railpart

West Coast Trains

West Anglia Great Northern

Scotrail Silverlink

Cross Country Trains Railcare Central Trains

Midland Mainline

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

4
4

Standard product lines

Urban & Suburban Trains

Metropolis

Citadis

Xtrapolis

Main Line & High Speed Trains

Locomotives

Coradia

TGV

Prima

Transport Service Service market share is increasing

93/94
Rolling Stock 82% Signaling 14%

98/99
Rolling Stock 61% Rolling Stock 50% Signaling 16%

02/03
Signaling 20%

Services 4% Services 23% Services 30%

1.9 billion

3.5 billion

5 billion

Transport Service
DESIGN MANUFACTURE MARKET FINANCE OPERATE MAINTAIN

Renovation ALSTOM
Transit - Freight Equipment - Track

Maintenance
Transit - Freight Equipment - Track

ALSTOM or non-ALSTOM >30 years

Parts and Replacement Units

Services for the complete life cycle

7
7

Transport Service

Bringing innovative solutions through R&D

Transport Service
Renovations e-Maintenance Condition Monitoring TrainTracer/CLAMP

FRACAS

LCPC

Design & Build

Operate & Maintain

Corrective Maintenance Preventive Maintenance Predictive Maintenance

R&D addresses the complete life cycle

9
9

The programme architecture

Core data Parts specification Logistic support data Logistic support engineering Internal agreement LCPC data & calculations Depot basic design RCM analysis Manpower plan Procurement plan Logistic support products Documentation Equipped workshops Training Inventory & stores Depot equipment pack Condition monitoring tools Feedback & management systems

Contracts

Customer contract

10

Parts specification & identification

Core data

Parts specification CLAMP

Logistic support data

Electrical Part Example COMMERCIAL PARTS

GEOMETRY
SUPPLIER/MANUFACTURER FILE CUSTOMER

TECHNICAL ATTRIBUTES FAMILY

PART MASTER Nominal Voltage: 220 volt

Box Type: characteristics One part = one number TechnicalSquare Flange Type 10 Contact Type: Male FILE Nominal Current: 13 amps Number of Contacts: 11 MATERIAL Tightness: IP66 Case Protection: Black Anodized PROTECTION Case Encoding: N Coupling Type: Bayonet ALSTOM DRAWING Connector Type: HE302 Temperature Range: FILE C to +200 C -55

REFERE NCE REFERENCE

FILE

PARTS One number = one part Part number Description Management datas Part status DTR PARTNUMBER .

CUSTOMER SNCF : 10-5171302

UNIT

UNIT PARTNUMB ER

DTR00251135AEU

CUSTOMER SPECIFICATION

ALSTOM SPECIFICATION

SUPPLIERS

FILE

PROJECT

Framatome: 8525-10R-18B11-PNHL Deutsch: FDBA 50-18.11-PNK

MANUFACTURED PARTS

STANDARD STANDARDS

FILE

UTE C93422

11

"LBS" breakdown
Core data Parts specification Logistic support data LBS / TrainTracer / LCPC

PBS Parts

LBS Generic Version LBS Project Application LBS Code

LOGISTIC BREAKDOWN STRUCTURE (LBS) GENERIC VERSION FOR VEHICLE MAINTENANCE

LBS CODE 01 0101 0102 02 BOGIES & SUSPENSION I----------TRAILER BOGIE I----------MOTOR BOGIE DYNAMIC BEHAVIOUR I----------BODY-BODY DAMPER I----------ACTIVE TILTING DEVICE DRIVER INTERFACE I----------DRIVER CONTROLS I----------ON-BOARD SIGNALLING I----------- COMMUNICATIONS CAB I----------DIAGNOSTICS & RECORDING EQUIPMENT I----------EXTERNAL SECURITY SYSTEM I----------DRIVER ENVIRONMENT THERMAL & AUTONOMOUS TRACTION I----------DIESEL ENGINE FUNCTION "SYSTEM & EQUIPMENT"

LRU Code Part Numbe r Zoning code

0201 0202 03 0301 0302 0303 0304 0305 0306 04 0401

12

TrainTracer & LCPC

Core data Parts specification Logistic support data LBS / TrainTracer / LCPC
S&E, LRU, or EC = Node n

Node n : related modules

Categories of modules

MDF Modules

Operation description iDrawings (sizes) ..... iDrawings (details and ident.) Assembly drawing MR Modules parts list servicing procedure remove/install procedure ....... ..... MG Modules

Task description
PUBLICATION / EXPORT Module unique number Node paper Breakdown of the equipment Publishing Module name Data integrity control PRODUCTION DATA MANAGEMENT

MP Modules

Module

Material needed Digital medium Modules metadata Skills required

Neutral format

Description under neutral format

Data management architecture

Tools needed Publishing

models

Task parameters

13

Methodology

Logistic support engineering LCC Competence Centre Depot basic design RCM analysis

Manpower plan

14

Logistic support products

Logistic support products

Documentation Inventory & Stores

Equipped workshops Training

Depot Equipment Pack Condition monitoring tools Feedback & Management systems

15

Diagnosis, troubleshooting, repair

Communication Event attributes Diagnosis

Documentation

16

Return of experience
FRACAS System
Defect Logging
Defect Verification

Events

Repairs

Corrective Action

Third Party Reporting Package

Third Party LCC Package

Third Party Reliability Package

External Data

17

Condition monitoring of equipment

Vision

Cracks

Vibration

18

Maintenance information system

Logistic support products

Documentation Equipped workshops Training Inventory & Stores Special tools Condition monitoring tools Feedback & Management systems

19

"New build" and "Service" relationship

SER contribution to projects Contribution to the gate reviews

Design Process Phase A DR DR

Design Process Phase B

GR

DR

DR

DR

GR

PR

PR

PR

PR PR

PR PR

PR

PR

PR

20

CONCLUSION

Our mission To provide the most innovative, cost effective and comprehensive quality service to the rail transportation industry around the world Requires The maintainability approach to become the common working practice throughout the company for Customer satisfaction.
21

22