Introduction to Bombardier's Lightweight Advisory Service

13 Trieste. May TransportationBombardier Director, VehicleEngineering Dr.Orellano Alexander ownership of cost vehicles related to Total developmentphase of in Optimisation Meeting ModeFRONTIER

International User

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. Contents 2 Conclusions Time to Market versus Optimisation O Aerodynamic Bombardier ptimisation related to “total cost ownership”of cost “total to related ptimisation

overview

Optimisation Optimisation

–

Motivation

and result

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. Transportation and Aerospace Overview Bombardier 3 1 1 for fiscal year ended January 31, 2011 31, ended January year fiscal for

worldwide people of 65,400 Workforce 1

bn US $17.7 of Revenues 1

Canada Montréal, office in based Corporate (BBD) Exchange Toronto Stock on Listed

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. Bombardier Transportation Transportation Bombardier 4 Light Rail VehiclesRail Light Regional TrainsRegional (Bruxelles, Belgium) (Bruxelles, FLEXITY (Paris, France) (Paris, EMU (Deutsche Bahn, Germany) Bahn, (Deutsche TRAXX Locomotives SPACIUM TRAXX FLEXITY (Dresden, Germany) (Dresden, Outlook P160 AC (RENFE, Spain) (RENFE, TALENT TALENT

(Germany) F

140 DC

3.O6

Classic

Products - / High Intercity

Total TransitSystems (Stockholm, Sweden) (Stockholm, C20 Airport Airport CX TURBOSTAR (UK) -

100 Metros (Shanghai, (China) Beijing Beijing (South Africa) (South Gautrain speed Trainsspeed ZEFIRO

MOVIA DMU

China)

–

presence Local in 25 countries 25 in production/engineering59 centres service 20 and sites

Advanced Engineering Process Engineering Advanced 6 Variation 80ies no series production series Requirements Requirements requirements prototype fulfilled? Design

yes

Variation no series production series Requirements Requirements requirements simulation

fulfilled? 90ies 90ies Design

today

yes

* Optimization with Optimised series series Optimised no

given : Optimisation Design space Design performance? requirements

boundaries simulation Best production

and

costs *

yes

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. Aero Optimisation Aerodynamic such as as such constraints account into takes technology AeroEfficient use that algorithms genetic on based is optimization train AeroEfficient art computer AeroEfficient 7 ...... ergonomic limits of the cab the of ergonomic limits design industrial crash structure solutions optimal determine Pareto to software Optimization aerodynamicSimulation of cross and drag three Parameterized, time. traveling reduces whichacceleration, increase stability also maximizing and Limiting drag regional trains 15 and high of % speed trains. of energy of % 8 to up aerodynamic saves Reducing drag Efficient - Train- state uses Optimization Shape aided engineering engineering (CAE) tools aided

Computer AidedOptimisation dimensional CAD models -dimensional CAD

wind stability

of-

the-

Zefiro China drivingunder cross wind conditions New process at Bombardier

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. - Multi Optimisation Aerodynamic . 8 Multi . . . . . ObjectiveOptimisation optimisation hours 173 ~ 7 * h 7CPUs * 8477 = CPU solution no unique but designs, optimal of is acluster Result are suitable algorithms Generic not applicable are or methods gradient SIMPLEX like algorithms search Directed iterations Significant of rise of thenumber objective optimization means optimization -objective for ZEFIRO 380 head shape 380 headshape ZEFIRO for

pareto-

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. High Performance Computation Performance High Optimisation Aerodynamic shown): is on surface (pressure phase design detailed in variations of Examples 9 ...... I I I I I VII:     

III: II: IV: V: VI:

ZEFIRO Design 380 bogie fairings bogie variation spoiler carbody nose slender more duck nose duck

front transition front

Example ...... VII VI V IV III II I

Head

. Aerodynamic drag reduction Tail

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. Trainheadsdeveloped approach new with Optimisation Aerodynamic 10 (MOR) Ministry Rail of the convinced aerodynamics High for MOR: ZEFIRO 380 end -end

decker double speed weight high light stable Cross for SBB: TWINDEXX -wind

weight end light facilitate wind stability cross highest Aerodynamics for responsible is Bombardier Icx for DB:

-car - -



resistance reduced to consumption due energy with lowest requirements all TSI Fulfils for V300ZEFIRO Trenitalia:

double decker double performance weight high light stable Cross for SNCF: Régio2N -wind

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. • • skirt banana shapedbogie This is the engineering concept witha “nice” 380km/h? even running train onthe No skirt full bogie Vehicle on Optimisation Level • the realisationtheThisis series production in 11 maintenance Optimised without ~2% Reduction of aerodynamicresistance by withOptimised PRIVATECONFIDENTIAL AND

ModeFrontier ModeFrontier

but for

Zefiro380 Zefiro380

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. Everybody is right but what decision is Everybody butwhatdecision right is one? the right • • • • can’t we aerodynamic findbogie covers Why Speed High Trains?allon Vehicle on Optimisation Level

12 drag andaeroacoustic aerodynamic reduce significantly can covers/skirts Bogie saysmanager themaintenance bogies” of maintenance easyprohibiting are skirts “Bogie reliability manager the reliable” says not are skirts “Bogie saysmanager are“Bogie themass toheavy”skirts

PRIVATECONFIDENTIAL AND

aerodynamicist the says noise BUT

Velaro CRH-1 TGV

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. • • • • chosen to convertthe following technical parameters to Eurossince autumn 2013 ( money to performance technical Convert reduction Cost Vehicle on Optimisation Level figures? conversion Euro the get do youHow 13 Maintainability Reliability Mass: Energy: • • • • • • • • • • Simple calculation with the hourly rate of the persons in the maintenance workshop maintenance in the persons the of rate hourlythe with calculation Simple workshop repair the in How do much you to have if pay is there a or and with failure train with stopping the to needs be longer calculate to is easynot mass to additional due & rail wear the of wheel impact The withcost energythe multiplied to due mass withadditional the consumption energy calculation simple by cost energymultiplied the withconsumption energythe calculation simple Volumeof conversion The in [ Maintainability [€/h] Reliability [fpmk Energy [kWh] mass [kg]

, failures per million kilometer]

€/m 3 ] reduction to Euroswillin follow2014 reduction ] € ). Bombardiers Vehicle Engineering function has has function Vehicle Engineering Bombardiers ).

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. Example: • roughly that is The result • • • process: Management Product Bombardiers to TCO leading Process the Optimisation Establish Vehicle on Optimisation Level • • 14 Euros we we Euros much how development introduce product per its line. costs with also we product (per line) And introduce product weyears Product roadmap the Book roadmap each 6 system and nextIn the for the additional labour costs for production and material cost material and production for costs labour additional the one. expensive less differential) the becomes equivalent € 18000 wouldbe to mass of each ton lifetime years30 based on is The calculation stretch envisaged. the running at reduction deducted. was kW one valueof the evaluation an of Also kg one of Euros valuein the the of done evaluation an of was TCOBerlin commuter For a of train phases developmentproduct their within processes decision their for figures this use can turn external partners. functions in and Theyinternal kW, and conversion kg This of maintenanceand product communicatedEuros per are reliability in to The conclusion is that the most expensive material and design principle for the the for principle design and material expensivemost the that is conclusion The 17000 equivalentbe to would each kW • • • • less maintenance and reliability higher value we euros much how kW, value one we Euros much how and kg one value

€



optimisation systems sub of optimisation

T he customer benefit in terms of energy is higher higher then energyis of terms customer he benefit in

and

carbody

(Aluminium

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. • • • • Typicalfollows: for asublooks system like specificationtodays and tomorrow today specifications System Vehicle on Optimisation Level • • goals: development for Tomorrows specification • 15 Energy consumption: Energymax. 500 consumption: W kilometer hours/ maintenance 0.1 max. Maintainability: 50 kg max. Mass: 0.01 Reliability: max.

optimisation based optimisation on withTCO little information flow required betweendifferent systems his own make can system a sub forengineer responsible each that is keyThe [ TCO Maximum values values values for might some be required in constraints Maximum to meet order €] <

/kWh] * energy consumption consumption energy[kWh] * [€/kWh] energy+ cost need[h] maintenance * hourlyrate+ maintenance [€/h] [kg] mass * value + [€/kg] of mass value of reliability [€/fpmk reliability of value fpmk

(failure per million per million (failure

] * failures [fpmk failures * ]

kilometer

)

]

Mortar… Time Market Time to Mortar… CTC TCMS Interfaces Product Level Product Subsystems Platform LevelPlatform –

Conventional

Train Control

Toundefinedhouseold with build an …a lot of …aof lotmortar isneeded! interfaces betweenbricks… Fieldstones

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. Optimisation Ownership Total of Cost Vehicle on Optimisation Level  Physical Integration and Design System with together - Pareto the finding . . Multi 17

the architecture work consists in consists work architecture the lowest cost the exhibits which choice component and system combination of concept, oneunique is there market) For to agiven (time time development solution Pareto- in results optimisation Total cost and tomarket time objective -objective optimal optimal

optimization means optimization designs, but no unique unique butno designs, optimal solution solution optimal

a cluster of a cluster

total costLow of drag ownership Pareto front Pareto component ( Design Space concept Time Design Space to , system

market

choice

and )

Savings in Euros per train -300000 -200000 -100000 100000 200000 300000 400000 500000 600000 700000 0 1 Years km/year) (~500000 in operation 2 3 4 5 6 7

breakeven 9 10

11 12 13 14 15

sum costmass cost reliability maintenance cost cost investment energy cost reduction

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved. • • • Frecciarossa Vehicle on Optimisation Level 19 Pay operation in Italy in 2014 in Italyin operation service start to envisaged and is moment the at testing undergoing is train This noise less Significant - off after 8 yearsoffafter aeroacoustic 1000 exhibits1000 skirt bogie

PRIVATE AND CONFIDENTIAL © Bombardier Inc. or its subsidiaries. All rights reserved...... disciplines or several one of Optimisation Conclusions and Summary Optimisation related to total cost of ownership of cost total to related Optimisation 20 time in deliver to able be to to orderTCO in related solution optimal the compromisemight building which blocks standard use to necessary isit requirements to “timemarket” meet to able be to However, parties the between minimum with interaction scope for their tools optimisation use or to suppliers) This all departments enables parties (other involved (TCO) ownership of cost total the Bombardier translates conflicting requirements into money a competitiveto The application of this methodto Bombardiers high- Thoseare methodsmatureenough to bein used industrial an context available M

ethods

related to optimisation of aerodynamic performance are performance of related to optimisation aerodynamic product related to aerodynamicsto related product

– speak the samethe speak to

–

the ZEFIRO familythe lead trains lead speed language reflecting reflecting