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Sst.2010.5.2-1 AUTOMAIN Augmented Usage of Track by Optimisation of Maintenance, Allocation and Inspection of Railway Networks Project Reference: 265722 Research Area: SST.2010.5.2-1 Improvement analysis for high performance maintenance and modular infrastructure Deliverable Reference No: D4.1 Due Date of Deliverable: 06/09/2013 Actual Submission Date: 09/09/2013 Dissemination Level PU Public Deliverable D 4.1 Improvements analysis in high performance maintenance and modular infrastructure Document Summary Sheet The main objective of this report is to deliver results from WP4.2, 4.3 and 4.4. The purpose is to study, identify and assess innovations that can improve the effectiveness and efficiency of large scale maintenance processes, including the improvement of track possession time. The maintenance activities considered include rail grinding and tamping and maintenance of switches and crossings This document is the report covering deliverable D4.1. Additional information Subproject / work package: WP4 Author : Ulla Juntti, LTU, Matthias Asplund, TRV, Burchard Ripke DB Netz, Björn Lundwall, Vossloh, Aditya Parida, LTU, Christer Stenström, LTU, Stephen Famurewa, LTU, Stephen Kent UoB, Filip Glebe, Vossloh, Arne Nissen, TRV Participant name: Henk Samson, Strukton, Willem van Ginkel, ProRail, Barend Ton, Strukton, Per-Olof Larsson-Kråik, TRV, Danny Mignott, KM&T, Dan Larsson, Damill, Kevin Blacktop, NR, Felix Schmid, Stefan Lundström-Sveder TRV Document date: 9 September 2013 Status: Final Version History V_ 11 Feb 13 first draft Initial draft version V0 15 Feb Second draft Sent to task leaders V1 25 March Third draft Sent to all V2 12 June Fourth draft Sent to all V3 25 July Fifth draft Sent to all V4 07 Sept Final draft Sent to task leaders Deliverable D4.1 Improvement analysis in high performance maintenance and modular infrastructure. Page 1. Contents Executive Summary ................................................................................................................................. 3 1. Introduction ............................................................................................................................... 5 1.1. Objectives ............................................................................................................................... 8 1.2. Methodology and Approach ................................................................................................... 9 2. Current practices...................................................................................................................... 11 2.1. Possession time .................................................................................................................... 11 2.1.1. Breakdown structure of maintenance possession time in practice. ................................. 11 2.1.2. Transportation and setup time .......................................................................................... 12 2.1.3. Maintenance on the track ................................................................................................. 13 2.1.4. Maintenance between trains ............................................................................................ 13 2.2. Grinding ................................................................................................................................ 14 2.2.1. Strategies and objectives ................................................................................................... 15 2.2.2. Measuring systems ............................................................................................................ 16 2.2.3. Grinding methods .............................................................................................................. 16 2.2.4. Workflow ........................................................................................................................... 19 2.2.5. Findings of lean analysis .................................................................................................... 19 2.3. Tamping ................................................................................................................................ 21 2.3.1. Strategies and objectives ................................................................................................... 22 2.3.2. Measuring systems ............................................................................................................ 22 2.3.3. Tamping methods .............................................................................................................. 22 2.3.4. Workflow ........................................................................................................................... 23 2.3.5. Findings of lean analysis .................................................................................................... 23 2.4. Switches and crossings ......................................................................................................... 25 2.4.1. Strategies and objectives ................................................................................................... 26 2.4.2. Measuring systems ............................................................................................................ 26 2.4.3. Methods ............................................................................................................................. 27 2.4.4. Workflow ........................................................................................................................... 27 2.4.5. Findings of Lean analysis ................................................................................................... 29 3. Improvements, Innovations and Best Practice ........................................................................ 32 3.1. Best Practice for Grinding ..................................................................................................... 33 3.1.1. High Speed Grinding .......................................................................................................... 33 3.1.2. Automated slag collector ................................................................................................... 36 3.1.1. Pre and& post measurements ........................................................................................... 37 3.1.2. Maintenance strategy ........................................................................................................ 37 3.1.3. Adopted grinding machine ................................................................................................ 38 3.1.4. Grinding trolley .................................................................................................................. 38 3.1.5. Speed up production by combining two or more machines ............................................. 39 3.2. Innovations for Tamping ....................................................................................................... 41 3.2.1. Quality versus speed .......................................................................................................... 41 3.2.2. Automatic adjustment of machine parameters for tamping requirements (Improvement) 43 3.2.3. Further Investigation and analysis of track geometry for different tamping techniques 43 Deliverable D4.1 Improvement analysis in high performance maintenance and modular infrastructure. Page 2. 3.2.4. Improvement of recording and transfer of all maintenance relevant parameters together with GPS coordinates ......................................................................................................... 43 3.2.5. Root cause analysis of single failure .................................................................................. 43 3.2.6. Combination of maintenance activities in order of importance ....................................... 44 3.2.7. Improvement of existing tamping machines or development of special single failure tamping machines for sections up to 100 m (Innovation) ................................................ 44 3.2.8. Use of track recording measurements directly for tamping machines ............................. 45 3.2.9. Higher priority of maintenance ......................................................................................... 45 3.2.10. Optimised tamping strategy .............................................................................................. 46 3.3. Switches and Crossings ......................................................................................................... 51 3.3.1. Increase inspectors’ skill .................................................................................................... 51 3.3.2. Grinding of built up welding .............................................................................................. 51 3.3.3. Water cooling equipment for build-up welding ................................................................ 51 3.3.4. Replacement strategy (modular concept) instead of repair and build-up welding on track 51 3.3.5. On-line measurement through camera from Overhead (OH) line .................................... 52 3.3.6. Modular concept ............................................................................................................... 52 3.3.7. Extended rail parts ............................................................................................................. 54 3.3.8. Create standard work .......................................................................................................
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