Magazine for Partners Of

PARTNERS

FOR

MAGAZINE 03/2013

№1 Tsentrosvarmash: Welded Structure Manufacturer page 4 Smart Car page 12 How to Manage Success? page 20

№ 1 03/2013 MAGAZINE FOR PARTNERS № 1 03/2013

Magazine for partners CJSC Transmashholding Contents Editor-in-Chief company Konstantin Dorokhin 2 [email protected] 2 news Editorial Office Address 2 Bld.1, 26 Butyrsky Val St., Moscow, 127055 Telephone: (495) 660-89-50

Magazine prepared with participation of MediaLine Publishing House cover story www.medialine-pressa.ru Tsentrosvarmash – Director General Larisa Rudakova leading national

Design Layout manufacturer of welded Ilya Malov structures 4 Editorial Director Dmitry Dorofeyev Issue Editor 8 Ilya Blazhnov

Design and Makeup Elizaveta Krasnova Alexey Kuznetzov Tatyana Kamenskaya personality Proofreading Interview with Аndrey Natalya Konnova Elena Savelyeva Solovey, general director Larisa Nikolina 8 Ekaterina Levenkova of jsc Tsentrosvarmash

Prepress Andrey Klochkov Maxim Kuperman 16 Oleg Mashkin Oleg Nikitin innovationsSmart car by Passed for printing on March 29th, 2013 Printed at Viva-Star Printing House Transmashholding 12 999 copies printed introduction Еd8 – new commuter electric 16 24 train for suburban railway

Project managementtechnologies of success 20

First Kievtimes tram 24 News RIC Cars Set Off to Tver Carriage Works (TVZ) sent the first Russian and European standards and equipped with electric and pneumatic batch of 12 RIC passenger sleeping cars granted a permit to operate in Russia connectors to minimize their for international traffic to OJSC Federal and Europe. replacement time. PassengerCustomer Company. RIC cars are equipped with two sets All up-to-date requirements to safety The supply contract for 200 cars was of undercarriages: undercarriages and comfort have been met. Each signed between OJSC TVZ and JSC produced by Siemens will be used for compartment has a wash basin built in Russian Railways in August of 2009. the 1435 mm gauge and rolling stocks the table. A temperature regulator The Contract is to be in effect until with new generation undercarriages allows providing a comfortable 2014. The project is being carried out developed and produced by OJSC TVZ environment for passengers in each in cooperation with Siemens. will be operated on the Russian 1520 compartment. RIC (Reglamento Internazionale delle mm gauge. The undercarriages are It is expected that the new RIC cars Carrozze) cars of the 61-4476 type are designed for operation at the speed of will be operated within the Moscow – designed for operation in international 160 km/h with the possibility of Nice, Moscow – Berlin routes and other traffic. They have been certified to acceleration up to 200 km/h. They are high-demand European routes.

BMZ Started Supplies of TEM18В

Bryansk Engineering Plant (BMZ) delivered to power equipment and low environmental Dieselrepresentatives of LocomotivesJSC Russian Railways the impact as compared to the diesel locomotives first two TEM18В diesel-locomotive shunters of the previous generation. equipped with Finnish diesel engines produced by The first diesel locomotive was produced in Wartsila. 2011 and passed manufacturing, operational, The new diesel locomotives arrived at certification and acceptance tests Oktyabrskaya Railway. RZD will receive 30 successfully. The Federal Railway Transport additional diesel locomotives within 2013. Certification Register issued a certificate for The TEM18В diesel locomotive is based on the manufacture of a pilot batch of 25 the proven TEM18DМ diesel locomotive. A locomotives. number of changes have been introduced in The structural design includes a heating the base structural design, and a 882 kW system agent for diesel heat transfer that diesel electric engine produced by Wartsila maintains optimum temperature, when the has been installed. TEM18В diesel diesel engine is inactive. It allows for fuel saving locomotives are notable for highly reliable during winter storage of diesel locomotives.

№ 1 03/2013 Transmashholding and RZD Signed Maintenance Agreement for EP20 Sales AlexeyElectric Vorotilkin, Locomotives the Vice-President of JSC RZD, and Alexander Increase Chebakov, the General As per 2012 performance results, Director of CJSC Transmashholdingby sales 22% of products and Roslocomotive, a part services increased by 22% reaching RUB 130 of Transmashholding billion against 2011. Group, have signed Peak sales were achieved in locomotive and their names on the freight car sectors. Sales of mainline freight document. electric locomotives and mainline freight The agreement diesel locomotives increased by 40% (from stipulates that CJSC 308 to 434 sections) and 36% (from 124 to Transmashholding as a locomotive after the last locomotive is 169 sections), respectively. The Group’s manufacturer will be responsible accepted for maintenance. EP20 supplies of freight cars to its customers for routine and non-routine dual-voltage electric passenger increased by 80% (8,810 units versus maintenance through the whole locomotives have been designed 4,905). locomotive life cycle. The Group as per JSC RZD order by TRTrans, JSC Russian Railways remained the will bear responsibility for the an engineering center established largest consumer of the Group’s products. operability of locomotives, by Transmashholding jointly with Major purchasing foreign countries were perform all types of maintenance Alstom Transport, a French Bulgaria, Byelorussia, Kazakhstan, Ukraine and repair work, including mid-life engineering corporate group. and Serbia. The largest export group of and overhaul repairs. Locomotive supplies started in products was metro cars, passenger diesel The agreement comes is November 2012. In total, Russian locomotives, diesel engines, freight cars, effective from the date of its Railways will receive 200 electric platforms, and diesel trains. signing and is valid within 40 years locomotives until 2020.

2ES5 Electric Locomotive static tests, as well as dynamic tests on The 2ES5 design embodies cutting- the test tracks, acceptance tests of the edge technologies, specifically: traction Undergoinglocomotive will be carried out onTests the drive with asynchronous traction motors Engineers of Transmashholding and proving ground of the Russian Scientific with individual voltage inverters, oil-free Alstom are performing shop tests of the Research Institute of Railway Transport piston compressors with air cleaning first 2ES5 AC mainline electric freight (VNIIZhT). At the same time, and drying systems, microprocessor locomotive at Novocherkassk Electric certification tests will be conducted to control and monitoring system. The Locomotive Plant (NEVZ). assess compliance with railway locomotive manufacturing plan 2ES5 is the first Russian AC electric transport safety standards. Future plans anticipates that key components of freight locomotive with an include the manufacture of the second 2ES5 (including those engineered asynchronous traction drive. After locomotive unit to accelerate the tests abroad) will be produced at Russian completion of shop tests that include at NEVZ. facilities.

Cover story

he plant’s history spans sales market and adjust to TSENTROSVARMASH JOINED over 40 years. Since its first the conditions of decreased days the enterprise started production. Experience in LongTRANSMASHHOLD INGTerm IN 2005. THIS Performanceits active collaboration with the producing metal structures for BECAME A NEW STARTING POINT IN THE Russian Scientific and Technical various sectors of the national TWelding Society. In addition to economy helped overcome the HISTORY OF THE FIRST SOVIET manufacturing of metal working difficult times with minimum machine and press frames, losses. The downturn became the SPECIALIZED ENTERPRISE production of metallurgical time for researching new ways MANUFACTURING INDUSTRIAL WELDED nonstandard equipment, of development, implementing excavating machine assemblies, complex orders from customers STRUCTURES. WITHIN THE LAST FEW motor frames and other products and developing numerous was implemented. In 1985, the products. YEARS, THE PLANT SIGNIFICANTLY product range included 300 Thus, it was the first plant INCREASED ITS PRODUCT RANGE AND items. in Tver that entered into a In 1992, the plant became cooperation agreement with BECAME THE LEADING NATIONAL Tsentrosvarmash Joint Stock the municipal administration MANUFACTURER OF WELDED Company. and became its partner in the At the end of the 1990s program for reconstruction and STRUCTURES FOR PASSENGER CARS, and the beginning of the development of the main city in 2000s, Tsentrosvarmash the region. CARS OF ELECTRIC TRAINS AND had to reposition itself in the Undercarriage manufacture LOCOMOTIVES. № 1 03/2013

DEVELOPMENT OF AN UNDERCAR- RIAGE TRUCK OF AN ELECTRIC TRAIN PAVED THE WAY TO THE NEW PERIOD IN THE PLANT’S HISTORY – MANUFACTURE OF PRODUCTS FOR RAILWAY ROLLING STOCK MANUFACTURERS.

Cover story

№ 1 03/2013 for rolling stock was developed. enterprise became a reliable supplier sections of EP2K end, main, center Under the contract with Tver Carriage of beams to SU-155, a Moscow-based pivot frames, respectively. Tver Works there were arrangements to company, and metal structures to Carriage Works completely transferred produce 70 frames and 240 units of Kaliningradskaya, Ivanovskaya power the manufacture of bolsterless undercarriage bolsters, as well as plants and Kalininskaya nuclear power undercarriages to the enterprise. five undercarriages of passenger plant. Tsentrosvarmash gained vast cars per month. Economic difficulties These innovations helped the experience in the manufacture of forced TMZ to decline the order and plant significantly change the line processing equipment. Manufacture make an effort to enter the market of its business within a few years. of products for metallurgical, coke independently. Development of an electric train and by-product processes was As a result of these efforts, two first undercarriage truck paved the way for implemented. The list of customers trailer undercarriages for an electric a new period in the plant’s history — includes prominent mechanical train were manufactured and delivered manufacture of products for railway engineering and machine tool building to Demikhovsky Engineering Plant. rolling stock manufacturers. enterprises: JSC Ryazan Machine Tool At the same time, boiler manufacture Plant, CJSC Dinamo-Plus, JSC Krasny was implemented, and development Proletariy, JSC Silovye Mashiny (Saint of new products in cooperation with Petersburg), NPO TveMos and others. Leningrad R&D Institute named after The plant’s products are in demand Polzunov started. at metallurgical and coke-chemical The market situation forced the enterprises — Magnitogorsky, enterprise to extend its scope of Nizhnitagilskiy, Cherepovetskiy, activities. OJSC Tsentrosvarmash Novolipetskiy, Kemerovskiy, Altayskiy, received a number of licenses outside TSENTROSVARMASH GAINED WIDE West Siberian, Orsko-Khalilovskiy of its core business: such as licenses complexes; and at military industrial for manufacture of pressure vessels complex facilities. Products are and mining equipment, overhaul repair EXPERIENCE IN THE MANUFACTURE exported to Austria, Belgium, of cranes, etc. Germany, Switzerland and other In 2001, the plant executed European countries, as well as to the an order placed by TsKB TM for OF PROCESSING EQUIPMENT. CIS countries — Ukraine, Byelorussia manufacture and installation of the and Kazakhstan. facility for replacement and repair MANUFACTURE OF PRODUCTS Currently, OJSC Tsentrosvarmash’s of undercarriages of the Sapsan management plans to introduce express train in Saint Petersburg (a new products, increase production 500 m railway track of this elevated FOR METALLURGICAL, COKE AND volumes, expand the product range, structure equipped with supports and diversify the production. After the for car adjustment and ramps for manufacture of excavating machine undercarriage withdrawal from the BY-PRODUCT PROCESSES WAS assemblies was implemented under rolling stock without separation). the contract signed with Hitachi Tsentrosvarmash produced a hydraulic Construction Machinery Eurasia unit for taking the rolling stock IMPLEMENTED Manufacturing and metro rolling stairs down from the elevated structure. in 2013, the production capacities are Uralmashzavod ordered continuous set to expand. blank casting machines. The enterprise sets a high value on Tsentrosvarmash developed In 2005, Tsentrosvarmash became a development of partnership relations production of new products (for member of Transmashholding. Since with consumers from Russia, the example, in 2002, a 28 m ejecting bar that time, intra-group cooperation CIS countries, Western European for coke cutting and ejecting from the has been expanding. In addition countries, and Transmashholding furnace was produced) and introduced to undercarriage production, enterprises. new continuous flow production manufacture of metal structures for Reconstruction, modernization (including large orders for JSC locomotives was developed. Serial and robotic automation, as well Severstal, Torzhok Carriage Works, production of frames, items and parts as introduction of state-of-the-art JSC KalugaPutMash, Kirov Foundry for the TEP70 frame by Kolomna technologies, including energy-saving and other enterprises in the industry). Plant was implemented. (Since 2008 technologies, will serve as the basis The plant also manufactured products and 2010 Tsentrosvarmash has been for implementation of these ambitious for the construction industry. Thus, the supplying common base frames and plans.

Personality Andrey Solovey: «We Focus on Constant Development!»

ANDREY MIKHAILOVICH SOLOVEY BECAME GENERAL DIRECTOR OF JSC TSENTROSVARMASH LESS THAN TWO YEARS AGO. DESPITE THIS SHORT TIME IN THE MANAGEMENT POSITION, HIS WORK IS ALREADY A SUCCESS. HIS MAJOR ACHIEVEMENTS INCLUDE PERSISTENT GROWTH, PRODUCTION MODERNIZATION AND STABLE ENTERPRISE PERFORMANCE. ndrey Mikhailovich, you here with a new management team not an end product manufacturer. came to the plant at a – in particular, Sergey Golikov, the We produce component parts, which difficult time. How did Director of Economic and Financial means that we are just a link in the you change the situation for the Affairs, Andrey Guskov, the Security chain of production cooperation better? Director, and Pavel Konstantinov, the between a number of enterprises. –— The А Transmashholding management Production Director. At that time the Therefore, our work depends on who appointed me to the position of the situation at the plant was difficult. wants to manufacture products, end plant’s director in May of 2011. I came The fact is that Tsentrosvarmash is products they want to manufacture

№ 1 03/2013

and if they are willing to order components from our enterprise. We had to promote our capabilities and adjust them to the market demands. Andrey Solovey: «We Focus on ConstantAnd we faced all those challenges. Development!» There were a few other factors that added to the situation, such as lack of stable customer orders and adequate plant management. The plant executed only those orders that were related to intra-group cooperation, which comprised more than 80% of the total production volume. At that time, we produced electric train undercarriages for Demikhovsky Engineering Plant and component parts for Kolomna Engineering Plant. We also had the opportunity to produce bolster undercarriages for passenger cars.

— What measures were taken on the priority basis? — After we analyzed the situation one of its essential objectives, the the largest manufacturer of this type of together with the Transmashholding production plan was to be executed products in Russia. management and colleagues from without reserve and within the timeline The enterprise managed to fulfill all TVZ, a program for Tsentrosvarmash’s agreed on in the contracts. Some of its obligations to the customers, sustainable production by the end staffing measures were taken, where organize the manufacture of the of 2011 was adopted. According to we managed to optimize the number main products and eventually shifted of employees without large-scale to a 5-day working week providing redundancies. We transferred some of a complete work load for staff and our functions (secondary workshops equipment. and machining) to outsourcing. Additional funds enabled us to Cooperation had to do with the renovate the main building of the necessity to reduce expenses, enterprise. The roof was repaired and optimize production processes and the building facades were insulated. organize efficient work, and Tver This work didn’t only improve the Carriage Works had to find additional working environment, but was one of facilities. Eventually, both enterprises the serious measures of the energy- were on the winning side: OAOL TVZ saving program. was able to establish production The second stage of our work of double-deck cars and metro involved searching for potential train undercarriage frames, and customers, as it was evident that we we increased the manufacture of couldn’t develop only on the basis of own products at reduced facilities. the available product range. Moreover, it was decided that our This work was carried out jointly partners should transfer complete with Transmashholding’s commercial production of bolster undercarriages management and became a success. and all required tooling to our Kryukov and Torzhok Carriage Works, company. Tsentrosvarmash became carriage repair enterprises in Russia

and Byelorussia became our major All these facts serve as a good Personalitycustomers. PRODUCTION VOLUME (BILLION RUB) example of how to change radically an We paid special attention to ensuring unfavorable economic situation for the the high quality of our products and better by adjusting the product range 2010 г. introducing innovative technologies. 0,7 accordingly. We continued to re-equip welding workshops and switched to more 2011 г. 1,1 — Today, Tsentrosvarmash advanced materials. This way we could is an active member of the offer undercarriages of a better quality Transmashholding program for as compared to the products of our 2012 г. 1,4 implementation of lean production. competitors. How is your work progressing in We had new customers, and under the 2013 this area? unstructions of the Transmashholding plan 1,7 — We joined the program within “the management and jointly with the third wave,” however, we managed technical management we were able to achieve significant results. At first, to join the production of rolling stairs the following objectives were set: to equipment for metro service, serial items Tsentrosvarmash’s major achievement reduce the stock by 30%, to improve of which have been delivered to the is a European certificate of quality the quality by 30%, to reduce the customer this February. assurance for welding production. It occupied facilities by 20% and to Among other significant projects for expanded our opportunities significantly increase labor efficiency by 20%. And extension of the product range, I could and provided the possibility for delivery the most important objective was to mention a contract with HITACHI on of products to any EU country. This improve the working environment and manufacturing of excavating machine has already brought about changes: a occupational safety. side frames that will be produced at manufacturing facility for production of Personally, I adhered to the lean the facility constructed in Tver Region. traction transformers for railway transport production concept when I worked for HITACHI is very selective in seeking has been constructed in Voronezh. TVZ, therefore, at Tsentrosvarmash potential partners: proposals of more Its owner, Siemens Group, considers my goal was to involve the maximum than 50 enterprises in Russia were JSC Tsentrosvarmash as a potential number of employees in this business reviewed. manufacturer of transformer tanks. philosophy.

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By all means, you cannot implement such system in one easy step or only by the discretionary decision of the management. This requires changing of the philosophy – from the heads of departments and production sites on to maintenance staff. I am convinced that we will succeed.I saw how lean production was implemented at HITACHI in Japan… More than a half of production facilities have implemented lean production since last October, and we are planning on implementing them throughout the plant by the end of this year. And we already see the effects. Our corporate culture has improved, which, in its turn, has enabled us to start the process of continuous cost-saving. The product quality has improved – and today every employee is personally interested in the quality…

— Is there any staffing problem at the plant? year. Also, we manage staff turnover for a particular purpose – to develop — Unfortunately, we could not avoid successfully. production of products that are in layoffs in the course of transfer of demand on the market. some of our specialists to TVZ. But, as — In what areas do you perform The list of critical tasks also includes I have said before, the best specialists technical re-equipment of the activities related to the increase of continue working for the plant. I am plant? the enterprise energy efficiency, as it convinced that new employees are — The plant equipment stock has is energy resources that make up the needed and we shouldn’t exploit been supplemented with a modern bulk of the expenses in the budget. our long-service employees. It is paint spray booth, a portal-type milling The new energy saving plan was necessary to attract young specialists machine, a sheet bending press and introduced in the Soviet era and was and form the skill pool. For us as a machining units that are capable of extremely ineffective. This year, we manufacturing enterprise it primarily milling and drilling of undercarriage are going to replace our compressor means to train highly skilled workers frames on the same mounting (it will equipment and switch to localized and engineering staff. We invite senior allow us to no longer use off-market compressors. Our plans provide for re- students and graduates from Tver radial-type drilling and portal-type equipment of the entire infrastructure Polytechnic University and specialized milling machines). of the energy complex for heat and colleges for training on a continuous Some of this equipment is owned by electric power generation. Some basis. TVZ and located at the facilities rented results have been already obtained: We also have our own training center at our plant, however, it is used to we have noticeably reduced energy and welding laboratory. They are execute Tsenrosvarmash orders, which expenditure and the production historically associated with the time expands our processing opportunities volume has doubled. Now we have to when the plant had a test facility of the significantly. maintain this trend… welding department of MVTU named Today, we are able to implement after Bauman and close relationship production of almost all types of metal — In your vew, what is the principal with Kiev Electric Welding Institute structures: both those structures objective of plant development in named after O.E. Paton was available. that we are going to produce at the the near term? There is a stronger interest in the plant moment and those that are being — I would like to succeed at making on the part of young specialists and considered for the future. New Tsentrosvarmash attractive both as an workers now due to the fact that we machines or equipment are acquired employer and a partner for potential managed to raise average wages last not for modernization as such, but customers.

11 InnovationsUPGRADE OF ELECTRIC EQUIPMENT OF RAILWAY ROLLING STOCK IS A NATURAL AND IMPORTANT PROCESS. NEW EQUIPMENT DESIGNED BY TRANSMASHHOLDING ALLOWS NOT ONLY FAULT-FREE OPERATION OF CAR SYSTEMS AND COMFORT, BUT ALSO CONTROL OVER ALL PROCEDURES IN AN OFF-LINE MODE.

Smart system chooses the best way to heat the car according to the set temperature

lectric equipment was installed OVERALL ELECTRIFICATION in passenger cars in Russia in With each passing year, the 1887, when electric lamps were electric equipment became more first used for lightning. Batteries were complicated. With the extension of installed in the cars to power them. electrified lines, it became more ELater on, generators that generated advantageous to use electric power electric power with a drive due to received from the overhead conductor wheel pair rotation during the car through the electric train instead operation were used. The first simple of solid fuel (coal and fuel wood) switching and control devices were for car heating. Forced ventilation used for switching car lighting power was introduced to provide more from the battery to the generator efficient ventilation of car space. With Vladislav MIRONOV, when the car would move and back to time, air conditioning systems were SmartHead of Passenger Car Department, the battery when the carCar would stop. implemented. CJSC Transmashholding They were called “a set of electric Since the 1990s the list of electric equipment for a passenger car”. power consumers has been increased

12 № 1 03/2013 by adding environmentally friendly prospects for its further development, cooperation between engineers and toilets, hot water supply systems, fire and third-party engineers are not manufacturers. alarm equipment, journal-box heating always able to forecast development A new set of electric equipment control, automatic door drive, audio- of car systems within the next several marked a breakthrough for the and video transmission and other years. In November of 2011, the national car building industry. The systems. project was completed and submitted high-speed Ethernet interface was From the beginning of the 2000s, to the acceptance board. used for systems communication electric equipment of the passenger Since TVZ is not an electrical instead of low-speed RS-485 cars produced at Tver Carriage Works engineering facility, the new product interface. It facilitated increase in the acquired the form, which passenger production was implemented on volume and speed of communication car attendants and depot workers the Promtekhmontazh site also between the control panel controller are used to now. Electric equipment located in Tver, which facilitated and car systems. The volume of consisted of 3 parts: the control diagnostic information received from panel in a service compartment, car systems increased by 50 times. the undercar box and the undercar During this process every message generator driven by a drive shaft displayed contains data on failures, from the wheel pair middle axle. hazard level for car motion and These equipment sets were produced operation and recommendations on by different manufacturers, but in troubleshooting. The size of the touch total they were similar in terms of NEW SET OF ELETRIC screen display has been increased applied engineering solutions and to 12 inches and acquired a color interchangeable in sets. screen. Today, no service devices The main electric equipment EQUIPMENT MARKS A are required to detect problems component was the control panel — all information is available on the used to control car systems. It had screen. There are various access a small display for car systems BREAKHROUGH FOR NATIONAL levels — for a car attendant (minimum monitoring and control. Car systems required information volume), a interacted through the RS-485 train electrician (information on interface. There were some diagnostic CAR BUILDING INDUSTRY methods of en route troubleshooting) error messages available. But the and depot workers — complete diagnostic content was not large — most car systems were controlled by their own controllers, and a special laptop computer with service software was required to perform car diagnostics. Another problem had to do with insufficient space on the control panel — the car equipment was constantly increasing. This resulted in arranging a part of the equipment, e.g. the control unit of the antiskid system, in the car attendant’s accommodation limiting the space designated for service needs. This situation impeded passenger car development.

KNOW-HOW In 2011, TVZ Chief Engineer’s Department set out to design a fundamentally new set of electric equipment. The decision to design electric equipment without outside assistance was prompted by the fact that only local engineers were familiar with the car structure and the

13 information on the control car, and from Innovationsnature of problems the train control car to and a manual for the ground services; troubleshooting, • access and including tips, figures security control and charts). and monitoring The application system of a program software of the passenger controller is run on the train that limits Linux operating system. access to the car The large memory compartment space of the controller with an electronic allowed downloading the key card issued electronic car operation to passengers manual into the system. boarding the train. Now it is not required Significant changes of a car attendant to have been introduced have thick folders of to the journal-box documentation “on heating control system. board” — he can just A modern system with open the system and digital temperature have the required car sensors that record the operation manual Tip for a train electrician current temperatures section displayed using of all eight car axle a simple menu. boxes online is used A large monitor allows displaying instead of the outdated system with an image from the surveillance fuse-type sensors that could only give video cameras in car corridors and a signal of car axle box overheating vestibules. The information taken (most often a false one). by video cameras is recorded in the car controller memory, and in case CONTROL CENTRALIZATION of abnormal situations, e.g. unlawful One of the main features of the new actions, these recordings can be TRAIN MASTER OR TRAIN set of electric equipment is advanced available for viewing. functions of train level. Railway Electric equipment configuration ELECTRICIAN AT “COMMAND operators seek to offer a lot of new has also changed. All power safety additional services in competition equipment was removed from the with the other modes of transport. service compartment to the vestibule CONSOLE” IS ABLE TO MONITOR Consequently, a car attendant does of the non-operational car end, which not have enough time to monitor allowed clearing space on the control and control car systems, being busy panel and placing there equipment ALL TRAIN CARS, CONTROL with passenger service. A new set of that had previously been located electric equipment allows centralizing in other places. The equipment control over all train cars in the itself received a block-modular ALL SYSTEMS OF ANY CAR AND control car. The train master or the configuration and is fixed on standard train electrician at the “command frame bearings, which helps save console” is able to monitor all train dismantling and mounting time during MONITOR PROBLEMS IN ALL cars, control all systems of any car maintenance and repair works. and monitor problems in all cars. All systems, which have become CARS Communication with car attendants is usual in passenger cars, are executed through video conferencing maintained. They include the — there are small video cameras following: mounted above the car panel • fire alarm and fire fighting • wireless radio-frequency monitors. equipment detecting fire and information communication It is possible to control another car smoke contamination sources in system transmitting diagnostic not only from the control car, but also any car compartment; and other information to the train from a neighboring one, or from any

14 № 1 03/2013 other train car. This function is provided for the events when one car attendant serves two or three cars in low-budget trains. All these functions are implemented through the wireless radio-frequency information communication system. In terms of monitoring, control and diagnostic systems, the passenger train represents a computer network, where a control car serves almost as a “server” and other cars are “personal computers.” The network is assembled automatically — when a car is coupled to the train, it is immediately registered in the system, and the control car issues an “IP-address”, and communication starts. Small semi-circular communication antennas are installed on the car end walls to implement these functions. By the beginning of 2013, a new set of electric equipment had modifications for all cars produced by TVZ — compartment, open-plan, control, interregional cars and diners. The trains having centralized power supply with a static converter instead of a generator, including double-deck trains, are also equipped with these sets. A new set of electric equipment designed by the engineers from Tver has marked a new era in the field of car equipment control. But the opportunities offered by it are not fully used. For example, there is an opportunity to arrange communication with the locomotive. The function that provides for driving a train by one dual-voltage electric locomotive along the whole route, e.g. from Moscow to Adler, may become relevant for the fixed train formation. Therefore, electric equipment and car control systems will continue to be developed and improved. Main view of control panel

15 Introduction

HowAS EARLY AS 2015, to THE Surprise Passengers? MUSKOVITES WILL BE ABLE TO ASSESS THE QUALITY AND COMFORT OF THE MODERN ED8 ELECTRIC TRAIN DESIGNED FOR URBAN TRAFFIC. IMPLEMENTATION OF THIS PROJECT WILL BECOME A MILESTONE FOR BOTH TRANSMASHHOLDING AND THE MOSCOW RAILWAY INFRASTRUCTURE.

HELPING MOSCOW thousand cars operated throughout What is the relevance of the project? emikhovsky Engineering Plant, a Russia, as well as Ukraine, Byelorussia The Muscovites stronger than ever part of Transmashholding, is a and Kazakhstan. Such iconic products before feel the need for improvement leading Russian enterprise of the electric train car building as of the capital railway infrastructure. All engaged in design and serial ED4М, ED9М and others have become of us are familiar with the problems Dproduction of suburban and regional the trademark of the plant. Relying on that getting around a big city involves. DC and AC electric trains. Today, it its vast experience in the production Traffic jams, inconvenient location of produces more than 80% of the total of suburban and regional electric metro stations, municipal transport amount of electric trains trains, the enterprise is moving to the stops, etc. — all of these are time manufactured in Russia. The next stage – design and production of wasters. And electric trains, being part enterprise is also the largest plant in urban electric trains. Demikhovsky of the Moscow transportation network, terms of the number of electric train Engineering Plant is ready to mitigates traffic congestion. cars being constructed in Europe. contribute to the development of the For example, ED8 may become a For the past 15 years, the highly Moscow railway infrastructure. good solution for the project for skilled employees of Demikhovsky — The plant’s specialists are passenger traffic arrangement along Engineering Plant have designed and building a new ED8 electric train: the Moscow rail beltway, which is to implemented production of 17 train comfortable, serviceable, reliable and be implemented in the next few types, produced more than 4 safe. years.

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SERGEY BEZRUKAVNY, cars, four motor cars and one trailing occupancy is 1,260 passengers. It is Technical Director, car. achieved due to the large volume of Demikhovsky Engineering The electric train has a total length free space inside the cars. During rush Plant: of 154.7 meters, and the car width is hours, this train is able to carry 1,957 3.48 m. Two doors on each side are passengers. The ED8 electric designed for head cars of the electric Convenient arrangement of doors train has many train, and three doors – for middle inside the ED8 cars provides for good fundamental cars. The seat arrangement is 2+2. passenger mobility within the limited distinctive features There are 48 passenger seats in head stopping time of the electric train at as compared to cars and 72 seats in middle cars. the transfer hubs. Every ED8 head car its predecessors. The specific urban character of the They include an ED8 electric train is noteworthy. It will asynchronous motor drive, three be designed specially for passenger passenger exit doors on each side of transportation in a megalopolis, where head cars body, and many more. the stops are in close proximity – The ED8 electric train design makes within a few kilometers. The electric it suitable for mass passenger train has to stop and start transportation. It should operate in approximately every 5 minutes. In a “metro mode.” Therefore, there order to provide fault-free operation of ED8: is a reduced number of seats and the rolling stock, it should have increased room for passengers excellent brake and start dynamics. • NUMBER OF PASSENGER SEATS: 456 standing during the electric train Demikhovsky Engineering Plant has movement. a vast experience in the production of As for its technical characteristics, the rolling stock of similar specifications: • RATED OCCUPANCY: 1,260 ED8 electric train is highly competitive the enterprise builds electric trains for with its Western competitors. In many passenger transportation in Moscow aspects, it has the edge against them Region, where the stops are also close • MAXIMUM OCCUPANCY: 1,957 due to complete “russification,” it is to each other. more affordable and easy to maintain Today, the project is at the stage of and repair promptly. development and agreement of the technical assignment. In the future, the plant’s engineers will be engaged has a special place for a baby in strenuous work involving carriage. These places are equipped production, testing and certification of with safety belts, fixtures used to EXCLUSIVELY FOR THE CITY the new electric train. The first batch fasten the baby carriage to the car The ED8 electric train is designed for of these trains is to be produced in floor, and a hand rail. Toilets which are urban passenger transportation along April – May of 2015. going to be located in the electric train designated routes with the round trip head cars will be suitable for disabled section length of 60 km maximum. The COMFORT passengers. Folding ramps (with the maximum speed of the electric train is FOR PASSENGERS carrying capacity of 350 kg) located in 120 km/h. The ED8 electric train has a high the front vestibule of the head car will The main ED8 electric train passenger capacity. It has 456 allow such passengers to get easy formation consists of 7 cars: two head passenger seats. The rated access to the cars. A powerful and reliable microclimate system will make traveling in a car compartment comfortable in any season at any outside temperature. A MAIN COMPETITIVE ADVANTAGES OF THE ED8 ELECTRIC TRAIN: similar microclimate system will be • Excellent brake and start dynamics built in cabins; it will allow a • Reliable engineering solutions locomotive crew to work in • Compliance with Russian safety rules and standards comfortable environment in any • Higher comfort level of passenger travel weather. • Train formation flexibility A sealed inter-car gangway provides • High passenger capacity a number of substantial advantages • Low maintenance costs for passengers and operators: it excludes the need for installation of

17 inter-vestibule doors and eliminates Introduction the floor height difference, which allows passengers to go from car to car without any risk of stumbling and provides complete protection from atmospheric precipitations, improves thermal insulating properties and reduces the noise level inside the cars. At the operator’s request, it is possible to have wireless access (Wi- Fi) to the Internet inside the electric train cars. An audio and video transmission system is provided for THE ED8 TECHNICAL CHARACTERISTICS convenient communication. It also allows transmission of advertising and Maximum service speed 120 information messages. According to the designers’ concept, the ride in the Type of current, kV Direct current, 3 ED8 electric train car should not be a waste of time for passengers. If a long Average acceleration to 60 km/h, m/s2 0.9 travel is expected, a passenger can enjoy a comfortable seat, browse the Internet, view video clips on the Length of cars based on automatic coupling axles, m: 22.6/22.1 screen or simply rest.

Wheel base, m 15 SERVICEABILITY The ED8 electric train will become not only a comfortable vehicle for Car width, mm 3480 passengers, but also a value- enhancing investment for the operator. Car height, mm 1100 With all its advantages (adequate power capacity, excellent brake and Number of doors per side start dynamics, comfort), the train 2/3 head/middle does not require large maintenance expenses. An important technical feature is the Seat arrangement pattern 2 + 2 asynchronous motor. Its major advantages are user-friendly Number of passenger seats 48/72 maintenance and operation, and structural simplicity. It is relatively Body material Structural steel inexpensive, and highly reliable as well. It is almost not prone to failure Type of traction drive Asynchronous and withstands significant mechanical overloads. This motor is resistant to Number of axles (with motor/general) 16/28 environmental impact and can be operated in severe climate conditions. The important advantage of the ED8 Empty weight, t 49.0/63.8/45 electric train from the operator’s Head/motor/trailing car standpoint consists in the base platform flexibility. The operator can at Maximum axle load, ton-force 21.7 their own discretion form an electric train set. The number of cars varies Continuous rating, kW 6400 from 6 to 12. It is also possible to couple two seven-car trains with each Service life, years 36 other and increase the number of cars to 14. The automatic coupling of two

18 № 1 03/2013 OPTIONS OF TRAIN SETS характеристики электропоезда основной составности • Electric train consists of head (H), motor (M) and trailing (T) cars Train length 154,7 m • Basic electric train set – 7 cars (2H+4M+1T) Passenger capacity • Possible formation of various electric train sets with 6-10 cars Number of seats 456 • Automatic coupling of two trains with the total number of cars in an electric train set up to 12 units takes not more than 5 minutes Design occupancy 1260 Maximum occupancy 1957

г01 м02 м04 п03 м06 м10 г09

trains will take not more than five Equipment and components for the electric train passengers. This data minutes. Upon the customer’s ED8 are supplied by will be collected and processed by a request, a customized compartment Transmashholding plants, as well as dedicated onboard computer. of any class can be built. leading enterprises from various One of the key advantages of the The ED8 external appearance will countries worldwide. ED8 electric trains is its onboard gladden the eye of the Muscovites. Its system of diagnostics and monitoring looks will be accentuated by the new CONSIDERATION OF of the electric train technical modern front part of the head car with STATE-OF-THE-ART TECHNOLOGIES condition. The diagnosable electric a low aerodynamic drag coefficient, a The integrated control, diagnostic and train assemblies include wheel pair smooth body without external safety system in the ED8 electric train journal-boxes, bearing assemblies of corrugation. performs the functions of automatic wheel and motor units, reduction The structure allows creating a train operation, collection and storing trains, converter and compressor, customized design of the train of information on its operating compressed air brake systems of exterior, making it unique and turning conditions. It will make it possible for electric trains, electric power circuits it into one of the city’s attraction. the train to be operated by one train and control circuits. driver without an assistant driver, as The system allows immediate online RELIABILITY well as to monitor online the technical transfer of information on the AND DURABILITY condition of the electric train. technical condition of individual The new ED8 electric train by The train driver’s control panel will assemblies and units to the onboard Demikhovsky Engineering Plant was be equipped with a telemechanic diagnostic station. The built-in GPS built with the utilization of modern system of the train driver’s diligence module will assist in identifying engineering solutions. monitoring which will provide position of the train, and the RF The structural steel used in continuous control of his condition at modem will allow the crew to transfer production of the body and special work. data from the train in a timely coating of external planes will make When feed voltage is supplied, the manner. the electric train reliable in operation video control system in car in aggressive environment and compartments and vestibules will turn resistant to corrosion. Normal on automatically. It will allow recording operation of the electric train will be events occurring in the rolling stock possible within the temperature range and saving them in the non-volatile from +40 to -40 °C. The crash system memory. Information about the in the electric train makes traveling occurring events will be displayed safe for passengers. This system online on the train driver’s panel. dampens the impact energy in case of Counting sensors will be installed on train collision with an obstacle. It is a the external doors to register incoming well-known fact that the crash system and outgoing passenger traffic and has helped save lives of electric train record it. They will enable to control passengers during collision with an whether the number of sold tickets obstacle. correspond to the actual number of

19 Technologies Project Management of Success

Sergey shatalov, director of investment policy and project management board

CJSC TRANSMASHHOLDING (TMH), A LEADING STAKEHOLDER IN THE TRANSPORT ENGINEERING MARKET, TARGETS PRODUCTION OF HIGH-QUALITY, MODERN AND COMPETITIVE PRODUCTS THAT MEET RUSSIAN AND INTERNATIONAL QUALITY STANDARDS. HAVING GAINED A LEADING POSITION AMONG RUSSIAN MANUFACTURERS, TMH ASPIRES TO ENTER NEW WESTERN AND EASTERN MARKETS. THE IMPORTANT FACTOR FOR REACHING OF THE SET GOAL IS MANUFACTURING OF RAILWAY ROLLING STOCK WHICH CANNOT BE PRODUCED WITHOUT AN EFFICIENT MANAGEMENT PROCESS.

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n order to increase the relate to project implementation are of high level business processes for competitive edge of the Russian well-known to companies worldwide. TMH. The fundamentals stipulated in railway transport, Alstom and Leading foreign companies have the Regulations are being implemented Transmashholding signed a partnership already found reliable solutions in the EP20 and 2ES5 pilot projects. agreement,I which can be considered and continue improving them by Currently, business-processes and as a starting point of implementation summarizing all the knowledge in management tools are being adjusted of project management fundamentals the project management system based on the management lessons in TMH. Thanks to this cooperation, that consists of three components: learned. The DFQ quality control Transmashholding has acquired an processes, staff, and tools. procedure is being adjusted on the opportunity to adopt experience in basis of supervisory checks of the project management from the global TRAINS ON THE MOVE project quality (GR), instructions transport engineering leader, which A year ago, the Investment Policy and for project schedule development, allows organizing work on creation and Project Management Board started communication management tool, risk Project Management implementation of new manufactured implementing project management management tool, adaptation of the products within the limited period and fundamentals and tools, which were organizational structure, etc. budget and in accordance with quality defined in the Project Management Reformation of the company can requirements. Regulations. be achieved only if its employees A lot of the problems that The document establishes an realize that it depends on each of them of Success Transmashholding faces and that organizational structure and a scheme individually. Figure 1. Matrix subordination

SENIOR MANAGEMENT высшее руководство

PROJECT FUNCTIONAL FUNCTIONAL FUNCTIONAL OFFICE MANAGER MANAGER MANAGER MANAGER

PROJECT SPECIALIST SPECIALIST SPECIALIST MANAGER

PROJECT TEAM

21 In 2012, four of the Group’s but it could not respond quickly and of others and improve the process Тechnologiesenterprises (TMH, TVZ, NEVZ and efficiently to the processes related to based on the lessons learned. It is BMZ) provided training courses on project activities. The organizational possible to access ISPD from any project management fundamentals for structures of Transmashholding and part of the world and carry out remote their senior management, managers NVZ were changed. These changes monitoring of the project. ISPD and teams of pilot projects. Another helped make the organizational stores required reports, business objective of the training program is structure correspond to the matrix plans, records of decisions, minutes gradual integration of basic terms and subordination structure shown in of meetings, results of supervisory definitions of project management. Figure 1. In 2012, Transmashholding checks and project plans. The meaning of such terms as established the Project Office which is Continuous work on the adjustment “life cycle’, “project manager” and new to its organizational structure; in of three key components of project “project team”, “communication 2013, a similar structure was formed management, i.e. processes, matrix”, “quality, schedule, budget at one of the largest plants of the personnel, tools, will lead to automatic management” becomes clear to Group, JSC PK NEVZ, based on the improvement of the system and everyone. The main growth driver example of the holding company. transfer to the new standard of of projects is the employees. Thus, The Information System of management. For example, Alstom project management as a subject Project Documentation (ISPD) was has been building the project has a very important section related implemented along with training management system for 10 years and to working principles and human courses and seminars, adaptation constantly accumulating experience in resources management, which of business-processes and order to avoid mistakes in the future. provides for the competencies organizational changes with active Transmashholding has the opportunity matrix available for every employee involvement of specialists from the to introduce project management and a plan of his/her development. Information Technologies Department. principles faster due to the partner’s Achievement of the goals set forth Application of this system allows support and experience. in the plan by the employee and managing documents and storing development of new competencies history for standard rules for all allow establishing the wage level and projects. The ISPD structure provides MOVING TOWARDS TARGET maintaining motivation at a high level. easy access to project data and helps Making progress in the course of Organizational structure is of great to efficiently adapt experience in introduction of project management significance to the management. implementation of previous projects. principles is not simple. Even the Until recently, it complied with the Another important aspect of project most powerful locomotive cannot operating business requirements, management is to learn from mistakes cause the acceleration of a freight train quickly, but the train begins to move car by car and achieves the set Figure 2. Information System of Project Documentation speed. Once the first steps of project management implementation have been taken and the first results have been obtained, it is possible to adjust START END a program of required measures for efficient functioning of the project management system. The major objective that we have for the nearest future is to establish common culture ISPD DATA BASE START END of project management and common vision of the business organization by using standard documents, meetings, training courses and business START END processes in the Group. Following up upon the training program for personnel of the holding company and enterprises started in 2012; in 2013, START END START END we are planning to implement an advanced program for the employees who attended the basic training PROJECT # FURTHER PROJECTS course in 2012 and to add three other enterprises, where implementation

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Road Map for introduction of project management tools (tools introduced currently are in red, tools used in pilot projects are in blue)

2012 2013 2014

• tools of financial cost control • tools of financial cost control, including all costs • computer-aided • monthly financial report report COST • historical cost information • unified financial model. Cost calculation by • monthly report components • new monthly financial report

• 8D (8 disciplines, • quality plan problem FMEA (Failure Modes and Effects Analysis) management • extended checklists for quality QUALITY • process) • checks of project quality using checklists (GR) checks (GR) with simplified requirements • ROE (Return on Effort)

principles of time planning (Master plan in MS TIME • Project)

• function description • organizational structure training program HUMAN RESOURCES training program and plan • • seminars for project team managers (DFQ • and plan planning) • training program and plan

• monthly and quarterly project reports COMMUNICATION • common data base for project document • standard project documentation management

• list of opportunities RISKS / ECONOMY / • risk list (RR) • project economy plan OPPORTUNITIES • risk analysis and risk management plan

long term contracts for • strategy for SUPPLIES supplies plan components supply, including • • suppliers backup localization plan

CONTRACT • integration of Sales Manager in MANAGEMENT project team of the Group’s major projects is change management and tools The first group of the set planned. of financial cost calculation by objectives for project management The process of introduction of components. We are planning on implementation has already been new project management tools will extensive work on the creation of executed at TMH: the foundation continue along with the training in a standard matrix of work sections that has to grow by using new project accordance with the Road Map for for each type of product lines. management tools has been laid. project management implementation Realization of these objectives will The introduced project management (Table 1) approved by the General require participation and support of system puts TMH at the first “maturity Director. It is necessary to focus the senior management and maximum level”, which indicates that extensive primarily on development and involvement of all company business work on our transfer to the second improvement of planning, risk and units. level lies ahead.

23 Times

IN 1892, IN KIEV THE FIRST ELECTRIC URBAN RAILWAY WAS OPENED IN RUSSIA. THE PROJECT WAS IMPLEMENTED BY AMAND YEGOROVICH STRUVE, AN OUTSTANDING ENGINEER AND FOUNDER OF KOLOMNA ENGINEERING PLANT, WHO WAS FAMOUS IN BOTH NATIONAL AND FOREIGN ENGINEERING CIRCLES. FIRST KIEV theTRAM way between for standing passengers (the total of Kreschatik and 42 people, including the tram driver Podol. Horsecars and the conductor). The tram was lit and steam-driven with five 100V filament lamps. Three trams moved along lamps were inside the car, and one such steep slope lamp – at each of the platforms. The with great difficulty. weight of each car with passengers On September 9 of was 7 tons. 1891, construction The residents of Kiev were proud of an electric tram of their tram. An important role was section at the assigned to it in many festivities. For Alexander rise and example, in 1897, the metropolitan of a temporary station Kiev Ionikiy (Rudnev) arrived by tram at started. On May 2 the opening ceremony of the Russian of 1892, two motor agricultural and industrial exhibition. t the time, this mode of transport tram cars that had been manufactured was used only in England, for the first time in Russia arrived from Germany, the USA, and France. Kolomna in Kiev. A test drive took Kiev authorities were concerned with place on May 8, 1892. public urban transport problems Regular passenger traffic started Аas in the city with the population of on June 1, 1892. In the presence of two hundred thousand people in hundreds of people, the first electric THE RESIDENTS OF KIEV WERE the 19th century the main means tram in the Russian Empire ran from of transport was the omnibus. This Tsarskaya Square to Alexandrovskaya is how a contemporary described Square. In 1893, two tram lines PROUD OF THE TRAM. AN IMPOR- the omnibuses: “They are awkward with the total length of 150 versts and clumsy, drawn by sickly horses. were operated in the city. Tram They accommodate up to twenty service connected suburban areas TANT ROLE WAS ASSIGNED TO IT passengers and move slowly stopping (Svyatoshino, Demyevka, Puscha- frequently to take in and let out the Voditsa) with the city center. IN MANY FESTIVITIES. passengers.” Amand Yegorovich tested Electric trams showed its all modes of public transport used at advantages on steep city streets within that time in Kiev streets (horsecars, the first months of operation. In 1893, In spite of distrust on the part steam-driven trams, electric trams), he the proceeds from that line covered of many enterprisers and the supplied cars and rails manufactured not only operation costs for this line, government, the electric tram became at his Kolomna Engineering Plant but also losses from operation of the main transport system in Kiev and Iron Rolling Plant in Kulebaki in horsecars and steam tram lines. The and, subsequently, in many Russian Nizhny Novgorod Province. The main tram would go from one of the two cities. The electric trams produced factor that encouraged him to give platforms, on each of which a main by Kolomna Plant were operated in preference to electric traction was the controller was installed. Passenger Moscow, Saint Petersburg, Odessa, steep hill of the Alexander slide on capacity was 22 seats and 18 places and Voronezh.

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• Transmashholding is NO. 1 IN CIS COUNTRIES in terms of the volume PRODUCTS AND SERVICES OF THE HOLDING: of rolling stock • mainline and electric industrial • diesel locomotive engines production and sales locomotives; and marine diesels; • mainline and shunting locomotives; • diesel generators and • freight and passenger cars; turbochargers; • electric train and subway cars; • transport components; • Transmashholding is • rail buses and diesel trains; • spare parts; among WORLD’S TOP • car casting; • repair and service maintenance. TEN LEADING MANUFACTURERS of OVER THE PAST FIVE YEARS, railway equipment THE COMPANY HAS PRODUCED: over over over • Transmashholding is THE ONLY RUSSIAN COMPANY to have 3000locomotives 4000passenger cars 3000electric train cars experience in creation and manufacture of over over over the machinery for the arctic service 230rail bus cars 1500subway cars 2700diesels • Transmashholding machinery is operated IN ALL CLIMATIC REGIONS OF THE EARTH

POSTAL ADDRESS: Latest shunting Russia, 127055, Moscow, Butyrsky Val Str., 26, bld. 1 TELEPHONE: +7 (495) 744-70-93; FAX: +7 (495) 744-70-94; E-MAIL: [email protected] locomotive TEM TMH www.tmholding.ru