THE MAINTAINABILITY APPROACH AT TRANSPORT Transport Service Technical Director Yves DURAND

November 2001 November 2001 1 • Transport Service INTRODUCTION – – How to build maintainability ? performances Maintainability approached with pragmatism for measurable • • •

Changes in the new build projects objectives Contents of the development programme Why the selected approach ? 2 Market dynamics Transport Service DESIGN Suppliers Suppliers Suppliers Suppliers MANUFACTURE Traditionnellement A new logic emerges MARKET New Players FINANCE Operators Operators Operators Operators OPERATE Suppliers Suppliers Suppliers

MAINTAIN 3 Where customers put a new focus their core competencies, on focus put a new Where customers Who are our customers Who are our customers ? Transport Service K19 UK 2001 UK 1990 British Rail new opportunities have arisen have opportunities Direct Rail Service Express Transit Railway Docklands Light Midlands Travel West Operators Operator Owners Rolling Stock Owners English, Welsh & Direct Rail Service Birmingham Express Transit Nottingham Railway Docklands Light Midlands Travel West English, Welsh & Freightliner South West Island Line Scottish Freightliner Scottish Trains (Sheffield) Blackpool Transport Services (Croydon) Metrolink(Manchester) (Sheffield) Blackpool Transport Services (Croydon) Serco Metrolink(Manchester) Tramlink Rail Thameslink Thameslink Rail Thameslink Renaissance Rail Stagecoach Renaissance Rail /Operators Mendip Rail Stagecoach Supertram Light Rail Owners Freight Stagecoach /Operators Mendip Rail Stagecoach Supertram Light Rail Owners Freight ARRIVA Connex Connex Connex Connex GOVIA Midland Mainline Light Rail Underground Underground National South Central Freight Metros Glasgow Underground Abbey Underground South Central Glasgow London Railcare Railpart Railcare Railpart Connex Rail Connex Connex Rail Connex Cross Country Trains West Coast Trains Cross Country Trains Chiltern Railways Connex South Connex West Coast Trains HSBC Angel Connex Eastern Virgin M40 Trains Eastern Eurostar Virgin M40 Trains South LTS Rail Wales & West Company Cardiff Railway LTS Rail Wales & West Company Cardiff Railway Prism Rail West Anglia Great FirstGroup Sea Containers GB Railways Prism Rail West Anglia Great FirstGroup Go-Ahead Sea Containers MTL Rail GB Railways Express National Northern Central Trains Go-Ahead MTL Rail Express National Northern Northern Spirit Electrics First North Railway Thames Northern Spirit Electrics Merseyrail Western Western First Great Scotrail Trains Railways Express Gatwick Mainline First North First Great Midland Scotrail Eastern Great North Eastern Railway Anglia Thames Western Western First Great Scotrail Trains Silverlink Railways Express Gatwick Mainline Scotrail Midland Eastern

Great North

Anglia 4 4 Standard product lines Coradia Metropolis Main Line & High Speed Trains Urban & Trains Suburban Citadis TGV Prima X’trapolis

Locomotives 5 Rolling Stock Transport Service Service market share is increasing 82% € 93/94 1.9 billion Signaling Services 14% 4% Rolling Stock 61% € 98/99 3.5 billion Services 23% Signaling 16% Rolling Stock 50% € 02/03 5 billion Signaling Services

30% 20% 6 Transport Service DESIGN Commissioning New Products ALSTOM Warranty MANUFACTURE Services for the complete life cycle ALSTOM or non-ALSTOM MARKET FINANCE >30 years OPERATE

Renovation Equipment - Track Transit - Freight Parts and Replacement MAINTAIN

Equipment - Track Transit - Freight Maintenance

Units 7 7 Transport Service

Bringing innovative

solutions through R&D

8 Transport Service Design & Build Operate & Maintain Build Operate Design & TrainTracer

Reliability Ce R&D addresses the complete life cycle     Condition Monitoring Condition Monitoring /CLAMP

n tred LCPC LCPC Maintenance Maintenance Corrective Maintenance Corrective

e-Maintenance e-Maintenance Maintenance Maintenance Preventive Preventive

Renovations Renovations Maintenance Maintenance Predictive

FRACAS

Predictive 9 9 The programme architecture Customer contract Contracts Parts specification agreement Internal Core data Documentation Logistic support & calculations Depot basic workshops LCPC data Equipped Training design data Logistic support Logistic support engineering products Condition monitoring tool Feedback & management Depot equipment pack Procurement plan Manpower plan Inventory & stores analysis systems RCM

s 10 Parts specification & identification Deutsch: FDBA 50-18.11-PNK Framatome: 8525-10R-18B11-PNHL SUPPLIERS SNCF : 10-5171302 SNCF CUSTOMER CUSTOMER SPECIFICATION CUSTOMER SUPPLIER/MANUFACTURER FILE GEOMETRY UNIT Parts specification FILE FILE CLAMP PROJECT PARTNUMB REFERENCE One number = one part One number = one number One part UNIT REFERENCE ER Electrical NCE REFERE DTR PARTNUMBER DTR00251135AEU COMMERCIAL PARTS FILE Core data MANUFACTURED Management datas Management datas Part Part number Description Part status Part number PARTS Description Part status PARTS ……. PARTS ……. Example Logistic support PART MASTER UTE C93422 STANDARDS data STANDARD ALSTOM SPECIFICATION Temperature Range: -55 ºC to +200 Connector Type: HE302 Coupling Type: Bayonet Case Encoding: N Case Protection: Black Anodized Tightness: IP66 Number of Contacts: 11 Nominal Current: 13 amps Nominal Voltage: 220 volt Contact Type: Male Box Type: Square Flange Type 10 TECHNICAL ATTRIBUTES ALSTOM DRAWING MATERIAL Technical characteristics PROTECTION FAMILY FILE

FILE 11 "LBS" breakdown Parts specification Parts PBS Core data Application Project LBS LBS / TrainTracer LCPC Code LRU code Zoning r Numbe Part Logistic support data Generic Version Code LBS LBS CODE 0401 0306 0305 0304 0303 0302 0301 0202 0201 0102 0101 LBS 04 03 02 01 DRIVER INTERFACE DYNAMIC BEHAVIOUR BOGIES & SUSPENSION

THERMAL & AUTONOMOUS TRACTION

FUNCTION

I------I------I------I------I------I------I------I------I------I------I------EXTERNAL SECURITY SYSTEM DIAGNOSTICS & RECORDING EQUIPMENT CAB COMMUNICATIONS ON-BOARD SIGNALLING DRIVER CONTROLS ACTIVE TILTING DEVICE BODY-BODY DAMPER MOTOR BOGIE TRAILER BOGIE DIESEL ENGINE DRIVER ENVIRONMENT GENERIC VERSION FOR VEHICLE MAINTENANCE LOGISTIC BREAKDOWN STRUCTURE (LBS)

"SYSTEM & EQUIPMENT" 12 TrainTracer & LCPC TrainTracer Parts specification Breakdown of the equipment Task parameters Node Module PRODUCTION format under neutral Description Core data control Data integrity LBS / TrainTracer LCPC Modules metadata Logistic support DATA MANAGEMENT Module unique number Task description data architecture management Data PUBLICATION / EXPORT Module name Material needed Skills required Publishing Tools needed S&E, LRU, or EC models Publishing Node n Neutral format Dig = ital paper medium modules Node n : related ..... servicing procedure parts list Assembly drawing iDrawings (details and ident.) iDrawings (sizes) Operation description ...... remove/install procedure Categories of modules

MDF Modules

MG Modules MP Modules MR Modules 13 Methodology Competence Centre Depot basic design LCC Logistic support engineering RCM analysis Manpower

plan 14 Logistic support products Documentation workshops Equipped Training Logistic support products C C C C F F F F o o o o e e e e D D D D n n n n e e e e e e e e d d d d d d d d p p p p ii i i t t b b t t b b o o o o ii i i a a a a o o o o t t t t c c c c n n

n n

Inventory E E E E k k k k & Stores s s s s

m m q q m m q q

y y y y & & & & u u u u s s s s o o o o

ii i t t i t t p p M M p p n n M M n n e e e e m m ii i m m i m m a a m m a a t t t t o o o o n n n n e e e e s s s s r r a a r r a a n n n n ii i i g g g g n n n n t t t t

e e

g g e e g g P P P P m m m m

a a a a t t t t o o o o e e c c e e c c o o k k n n o o k k n n t t ll l t t l

s s s s 15 Diagnosis, troubleshooting, repair Communication Documentation Communication Documentation Event attributes Diagnosis

Diagnosis 16 Return of experience FRACAS System Events Third Party Reporting Package Logging Defect LCC Package Third Party External Data Verification Defect Repairs Third Party Reliability Package Corrective

Action 17 Condition monitoring of equipment Vision Cracks

Vibration 18 Maintenance information system Documentation workshops Equipped Training Logistic support products Condition monitoring tool F F F F e e e e e e e e d d d d b b b b a a a a Special tools c c c c Inventory k k k k & Stores s s s s

y y y y & & & & s s s s

M M t t M M t t e e e e a a a a m m m m n n n n s s a a s s a a g g g g e e e e m m m m e e e e n n n n t t t t

s 19 "New build" and "Service" relationship SER contribution to projects PR Design Process Phase A DR PR PR PR DR PR GR Contribution to the gate reviews DR Design Process Phase B PR PR DR PR PR DR PR

GR 20 CONCLUSION To provide the most innovative, cost effective and common working practice throughout the company The maintainability approach to become the comprehensive quality service to the rail transportation industry around the world for Customer satisfaction. Our mission

Requires 21 22