FINAL TriMet/City of Portland Bureau of Transportation Technical Capacity and Capability Review of Oregon Iron Works August 17, 2010 by LTK Engineering Services Technical Capacity and Capability Review of Oregon Iron Works Table of Contents Executive Summary 1. Introduction and Background ................................................................................................3 1.1 Purpose.........................................................................................................................3 1.2 Review Team ................................................................................................................4 1.3 Methodology..................................................................................................................4 2. Company Overview...............................................................................................................5 2.1 History and Scale of Operations....................................................................................5 2.2 Facilities ........................................................................................................................5 2.3 Products ........................................................................................................................5 2.4 Organization and Subsidiaries ......................................................................................6 3. Physical Plant and Equipment ..............................................................................................8 3.1 Principal Features .........................................................................................................8 3.2 Ownership .....................................................................................................................8 3.3 Equipment and Comparison to Other Assembly Facilities ............................................9 3.4 Production Documentation..........................................................................................11 3.5 Maintenance of Equipment..........................................................................................11 3.6 Extent of Plant Capacity in Use...................................................................................11 3.7 Safety Record..............................................................................................................11 3.8 Availability of 750 Vdc .................................................................................................11 3.9 Availability of General Test Equipment .......................................................................12 3.10 Availability of Test Track .............................................................................................12 3.11 Summary.....................................................................................................................12 4. Organizational Structure for Streetcar Work ......................................................................13 4.1 General Division of Work.............................................................................................13 4.2 Major Suppliers and Location of Work ........................................................................13 5. Management Experience and Capabilities..........................................................................16 6. Design.................................................................................................................................17 6.1 Internal Capacity .........................................................................................................17 6.1.1 Mechanical Engineering ......................................................................................17 6.1.2 Electrical Engineering..........................................................................................18 6.1.3 Systems Integration.............................................................................................18 6.1.4 Tools....................................................................................................................19 6.2 Role of Elin..................................................................................................................19 6.3 Role of Third Parties....................................................................................................19 6.4 Summary.....................................................................................................................19 7. Manufacturing .....................................................................................................................20 7.1 Transit Specific Manufacturing Experience.................................................................20 7.2 Internal Capacity .........................................................................................................21 7.2.1 Production Engineering .......................................................................................25 7.2.2 Tooling and Fixtures............................................................................................25 7.2.3 Mechanical Fabrication and Assembly................................................................27 7.2.4 Painting ...............................................................................................................27 7.2.5 Equipment Installation and Wiring.......................................................................28 7.2.6 Outfitting and Finishing........................................................................................28 LTK TCC Final Page i August 17, 2010 7.2.7 Project Control.....................................................................................................29 7.3 Role of Elin in Manufacturing ......................................................................................29 7.4 Role of Other Third Party Suppliers ............................................................................30 8. Procurement........................................................................................................................31 8.1 Major Supplier Contracts.............................................................................................31 8.2 Procurement Tools......................................................................................................31 8.3 Summary.....................................................................................................................31 9. Quality Assurance/Quality Control ......................................................................................32 9.1 Staffing ........................................................................................................................32 9.2 QA/QC Plan.................................................................................................................32 9.3 First Article Inspections ...............................................................................................32 9.4 In-process Inspections ................................................................................................32 9.5 Car History Books .......................................................................................................33 10. Testing and Commissioning............................................................................................34 10.1 Master Test Plan .........................................................................................................34 10.1.1 Materials and Standards Tests............................................................................34 10.1.2 Proof-of-Design or Qualification Tests.................................................................35 10.1.3 Conformance Tests .............................................................................................35 10.1.4 Vehicle Acceptance Tests ...................................................................................35 10.1.5 Status ..................................................................................................................36 10.2 Procedures..................................................................................................................36 10.3 Testing/Commissioning Staffing Plan..........................................................................36 10.3.1 In-house Staff ......................................................................................................36 10.3.2 Role of Elin in Testing .........................................................................................36 10.3.3 Role of Other Parties...........................................................................................37 10.4 Internal/External Testing Facilities ..............................................................................37 11. Additional Considerations ...............................................................................................38 11.1 Scheduling Capabilities and Schedule Adherence......................................................38 11.2 Capacity to Manage Multiple Streetcar Projects Concurrently ....................................38 11.3 Ability to Recognize Problem Areas Early...................................................................38 11.4 Corporate Philosophy..................................................................................................39 12. Summary and Conclusions .............................................................................................40