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Transport Service

THE MAINTAINABILITY APPROACH

AT ALSTOM TRANSPORT

Yves DURANDTechnical Director

November 2001November 2001

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• INTRODUCTION

– Maintainability approached with pragmatism for measurable performances

– How to build maintainability ?• Why the selected approach ?• Contents of the development programme• Changes in the new build projects objectives

Transport Service

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A new logic emergesA new logic emerges

Operators SuppliersSuppliers

DESIGN MANUFACTURE MARKET FINANCE OPERATE MAINTAIN

Suppliers OperatorsNew Players Suppliers

Suppliers Operators Suppliers

Transport Service

Market dynamicsTraditionnellementTraditionnellement

OperatorsSuppliers

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Cross Country Trains

Cross Country Trains

West Coast TrainsWest Coast Trains

Railpart Railpart

Railcare Railcare

Serco Metrolink(Manchester) Tramlink (Croydon) Stagecoach Supertram (Sheffield) Blackpool Transport Services

Serco Metrolink(Manchester) Tramlink (Croydon) Stagecoach Supertram (Sheffield) Blackpool Transport Services

Travel West MidlandsDocklands Light RailwayNottingham Express TransitBirmingham

Travel West MidlandsDocklands Light RailwayNottingham Express TransitBirmingham

Light RailLight Rail

English, Welsh & Scottish

Freightliner

Direct Rail Service

English, Welsh & Scottish

Freightliner

Direct Rail Service

Freight Owners

/Operators

Freight Owners

/Operators

Chiltern RailwaysChiltern Railways

ScotrailScotrail

Thames Trains

Thames Trains

Connex South Eastern

Connex South Eastern

First North Western

First Great Western

First North Western

First Great Western

Merseyrail ElectricsNorthern Spirit

Merseyrail ElectricsNorthern Spirit

Cardiff Railway Company

Wales & West

LTS Rail

Cardiff Railway Company

Wales & West

LTS Rail

Anglia Railways

Anglia Railways

First Great Eastern

First Great Eastern

West Anglia Great Northern

West Anglia Great Northern

Great North Eastern Railway

Great North Eastern Railway

Gatwick Express

Gatwick Express

ScotrailSilverlink

ScotrailSilverlink

Midland Mainline

Midland Mainline

Central TrainsCentral Trains

Island LineIsland Line

Midland MainlineMidland Mainline

Connex South Central

Connex South Central

Thameslink RailThameslink Rail

South West

Trains

South West

Trains

British

Rail

British

Rail

Who are our customers ?

UK 1990UK

2001

FreightMetros

Light Rail Sea Containers

Sea Containers

National

Express

National

Express

GB RailwaysGB Railways

M40 TrainsM40 Trains

Go-AheadGo-Ahead

FirstGroupFirstGroup

MTL RailMTL Rail

Prism RailPrism Rail

Connex RailConnex Rail

GOVIAGOVIA

StagecoachStagecoach

ARRIVAMendip Rail

Renaissance Rail

ARRIVAMendip Rail

Renaissance Rail

VirginVirgin

London Underground

London Underground

Glasgow

Underground

Glasgow

Underground

EurostarEurostar

HSBC

AbbeyNational

Angel

Rolling Stock OwnersOperator Owners

Operators

Where customers put a new focus on their core competencies,new opportunities have arisen

Transport Service

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Standard product lines

Coradia Prima

X’trapolisMetropolis Citadis

TGV

Urban & Suburban Trains

Main Line & High Speed Trains Locomotives

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€ 1.9 billion

93/94

Rolling Stock82%

Signaling14%

Services4%

€ 3.5 billion

98/99

Rolling Stock61% Signaling

16%

Services23%

€ 5 billion

02/03

Rolling Stock50%

Signaling20%

Services30%

Transport Service

Service market share is increasingService market share is increasing

7Services for the complete life cycle

>30 yearsALSTOM or non-ALSTOM

MANUFACTURE MARKETDESIGN

ALSTOMNew Products

CommissioningWarranty

FINANCE OPERATE MAINTAIN

MaintenanceTransit - Freight - Equipment - Track

RenovationTransit - Freight - Equipment - Track

Parts and Replacement Units

Transport Service

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Transport Service

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Bringing innovative

solutions through R&D

Bringing innovative

solutions through R&D

9R&D addresses the complete life cycle

Design & Build Operate & Maintain LCPC

Renovations

FRACAS

TrainTracer/CLAMP

e-Maintenance

Condition Monitoring Relia

bility Centre

d Maintenance

Corrective Maintenance

Corrective Maintenance

Preventive Maintenance

Preventive Maintenance

Predictive Maintenance

Predictive Maintenance

Transport Service

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The programme architecture

Parts specification Logistic supportdata

Customercontract

Internalagreement

Contracts

LCPC data& calculations

RCManalysis

Depot basicdesign

Manpower planProcurement plan

Documentation Inventory& stores

Equippedworkshops

Depot equipment packCondition monitoring tools

Training Feedback & managementsystems

Logistic supportproducts

Logistic supportengineering

Core data

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Parts specification & identification

Parts specificationCLAMP

Logistic supportdata

Core data

Electrical Part Example

CUSTOMERSNCF : 10-5171302

DTR PARTNUMBERDTR00251135AEU

TECHNICAL ATTRIBUTESBox Type: Square Flange Type 10Contact Type: MaleNominal Voltage: 220 voltNominal Current: 13 ampsNumber of Contacts: 11Tightness: IP66Case Protection: Black AnodizedCase Encoding: NCoupling Type: BayonetConnector Type: HE302Temperature Range: -55 ºC to +200 ºC

GEOMETRY

SUPPLIERSFramatome: 8525-10R-18B11-PNHLDeutsch: FDBA 50-18.11-PNK

STANDARDSUTE C93422

ALSTOM SPECIFICATIONCUSTOMER SPECIFICATION

COMMERCIAL PARTS

PARTSPart numberDescription

Management datasPart status

…….

PARTSPart numberDescription

Management datasPart status

…….

SUPPLIER/MANUFACTURER

REFERENCE

CUSTOMER

MANUFACTURED PARTS

PROTECTION

STANDARD

ALSTOM DRAWING

MATERIAL

UNIT

REFERENCEREFERENCE

UNIT PARTNUMB

ER

PROJECT

PART MASTER

FAMILYTechnical characteristics

FILE

FILE

FILE

FILE

FILE

FILEOne part = one number

One number = one part

One part = one number

One number = one part

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"LBS" breakdown

Parts specification Logistic supportdata

LBS / TrainTracer / LCPC

Core data

PBS

Parts

LBSGeneri

cVersionLBS Code

LBSProject

Application

Part Number

LRU Code

Zoningcode

LBS FUNCTION

CODE

01

0101 I-----------

0102 I-----------

02

0201 I-----------

0202 I-----------

03

0301 I-----------

0302 I-----------

0303 I-----------

0304 I-----------

0305 I-----------

0306 I-----------

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0401 I-----------

TRAILER BOGIE

DRIVER INTERFACE

DRIVER CONTROLS

ON-BOARD SIGNALLING

CAB COMMUNICATIONS

DIAGNOSTICS & RECORDING EQUIPMENT

EXTERNAL SECURITY SYSTEM

BODY-BODY DAMPER

ACTIVE TILTING DEVICE

MOTOR BOGIE

DYNAMIC BEHAVIOUR

BOGIES & SUSPENSION

"SYSTEM & EQUIPMENT"

LOGISTIC BREAKDOWN STRUCTURE (LBS)GENERIC VERSION FOR VEHICLE MAINTENANCE

DRIVER ENVIRONMENT

THERMAL & AUTONOMOUS TRACTION

DIESEL ENGINE

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TrainTracer & LCPC

Parts specification Logistic supportdata

LBS / TrainTracer / LCPC

Core data

PRODUCTION DATA MANAGEMENT PUBLICATION / EXPORT

Descriptionunder neutralformat

Datamanagementarchitecture

Publishingmodels

paper

Digital medium

Neutral format

Publishing

Data integritycontrol

S&E, LRU, or EC=

Node n

Operation description

iDrawings (sizes) .....iDrawings (details and ident.)

Assembly drawing

parts list

servicing procedureremove/install procedure

............

Categories of modules

MDF Modules

MG Modules

MR Modules

MP Modules

Node n : relatedmodules

Modules metadata

Breakdown of the equipmentNode

Module

Module name

Module unique number

Task description

Tools needed

Material needed

Skills required

Task parameters

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Methodology

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Documentation Inventory& Stores

Equippedworkshops

Depot Equipment PackCondition monitoring tools

Training Feedback & Managementsystems

Logistic supportproducts

Logistic support products

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Diagnosis, troubleshooting, repair

CommunicationCommunication

DocumentationDocumentation

DiagnosisDiagnosis

Event attributes

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Return of experience

FRACAS System

EventsDefect

LoggingDefect

VerificationRepairs

Third Party Reporting Package

Third Party Reliability Package

Third Party LCC Package

External Data

Corrective Action

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Condition monitoring of equipment

VisionVision CracksCracks VibrationVibration

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Maintenance information system

Documentation Inventory& Stores

Equippedworkshops

Special toolsCondition monitoring tools

Training Feedback & Managementsystems

Logistic supportproducts

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"New build" and "Service" relationship

Design Process Phase A Design Process Phase B

GR DRDR DR DR DR

PR PR PR PR PR PR

GR

PR PR PR PR

SER contribution to projectsSER contribution to projects Contribution to the gate reviewsContribution to the gate reviews

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CONCLUSION

The maintainability approach to become the common working practice throughout the

company

The maintainability approach to become the common working practice throughout the

company

To provide the most innovative, cost effective and comprehensive quality

service to the rail transportation industry around the world

To provide the most innovative, cost effective and comprehensive quality

service to the rail transportation industry around the world

Our mission

Our mission

RequiresRequires

for Customer satisfaction.for Customer satisfaction.

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