cepm - railinc corporation

CEPM Comprehensive Equipment Performance Monitoring Project

AAR Component ID (CID) Development and Use

Agenda

CEPM Overview

Objectives, Benefits, Requirements

Bar Codes, CID

Registration, Association

Data Flow Summary

Key Documents, Standards, Rules, Timeline

Next Component – Reusable Framework

CEPM Project Systems and Data Flow Detail

Formats

User Interface Walk-Through

Registration/Retrieval, Association/Retrieval, Reports

© ASSOCIATION OF AMERICAN RAILROADS PAGE 2

What is the CEPM Project?

Comprehensive Equipment Performance Monitoring

=

CEPM

=

Component Tracking

=

Use of Component Barcodes and UMLER Expansion

(including mileage)


CEPM Task Force

CEPM Project Deliverables are being developed in

coordination with representatives from across the Industry;

• Equipment Owners

• Shops

• Repair Shops

• Manufacturers

• Railroads

• Software Providers

• Industry Committees

• TTCI


Implementation via AAR Circular Process

History of Industry Equipment Information

For over 50 years, industry tracking of owner reported

equipment characteristics was accomplished via the

legacy Umler System.

In 2009, Railinc, in coordination with the industry,

re-designed Umler to create a new platform that could

support increasing requirements for tracking and

communicating equipment level information.


CEPM - Extension of UMLER to expand Component Details

Expanding Equipment Information Details

The industry has taken another step in a multi-year program to

track more detailed information.

Manufacturer, Shop, and other critical reported details will

support safety, operations, planning, and performance

analysis.


Critical components, Dynamic/Wayside, Machine Vision

CEPM Component Tracking Objectives

• Support Recall of Components identified with safety

issues – EW/MA process

• E.g. Wheels, Castings, Brake Valves

• Support equipment owners with details of

components on their equipment

• Capability to track performance of components

related to component life, failure rates, and

history of the components.


Automation, Prioritization, Optimization

Efficient Recall is a major benefit

Railinc will maintain a central database of Component details

and the association of those components to equipment.

Combined with derailment history and component details and

history, safety and defect trends can be more quickly

identified.

Benefits

1. Reduce time between issue id and recall ↑Safety

2. Provide more targeted recalls ↓Cost

3. Design and Quality of components ↑Safety + ↓Cost


Performance Measurement is a major benefit

Performance Examples

Bearing OEM/Reconditioner

Bearing cage, backing ring, …

Wheel Heat/Batch

Wheelshop

Mileage

Future

Castings

Knuckles, Couplers

Side Frames, Bolsters, Truck Type

Braking System Components


Industry Requirements Set Forth

10

• Establish industry rules and standards for reporting component

details and application to equipment

• Develop a re-usable framework that can support the entire list

of priorities for tracking: wheelsets, castings, valves, PTC, GPS

devices, brakes, cushioning, traction motors, etc.

• Maintain Confidentiality of reported data dictated by possession

• Support Bar Code and RFID standards

• Automation, data integrity, inventory management

CID Definition

AAR Component ID (CID) – e.g. ABCD1234567890

Combination of:

#1) AAR Component ID Company Code - Code

assigned by AAR/Railinc which identifies the parent

company

#2) AAR Component ID Number - The number used in

union with the AAR Component ID Company Code for

the purpose of creating a unique identification of the

component or assembly. This number is generated

and assigned by the Parent Company in #1.

**CID is used as the KEY to store and retrieve all detail**


CID = Standard, Unique ID methodology for any and all components

CID Example

Parent Company = ABCD makes wheels and castings

ABCD Wheel Mfg = WWWW

ABCD Castings Mfg = CCCC

Parent Company = DEFG makes wheelsets and castings

DEFG Wheel Shop1 = WSWS

DEFG Wheel Shop2 = SSSS

DEFG Castings Mfg = KKKK


Wheel Casting

Serial Number 123456 A1A2A3

CID ABCD 0000000123 ABCD 9000000123

Wheelset1 Wheelset2 Casting

Serial Number K1K2K3

CID DEFG 0000000123 DEFG 0000000124 DEFG 000000125

Bar Codes, RFID primer

BarCode: 1D BarCode

ABCD1234567890 =

Used for AAR Component Identification, Little Data

BarCode: 2D BarCode or Bar Code Matrix

ABCD1234567890 =

Used for Carrying much data, with redundancy

RFID: Example: AEI

Used for Carrying much data, wireless/remote


Costs, Equipment/Reliability, Longevity – Wheelsets: Survive until application

Railcar Component Tracking


Priority #1 - Wheelsets

Wheelset Component Tracking


New Wheel Data (not all fields required in some cases)

AAR Facility Code

Design Code

Finger Gauge Reading

Stamped Month

Stamped year

Manufactured Timestamp

New or Turned

Nominal Diameter

Rim Thickness Side Scale Reading

Stamped Class

Stamped Mfg Code

Stamped Serial Number

Tape Size

…


Data Sent Via Bar Code to Wheelshop

Bar Code contains all required data

Some readable data is also printed on label

Turned Wheel Data

AAR Facility Code

Design Code

Finger Gauge Reading

Stamped Month

Stamped year


New or Turned

Nominal Diameter

Rim Thickness Side Scale Reading

Stamped Class

Stamped Mfg Code

Stamped Serial Number

Tape Size

…


Data Captured at Wheelshop



Bearing Data (New or Reconditioned)

Reconditioned Classification

AAR OEM/Recon Facility Code

Backing Ring Type

Cage Type

Grease Type

Seal Type

Certificate #

Cup Stamped Month

Cup Stamped year


New or Reconditioned

Nominal Diameter, Nominal Length

Cup Serial #

…





Axle Data (New, Converted)

AAR Condition Code


AAR Type

Body Design

Classification

Converter AAR Facility Code

Converter Timestamp


Nominal Diameter

Nominal Length

Plating

S# and Heat ID

…





Secondhand Axle Data

AAR Condition Code


AAR Type

Body Design

Classification

Converter AAR Facility Code

Converter Timestamp


Nominal Diameter

Nominal Length

Plating

S# and Heat ID

…


Data Generated at Wheelshop



Wheelset Registration Data

Bar Code

Component ID Company Code

Component ID Number

Wheelset Specific Data (Database)

Component AAR Facility Code

Component Assembly Timestamp

Compiled Wheel, Axle, and Bearing Data (Database)


Data Sent Electronically to Railinc (REGISTER)

Bar Code on wheelset contains ONLY the CID


Data Accessible via Web/UI using CID

Umler

Component

Register

3.

REGISTER

Component

Details

With

Railinc

CEPM-Wheelset Process Flow


Railroads

Car Owners

Shops

7. Confidential

Reporting

Note:

Only high level processes

displayed

Component

Repairs

5. Report Repair via CRB or EHMS

- ASSOCIATE

Wheel Shop

2. Assemble Components

And Tag Wheelset

4. Ship

Component

To Repair

Shop with

Tag

Repair Shop (incl RIP Tracks)

AAR Early

Warning

6. Update

Component

Status

Manufacturer

1. Mfg, Tag, & Ship Components

REGISTER ASSOCIATE

Key Contributions/Contributors for Success

Manufacturers –

Communicate Detail to Shops via 2D barcode

Wheel Shops –

Data Compilation and Entry to register wheelset details

Repair Shops –

Report wheelset application to equipment using 1D barcode

Railinc –

Data processing and Integration

Railroads –

Event reporting to accumulate mileage

TTCI –

Standards, Analysis


Key Benefits of CEPM

Manufacturers – Measure Quality and Fewer,Smaller Recalls

Shops – Inventory of Wheelsets (ability to determine performance)

Repair Shops – Comprehensive Maintenance Planning

Railinc – Increased Safety and Value for the industry

Railroads – Safety, Reduced Rail and Property Damage

TTCI – Strategic Research Initiative Support

Equipment Owners – Safety, Equipment and Component

Mileage for Planning, Component Details and History,

Improved Purchasing Decisions, Reduced Change outs,

Billing Validation, In-Kind Repair Quality, Home Shop

Maintenance Planning


Agenda Checkpoint

CEPM Overview


Bar Codes, CID


Data Flow Summary


Reusable Framework - Next Component


Formats

User Interface Walk-Throughs



Key Documents and Standards

NEW DOCUMENTS

1) AAR Component ID Wheelset Data Glossary

2) AAR Component ID Bar Code Specification

www.railinc.com/CEPM (with support docs)

www.railinc.com/reference (long term)

EXISTING STANDARDS

1) MSRP Section G, G-II, H, H-II (Existing)

2) Field Manual of the AAR (Addition of CID reporting)

Rule 44 – Wheelsets –CRB requirements

Rule 88 – Mechanical Requirements for Acceptance

• All Wheelset Installations/Repairs


http://www.railinc.com/CEPM

http://www.railinc.com/reference

CEPM Tentative Industry Timeline


-Registration of

Wheelsets

(Optional)

-Report

Component ID

via CRB

(Optional)

-Report

Component ID

via EHMS

(Optional)

-OEMs provide

required data to

Shops (Mandatory)

-Wheelset

Registration by

Wheel Shops

(Mandatory)

-Shops provided

informational

notice in CRB for

missing Wheelset

Component IDs in

Field 327-340 on

changes

-All Wheelset

changes must

be reported

with

Component ID

(Mandatory)

-CRB rejected

for missing

Component ID

AAR Component ID Wheelset Data Glossary

Spreadsheet Handout-

Technical Detail for What is Required for each component:

In Dataset, On Bar Code, Format


AAR Component ID Wheelset Data Glossary

Wheelset

Wheel 1 and 2

Bearing 1 and 2

Axle


CIRCULAR

Comments

AAR Component ID Bar Code Specification

Document Handout-

Physical Bar Code Requirements (Prior RP-021, MSRP L)


AAR Component ID Bar Code Specification


CIRCULAR Comments

2 1 3 4 5

6 7 8 9 10

Wheelset Wheel Axle Bearing

Development Model – Next Component

Reusable Framework

Data Definition Spreadsheet

AAR Rules/Standards Compliance, Additions

Railinc Involvement

Physical Barcode Specification – Added Sections

Vetting with Domain Experts/Vendors/Users

Implementation Schedule

Responsible AAR Committee Review(s)

CRB and Umler Modifications

Circular Process


Truck System


Agenda Checkpoint

CEPM Overview


Bar Codes, CID


Data Flow Summary



CEPM Project Systems

Data Flow Detail, Formats

Walk Throughs



Industry Systems affected

• Equipment Characteristics

• Store confidential component details and association to equipment

Umler

• Equipment Health

• Report Component TAG ID through EHMS

EHMS

• Repair Billing

• Submit application/repair details via CRB CRB

35

XML Format (Tagged: Extended Markup Language)

Wheel Blank Example:

Elements C101 to C118

(from spreadsheet)


<Wheel>

<C101></C101>

<C102></C102>

<C103>GRFI</C103 >

<C104>2/1/2011 18:55:12</C104 >

<C105>11</C105 >

<C106>01</C106 >

<C107>GK</C107 >

<C108>D</C108 >

<C109>22</C109 >

<C110>0</C110 >

<C111>1231</C111 >

<C112>1234abcd</C112 >

<C113>36</C113 >

<C114>CH</C114 >

<C115>CrvS</C115 >

<C116>241.25</C116 >

<C117>N</C117 >

<C118>AMST1234</C118>

</Wheel>

Encoded into Bar Code


Wheel Blank Example (Same thing):


<Wheel><C101></C101><C102></C102><C103>GRFI</C103 ><C104>2/1/2011

18:55:12</C104 ><C105>11</C105 ><C106>01</C106 ><C107>GK</C107 >

<C108>D</C108 ><C109>22</C109 ><C110>0</C110 ><C111>1231</C111 >

<C112>1234abcd</C112 <C113>36</C113 ><C114>CH</C114 ><C115>CrvS</C1

15> <C116>241.25</C116 ><C117>N</C117> <C118>AMST1234</C118></Wheel>

International Standard:

XML 1.0, 5th ed, 2008, Nov 26 –

http://www.w3.org/TR/2008/REC-xml-20081126/






Wheelset Registration Example:

Sample Elements: CID and C003(Wheelshop Facility Code-QA Code)




<r202:componentId>

<r202:companyCode>SHOP</r202:companyCode>

<r202:idNumber>1234567890</r202:idNumber>

</r202:componentId>

<r202:componentType>WHEELSET</r202:componentType>

<r202:elements>



<r202:element>

<r202:elementId>C003</r202:elementId>

<r202:elementValue>GRBT</r202:elementValue>

</r202:element>

Sent to Railinc to Register Wheelset prior to shipping

CRB Format

500 byte

New CRB process

McGinn - Pricemaster?


CEPM Systems – Data Entry

Umler

Equipment Registry – changes will include links

in the equipment record to the component details

Component Registry - new Component Registry

will provide access similar to the equipment

registry customers are familiar with

CRB/BRC/EHMS/LRB – UI changes to include

component Tag ID with repairs

Web Services – Integration for registering and

applying components to equipment

Batch/File Uploads (Historical Data, New Cars)


Car

ABT

Date, Performer

Wheelset

CID

WheelSerial # WheelShop Axle Type Bearing

Reconditioner

…

User Interface (UI) and Web Services and Legacy Uploads/Backfill

CEPM – Data Access & Integration

User Interface – Web Page

Retrieval Using CID, Car Mark/Number

Retrieval Using Detail – e.g. Wheel Stamped Serial #

Web Services – Computer Messaging / Requests using XML

Real time transactional integration will allow companies to

integrate information into their own systems to enhance the

processing of component information on equipment


Process Flow Chart Section

From Standpoint of:

OEM

WheelShop

Car Shop (Repair, Builders, …)

Car Owner


OEM / Reconditioner

*Additional Detail Required for Bearings, Wheels, and Axles

1) Capture Required Data (database)

2) Encode into 2D Bar Code Matrix and Print

3) Apply to Wheel, Bearing, or Axle and Ship

Future Option ?

1) Capture Required Data

2) Create CID for Wheel, Bearing, or Axle

3) Apply 1D CID Bar Code Label

4) Electronically Register component with RailInc and Ship

Note: Wheelshop would have to retrieve any necessary data from Railinc


Wheelshop - Registration

1) Track Wheelset through facility (using CID barcode?)

2) Capture Necessary Data

a) (from Barcodes or Manually)

b) Assemble Dataset for all subcomponents

c) Link with CID

3) Ensure CID Bar Code is applied to wheel plate

4) Register with Railinc and ship wheelset

a) UI for small quantities

b) Web Service Message (XML) for bulk


Car Shop - UI Association


Wheelset has AAR CID

YES

NO

Report Car Mark/Nbr,

Location on Car, CID via

EHMS, Umler, or CRB UI

Use Umler UI

to retrieve CID

using wheel S#

Car Shop - CRB Association



YES

NO

Report CRB 500 byte

format to Railinc with CID

in position 327-340 on

Wheelset line (Rule 44)

Use Umler UI

to retrieve CID

using wheel S#

CRB 500 Byte format:

Railinc is building a web service

that accepts the 500 byte

format and reconciles billing for

single car messages. July 2012

Car Shop - Batch Association



YES

NO

Report Car Mark/Nbr,

Location on Car, CID

in .csv file sent via FTP

Use Umler UI

to retrieve CID

using wheel S#

Car Shop Repair Sample Process

Web Service Data Retrieval

CRB or Web Service Association


Car Owner

CCH


Agenda Checkpoint

CEPM Overview


Bar Codes, CID


Data Flow Summary




Formats

Walk Throughs



Info & Walk-Throughs

1) Circulars – Mike Fore ([email protected])

2) Railinc – Ron Tsolis, Program Manager

1) [email protected] – Mailbox for anything CEPM

related

2) www.railinc.com/cepm

1) All current information for CEPM project

2) Current Project Documents

1) Bar Code Specification

2) Data Glossary Specification


mailto:[email protected]

http://www.railinc.com/cepm

Railinc Test Environment

wwwtst.railinc.com


Create

your own

SSO ID

Request Permissions in Test


Permission Request


Enter your 4 character

Company ID assigned by

Railinc

Railinc Launch Pad


Umler Home Page


Component Registry menu

- Add / Modify components

- Associate to Equipment

Register New Component


Add New Component


Company Code is assigned by

Railinc and is associated to

your SSO ID Component ID Number is

assigned & managed by Wheel

Shop

Component Type will be used

when adding future

components

Add Component Details


Existing Wheelset Data


Associate Component to Equipment


Position from B end

based off of Umler

record

Component ID in Umler


Managing Component Details


Need More Information

[email protected] -email

www.railinc.com/cepm - project website

You Survived the AAR Town Hall on the CEPM Project

Tuesday July 12th, 9am-4:30pm

Westin Hotel, Chicago (Rosemont) (see the project website for more details)




http://www.railinc.com/cepm

Questions?

Thank you for the opportunity to discuss this significant

project with the industry.
