gibela maintenance strategies - 2016

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MAINTENANCE STRATEGIES TO MINIMISE THE IMPACT ON SERVICE DISRUPTION AND SECURE AVAILABILITY

Stéphane Guy, Maintenance Director | Africa Rail | Sandton | 28 June 2016

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AGENDA

1. Introduction

• our mandate

• our structure

• SA footprint

• project timeline

• economic development

2. Minimising service disruption and securing availability

• design for serviceability

• make it local

• commit to parts availability

• invest in people

• set up performance-driven, long- term partnership

3. Conclusion

28 June 2016Africa Rail, Sandton 2

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OUR MANDATE

Our mandate has three parts:

Africa Rail, Sandton 3

Foster rail as preferred mode of commuter transport for all South Africans

Build new, reliable, safe trains for SA’s 2.3 million daily rail commuters

Revitalise SA railway industry

Support customer with maintenance operations for 19 years

Build manufacturing/parts/maintenance/ training facilities

Create jobs

Develop skills

Achieve > 65% local content

Promote black economic empowerment

Support communities

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1

3

28 June 2016

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OUR STRUCTURE

• Structured to drive development and growth of BEE companies operating in the rail sector

• 61% Alstom Southern Africa Holdings

• 9% New Africa Rail: black-owned rail/infrastructure conglomerate

• 30% Ubumbano Rail: 100% black-owned


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SA FOOTPRINT

1 LOCAL FACTORY(Dunnottar, Gauteng)Gibela site for:

• manufacturing facility• training centre

1 CENTRAL SERVICE FACILITY(Gauteng)Gibela site for:

• logistic platform• technical support centre; 24/7 hotline• repair, overhaul• central technical support

2 REPAIR CENTRES(Cape Town, Durban)Gibela site for:

• local repairs, overhauls• local warehouse

5 MAINTENANCE DEPOTS• Braamfontein, Gauteng: 202 trains• Salt River: 197 trains• Wolmerton, Gauteng: 62 trains• Durban: 101 trains• Port Elizabeth or East London: 38 trainsPrasa sites for:

• 24/7 fault-finding support• reliability engineering• controls, monitoring• materials requirement planning


1,400km2.5 days

900km1.5 days

600km1 day

900km1.5 days

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PROJECT TIMELINE

6

Design engineering

Production in Brazil

28 April 2014 Contract effective

September 2014

September 2015 First train shipped

November 2015 First train arrives in SA

Commissioning

First train in revenue serviceOctober 2016

Factory and Supplier Park construction

Maintenance support and material supply services 2035

Africa Rail, Sandton 28 June 2016

Maintenance project mobilisation

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ECONOMIC DEVELOPMENT

Refers to all initiatives and activities that result in:


Jobs, skills development• 1 500 direct jobs within Gibela• supply chain: 1000s of direct, indirect jobs• skills development: R700m budgeted• 19 000 skilled workers required over project life

Preferential procurement• ~ R30bn: black-empowered entities• ~ R5bn: qualifying SMMEs• ~ R1.5bn: black women-owned entities

Local content• develop robust, sustainable local supplier base• >65% local content • leverage Gibela expertise to equip emerging rail

enterprises with capabilities to be competitive

Enterprise development• ~ R700 million for development of

rail sector enterprises

Socio-economic development • ~ R300 million for community development

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MINIMISING SERVICE DISRUPTION AND SECURING AVAILABILITY


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WHAT IS PREVENTIVE MAINTENANCE?

Imagine you had a car… When would you refuel?


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WHAT IS PREVENTIVE MAINTENANCE? cont’d


Type of maintenance

CORRECTIVE SYSTEMATIC CONDITION-BASED PREDICTIVE

Preventive

When it fails Every day Upon low fuelindication

Upon a measurement (gauge) and a prognostic

Number of refills Fewest Many Few Minimal and planned

Car availability Lowest Medium High High

Breakdown risk 100%Low

(if no change in usage) LowLowest

(if accurate algorithms)

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MAINTENANCE IN BRIEF: categories of maintenance


Corrective

Diagnostic

Palliative Curative

Temporary repair:-provisional intervention allowing to allowing service completion

MAINTENANCE

Preventative

Complete repair: - restoring to original condition according to specification

Suffer failures (drive to failure)

SystematicOn-condition

Avoid failures

Task performed just-in-timescheduled or continuous monitoring of train or components condition.Ad’hoc scheduled intervention

Predictive

Data accumulation and analysis allow to adjust programming of maintenance tasks, or even avoid failures

Tasks performed in accordance with predefined schedule (time or km), organised at train level or per components (estimated lifetime or potential of component)

Don’t understand these

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PERFORMANCE DECREASE CIRCLE


Higher pressure on available rolling stock from operator

Preventive operations get delayed

Fleet reliability drops

Weight of unscheduled visits increases

Fleet regularity decreases

More corrective operations

Spares not available on time

Decrease of fleet availabilityImmobilisation of fleet increases

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DESIGN FOR SERVICEABILITY: life-cycle approach

• Design trains that are:

• safe, reliable, available

• easy to clean, maintain, operate

• cost-effective to maintain, operate

• supported by:

• solid documentation

• necessary spare parts

• tools

• backed by efficient supply chain

• compliant with environmental regulations

• supported on obsolescence issues


Cascade serviceability requirement to all suppliers

Maintenance plan, life-cycle cost commitment

Reliability commitment

Testability, maintainability

Maintenance safety requirements

Maintenance documentation

Spare parts, tools

Training

Obsolescence management

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• Maintenance using 3D modelling

• accessibility of equipment

• inspection condition

• ease of dismantling

• ease of component replacement

• replacement of sub-assembly or component

• use of standard tools

• handling conditions

• operating time

DESIGN FOR SERVICEABILITY: design verification


Brakecaliper

High voltage box HSCB accessibility

Operatorview

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• Data capture, real-time transmission

• Assess, monitor, analyse data

• Health status, diagnostics

• Condition monitoring

• Prognosis

• Real-time remote fault investigation

• Schedule corrective action

• Preventive maintenance (condition-based)

• Round-the-clock health status, reliability measurement

• Anticipated maintenance

• Reduced downtime

• More effective maintenance

• Less repeat failures

SERVICEABILITY BY DESIGN: condition monitoring (TrainTracer™)

• TrainTracer™: train-borne system to maximise train availability by optimising maintenance operation


ASSESSMENT TAKING ACTION OUTCOMES

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DESIGN FOR SERVICEABILITY: condition monitoring for infrastructure

• Optional train-borne capabilities to monitor infrastructure during commercial service

• overhead-line dynamic monitoring

• camera-based data capture

• wire and overhead line condition

• data processing, image analysis

• track dynamic monitoring

• beam mounted 3D cameras, sensors

• track geometry, condition


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MAKE IT LOCAL


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Gearbox

Doors

Air conditioning

Traction

Motor winding

Pantograph

Interior\lighting

Auxiliary converterBatteries

CCTV

Interior/panels

Suspension

MAKE IT LOCAL: manufacture, repair

• Local manufacture supported by network of service, repair centres

• Integration facility at Dunnottar

• Supplier park for component manufacture

• Main component repair, overhaul facility in Gauteng

• Two regional repair centres in Durban, Cape Town

• Highest design quality, international standards


WheelsetsWheel bearing

brake systemBrake pads

Passenger information system

Motor

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MAKE IT LOCAL: supplier development

• Develop local supplier network

• Support materials, components, services

• 69% local content by year two

• Development programmes ongoing

• existing local suppliers in rail or other industries

• emerging suppliers, new local entrepreneurs

• large international railway suppliers committed to localise

• Local materials, components supplied for first train

• Potential to supply industry with ‘high-spec’ products of international standard

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MAKE IT LOCAL: skills development

• High training commitment (+19 000)

• Development focused on scarce skills

• Skills development to address entire train life cycle

• Attract young people to railway industry

• provide real opportunities

• Skills reserve to benefit other manufacturing industries

• In-house training centre to support communities

• improve employment prospects for unemployed people with limited skills

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COMMIT TO PARTS AVAILABILITY


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COMMIT TO PARTS AVAILABILITY

Supply chain at the core of maintenance efficiency


Maintenance quality Vehicle reliability Maintenance costs Vehicle availability

• Spares supply

• Repairs

• Overhauls

• Parts quality

• Repair quality

• OEM warranty

• OEM suppliers

• Parts kit

• Optimised stock levels

• Availability service

• Reduced lead-time

• On-time delivery

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COMMIT TO PARTS AVAILABILITY cont’d

Localised service centres with necessary skills for repairs, overhauls


Cape TownService centre• Warehousing• Local repairs• Minor overhauls

Durban Service centre• Warehousing• Local repairs• Minor overhauls

Gauteng Central services• Logistics platform• Technical centre• 24/7 hotline• Repairs, overhauls,• Training centre

1,400km2.5 days

900km1.5 days

600km1 day

900km1.5 days

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Deliver: • efficient systems• data tracking enhancement• advanced planning tools

Benefits: • no train disruptions because of

spares shortages• reliability guaranteed• no inventory costs• reduced supply chain costs• less risk

Commitments: • immediate availability • reliability• delivery closest to maintenance • fixed price per km over 19 years• maintenance parts, consumables• repairable components• component overhaul• demand planning, forecasting• managing obsolescence• 70% localisation • support for accident/vandalism

Adjust to:• supplier capacity• repair centres, distribution

capacity• maintenance plan

Get it right: • sourcing suppliers• industrial strategy• distribution network

COMMIT TO PARTS AVAILABILITY cont’d


Information systems and technologies

Maintenance efficiency

Lead time, availability guaranteed

Supply chain

strategy

Operations planning

5

Efficient:• warehousing• material requirement planning

management• logistics • transportation

Execution

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INVEST IN PEOPLE


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• Knowledge-sharing• support services to increase operation efficiency, train availability• integrated on-the-job training: use of simulators• obsolescence management: entire life cycle• shared best practice, tools, processes• manufacturer's expertise• product post-design services, to customer needs, throughout

• Continued technical support• training• documentation• obsolescence• expert support• reliability growth• help desk• accident/vandalism

INVEST IN PEOPLE


Documentation

Condition monitoring

Helpdesk 24/7Accident/vandalism Reliability growthExpert support

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INVEST IN PEOPLE, cont’d

• Sustainable training

• training services, over 19 years, based on modern support technologies

• train driver

• train maintenance

• fleet familiarisation

• expert training

• new starter training

• on-going training

• TrainTracer™ system

• maintenance information system

• combined classroom, on-the-job training

• supported by Gibela training centre


Training course Web e-learning

Virtual reality 3D

On-the-job coaching Training on real equipment

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SET UP PERFORMANCE-DRIVEN:LONG-TERM PARTNERSHIP


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SET UP PERFORMANCE-DRIVEN, LONG-TERM PARTNERSHIP

• Agree and share common targets

• prioritise train availability

• focus on passenger service

• developing common strategy

• Drive operational set-up towards performance

• upgrade maintenance depots

• customise facilities to deliver productivity

• adapt organisation, interfaces

• continuous improvement

• Adapt to change

• deliver customer requirement

• meet continuous, growing demand

2928 June 2016Africa Rail, Sandton

Wheel profile

Brake pads

Carbon strips

Train integrity

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SET UP PERFORMANCE-DRIVEN, LONG-TERM PARTNERSHIP cont’d


Share the vision:common/shared

objectives

Deliver operational performance:

priority to passenger service

Define robust interfaces, clear

processes

Anticipate, manage co-activity

Anticipate, support change

Build solid partnership, joint team approach,

work as ONE

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CONCLUSION: reducing maintenance down-time


Design for serviceability

Make it local

Commit to parts availabilityInvest in people

Set up performance-

driven, long- term partnership

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CONTACT DETAILS

Pam RadebeCommunications Director+27 (0)11 518 8235 (tel: reception)+27 (0)11 518 8210 (fax)+27 (0) 83 277 8766 (mobile)[email protected] (email)


© GIBELA 2014. All rights reserved. Information contained in thisdocument is indicative only. No representation or warranty is given orshould be relied on that it is complete or correct or will apply to anyparticular project. This will depend on the technical and commercialcircumstances. It is provided without liability and is subject to changewithout notice. Reproduction, use or disclosure to third parties, withoutexpress written authority, is strictly prohibited.

gibela maintenance strategies - 2016

Engineering