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CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance...

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Rolling Stock Maintenance Fiscal Challenges for Rail Operators Gary Campbell CH2M HILL Boston, MA
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Page 1: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

Rolling Stock Maintenance Fiscal Challenges for Rail Operators

Gary Campbell

CH2M HILL

Boston, MA

Page 2: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

Copyright [insert date set by system] by [CH2M HILL entity] • Company Confidential

The Riding Public Expects Vehicles That Are:

On time

Warm in winter

Cool in summer

Available in sufficient numbers that minimize headways (Waiting)

Page 3: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Challenges to Keeping a State of Good Repair

Increasing average fleet age Increased competition for State and Fed funds Mandates for upgrades, both funded and unfunded

Page 4: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Who are the Stakeholders?

The Agency / Operator

– Management

– Labor

Funding Provider

– Fed, State and Local

Vendors / Suppliers

End Users

– Operations and Maintenance

– The Customer

Page 5: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Long-Term Maintenance Strategies

RCM – Reliability Centered Maintenance

System replacement programs (SSRP, SRS, SMS etc.)

Traditional Mid-Life Overhauls

Run to Failure

Page 6: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Approaches to Fleet Management

In-House Programs vs. Outsourced Efforts ­ Full Scale Program (all systems) ­ Selected Systems (scaled back to defined scope)

Resolution of Issues ­ Repair Existing in Kind ­ Develop, Test, and Procure new solutions or technologies

Page 7: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Areas of Focus

Safety

Obsolescence

Reliability

Economies of Scale Points

Materials Consolidation

Product Improvements

Amenities / Nice to Have’s

Page 8: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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What is Right for Your Organization?

What Matters Is:

–Understanding the benefits / limitations of the method chosen

–Taking the time to lay the foundation

–Commitment to the plan by all parties at all levels

Page 9: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Successful Implementation will result in

Establishment of Safe Minimum Levels of maintenance

Eventual reduction of labor costs

Increased asset reliability, availability and service life

Greater risk awareness for management and staff

Page 10: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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What this looks like

Page 11: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Maintenance Strategy Options

Scheduled Maintenance

General Overhaul (GOH)

Deferred Maintenance (D/M)

Page 12: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Scheduled Maintenance

Perform scheduled car inspections in conjunction with a component overhaul program at periodic cycles

Also called SSRP (MBTA) SMS (NYCT), SMP (BART), RCM (LIRR/MNR), etc.

Page 13: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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General Overhaul (GOH)

Perform scheduled car inspections in conjunction with a comprehensive overhaul at the midpoint of a car’s life

Also called mid-life overhaul

Page 14: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Deferred Maintenance (D/M)

Perform scheduled car inspections in conjunction with reactive campaigns

Also called ‘run-to-failure’

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Impact of Method Choice on Cost Per Car

PM

Costs

Corrective

Maintenance Spare

Total

Cost

(nom.)

Total Cost

(NPV)

SMS $946,932 $347,640 $55166 $1,349,738 $749,670

GOH $1,076,578 $488,948 $78,228 $1,643,754 $879,390

D/M 0 $2,118,796 $321,360 $2,440,156 $987,188

*(adjusted for inflation, Non FRA Required)

Page 16: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Goal of a Maintenance Program

Is to focus economic resources on equipment(s) that will cause the

greatest interruption to the operation should it fail

Key to Success:

Identify Preventable Failures

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Risks Associated with Equipment Failures

Recognize 3 Primary Risks from Equipment Failures.

Safety

Operations Environment

Budget

Environmental impacts are a subset risk of the Primary 3

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Advantages of a Long Term Maintenance Program

Funding spread over multiple FY budgets

React rapidly to undesirable failure modes

Potential for reduced labor costs

Minimizes impact to vehicle availability

Can and should reduce overall Life Cycle Costs

Maintain control and adjust for changes in the

operation

Page 19: CH2M HILL Boston, MA - American Public Transportation ... · PDF fileRolling Stock Maintenance ... RCM – Reliability Centered Maintenance System replacement programs (SSRP, SRS,

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Disadvantages of a Long Term Maintenance Program

1. Significant upfront costs for:

o Evaluating / Developing each component in the workscope

o Training

2. Savings not immediately seen by Senior Management

3. Commitment to an Ongoing Process by

Everyone, Everyday!

4. Plan must be flexible enough to be sustainable when unexpected changes in priorities, management and facility infrastructure occur

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Conclusion

1. Workscope and internal capabilities will shape method choices

2. If done well, lower maintenance costs, increased performance indicators and extended vehicle life can be expected

3. Commitment is Key!

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Discussion / Q&A


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