Knowledge requirementsfor rolling stock maintenance

TU Eindhoven – 19th of June 2007

by Bob Huisman

(b.huisman@nedtrain.nl)

NedTrain - Fleet Management

Strategic Development

Pagina 2

TU Eindhoven - 19th of June 2007

NedTrain is part of the NS Group

NedTrain provides

Rolling Stock Maintenance,

Cleaning and Overhauling

Pagina 3

TU Eindhoven - 19th of June 2007

Questions & Challenges

1. How to preserve knowledge and experience?

• Older people retire, but older systems (should) remain operational.

2. How to obtain knowledge about reliable complex technical systems?

• Configuration, condition, use, contracts, performance?

• What should be done and when? How?

• Better system performance means less diagnostic experience!

3. How to share knowledge in a highly flexible organisation?

• How to deal with different systems over time, at different locations?

4. How to exchange knowledge between companies across borders?

• Many companies are involved in the life time of a technical system.

• How to communicate between different local (national) cultures?

Pagina 4

TU Eindhoven - 19th of June 2007

Double goal:effectiveness and efficiency

Pagina 5

TU Eindhoven - 19th of June 2007

Goal 1: to maintain system functionality (effectiveness)

100% 100% 100%

Time

Yesterday Today Tomorrow?

How do functions evolute? When is a functional failure to be expected?

What maintenance is required?When?

Pagina 6

TU Eindhoven - 19th of June 2007

Goal 2: to minimize means of production (efficiency)

100% 100%

100% 100%

Fleet availability

Use of maintenancemeans of production

Past

Past

Future

Future

Pagina 7

TU Eindhoven - 19th of June 2007

Effective maintenance:derive required maintenance

from technical conditionof individual systems

by intelligent reasoning

Pagina 8

TU Eindhoven - 19th of June 2007

Component

Function

Use

How to predict degradation and failure?

100%

Time

New

Time

Functionality

Dimension, quantity

-

Time

Cycles, energy

Now

influences technical condition

enables/disables function

Extrapolation

Cause-effect analysis

Wear and tear modelling

Pagina 9

TU Eindhoven - 19th of June 2007

Component 1 Component 2 Component 3 Component 4

Function A Function B Function C Function D

Usage Incidents Environment Maintenance

Technical system

Complex interaction between use, components and functions

Pagina 10

TU Eindhoven - 19th of June 2007

Computer system

Predictive model(not perfect)

Predictive model(not perfect)

Mimic model(not perfect)Mimic model(not perfect)

Technical systemTechnical systemTechnical system

Mimic model(not perfect)

Maintainer

Observer andinterpretator

Jobs

Technical status

Derive required maintenance continuously during operation

Measurement

Synchronisation

Predictive model(not perfect)

Expected status

Required Maintenance

Required Maintenance

Maintenanceplan

Maintenance rules and job descriptions

Knowledge

Configuration

Design,Requirements,Environment,

Use

Configuration

Expected use

Pagina 11

TU Eindhoven - 19th of June 2007

Efficient maintenance:derive maintenance schedulefrom required maintenance

and availability of means of productionby intelligent reasoning and negotiation

Pagina 12

TU Eindhoven - 19th of June 2007

ManufacturingSupplier

Supplier

Supplier

Backwards scheduling

(Pull)

Delivery dateQuantity

DesignQualityPrice

Order

Production & Delivery orders

Scheduling manufacturing orders

New products

Pagina 13

TU Eindhoven - 19th of June 2007

Maintenanceproduction

Supplier

Supplier

Maintenance plan

ThroughputQualityPrice

Contract

Scheduling

(Push)

km-counter

Local scheduling

Technical condition

Production order

Traditional rolling stock maintenance scheduling

Maintained products

Arrival & Inspection orders

Pagina 14

TU Eindhoven - 19th of June 2007

Technical condition

Required maintenance

Maintenance schedule

Maintenance planTransport operations

Required staff,shop and stock

Availability of staff, shop and stock

Future maintenance scheduling

Pagina 15

TU Eindhoven - 19th of June 2007

Maintenanceproduction

Supplier

Supplier

Backwards scheduling

(Pull)

Technical condition

Production & Delivery orders

Generatemaintenance

required

Maintenance plan

ThroughputQualityPrice

Contract

Request

Rolling stock condition based maintenance scheduling

Maintained products

Pagina 16

TU Eindhoven - 19th of June 2007

DepotTrainTrain

Agent(depot )

Agent(train )Agent(train )

Train

Intelligent agent(train )

DepotOperator

Intelligent agent(operator )

Intelligent agent(depot )

Configuration Maintenance rules

Time table Status Availability

Work ordersTransport orders

Co-ordination Negotiation

Maintenance scheduling by a Multi Agent System (Society)

Pagina 17

TU Eindhoven - 19th of June 2007

Where do we need knowledge of operation?

Tactical(Maintenance Plans,Means of Production,

Organisation)

Operational(Maintenance

Planning and Control)

Depot / Workshop(Performing

Maintenance)

Technical Condition of Rolling Stock

Diagnostic Data

Operation Data

Inspection and Maintenance Orders

Maintenance Plans

Performance Requirements

Performance of Rolling Stock and Maintenance Results

Fleet Performance

Trains

Strategic(Rolling Stock,

Locations,Contracts)

Trains

Railway Operators

Government, Authorities

Infrastructure Managers

Traffic Control

Rolling Stock Manufactures

Pagina 18

TU Eindhoven - 19th of June 2007

Thanks for Your Attention!

Any questions?

Pagina 19

TU Eindhoven - 19th of June 2007

Train

Coach CoachCoach

Boogie Boogie

MotorWheel set Wheel set

Consists of Is part

of

Subsystem

Component tree

Pagina 20

TU Eindhoven - 19th of June 2007

To transportpassengers

To drive

To offer comfort

To remainon track

To accelerate

To offer seats

To control climate

To decelerate

Function tree

To inform

Requires

Pagina 21

TU Eindhoven - 19th of June 2007

To transportpassengers

To drive

To remainon track

To accelerate

Train

Boogie

Wheel set Motor

Energy supply

Relations between functions and components

Pagina 22

TU Eindhoven - 19th of June 2007

Triple valve leaks,caused by dirt

Air pressure drops, coach does not brake,causing lower train deceleration

Train at 140 km/h doesnot stop within 1000m

Failure does effect safety directly

Frequent test of brake system

Enable train driver to brake and to stopFunction

Root failure

Failure effect

Functional failure

Business consequence

Maintenance

RCM (Reliability-Centred Maintenance) analysis

Pagina 23

TU Eindhoven - 19th of June 2007

Function

Functional failure

Failure effect

Root failure

Functional failure

Failure effect

Failure effect

Failure effect

Root failure

Function

Functional failure

Failure effect

Root failure

Functional failure

Failure effect

Root failure

Complex cause-effect relations

Pagina 24

TU Eindhoven - 19th of June 2007

Design ofTechnical system

Maintenanceengineering

Maintenance

Maintenanceplan

Technical systemTechnical system

Technical system

Construction

Requirements,Environment,

Use

Real life

Expected conditionsand use

Phase 1

Phase 2

Phase 3

System design, maintenance engineering and operation

Pagina 25

TU Eindhoven - 19th of June 2007

Implementation model

Demarcation graduation

XML-interface

Health & Usage

Monitoring System

Product Engineering

Configuration management

&Product lifecycle

management

Maintenance Recommendation

System

Knowledge base

& Maintenance engineering

Maintenance execution

Configuration&

Documentation

Maintenance concept

Maintenance recommendation

External measurements

Internal measurements

Inspection

Entrance material from carrier

Means of production

Actual &Historical

Actual configuration

External

External

External

External

External

Initial maintenance concept

Prescriptions & documentationMaintenance

Maintenance results &Scheduling information

Functional changes

Generic configuration

Pagina 26

TU Eindhoven - 19th of June 2007

Ontologies en RDFOntologies en RDF