© Hitachi Rail Europe Ltd. All rights reserved.
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
• Adversarial approach to Project Management on all sides • Very prescriptive contractual requirements and punitive LD regime • Suppliers build contingency for penalties into their pricing • Led to a reliance on Variations and Lawyers • Customers sometimes forced to accept trains with many problems • Bad project performance, late deliveries, non-compliance, trains sat in
sidings awaiting approvals. • Many projects ended in legal challenges, litigation • Closing of open issues takes a long time • Operational performance of trains inadequate, non compliant, unreliable. • Unhappy customers
UK Rail projects – historical performance
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
Project Aims
• High Speed Commuter Service into London • Regenerate South East corner of UK • Link South East to North London & Docklands • Maximise use of High Speed 1 Route • Release capacity on Local Rail Lines • Increase capacity for London Olympic Games 2012 • Benchmark Reliability in UK
Hitachi Aims • Deliver what we promise
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
High Speed 1 route and domestic network
Hitachi Maintenance
Depot
Delivering High Speed Commuter Trains into the UK
© Hitachi Rail Europe Ltd. All rights reserved.
Project Challenges - Technical
• First Japanese design to UK/EU standards and High Speed TSI • Complex train design
HS TSI Crashworthiness standards 225 kph operation on HS1 – French Network Dual voltage (25KV OHLE, and 750 VDC 3rd rail) 4 Signalling systems French TVM/KVB and UK TPWS/AWS Safety approvals required for NR AC, DC and Eu HS1 AC In cab Driver Only Operation using bodyside cameras 2 Infrastructures – High speed and local tracks Bogie design optimised to minimise track wear on Classic routes
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
• Complex train interface Rescue existing trains on both Networks Operate as 6 & 12 car and Split / Join en route. On Board Seat Reservation System Journey times necessitated high installed power (4Mw) Challenging Tunnel Fire standards
• Train operator not chosen at contract award • Integrate Maintenance into Design • Deliver on time and to budget • Deliver 55,000 MDBF reliability – performance contract
Project Challenges - Operation
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
Project Challenges - Design
DPTS1 Standard Seating Priority Seating Tip-Up Seating Total Seating
Wheelchair Accessible Toilet Wheelchair Area
24 4
13 41
1 2
MS1 Standard Seating Priority Seating Total Seating
60 8
68
MS2 Standard Seating Priority Seating Total Seating
Guard Panel
60 8
68
2
MS3 Standard Seating Priority Seating Total Seating
60 8
68
MS4 Standard Seating Priority Seating Total Seating
60 8
68
DPTS2 Standard Seating Priority Seating Total Seating
Standard Toilet
42 6
48
1
Delivering High Speed Commuter Trains into the UK
© Hitachi Rail Europe Ltd. All rights reserved.
Hitachi (Manufacturer)
Safety & Approvals Manager
Independent Safety Assessor
(AEA Technology Rail)
3 rd Party Neighbours
Network Rail
CTRL
(Supervisory Authority)
HSBC (Owner)
Vehicle Owner and NoBo Contracting Entity
IKF/SRA (Operator)
Service & Test TOC
3
HSE (
(
Interfleet Certification
Independent Competent
Review Body
Notified Body / Engineering
Conformance Review
LR Rail
RAM Analysis Safety Case
Software Assurance
Vehicle Acceptance Body
Interfleet Technology
Project Challenges - Contract, Regulations and Approvals
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
• Project Procured by Government • Trains owned by ROSCO • Train Operator unknown • Transition phase for Standards - prototype • Transition phase for Regulatory bodies – prototype project • Owner and UK Consultancies lack of High speed experience • Inclusion of Maintenance contract – Train Service Agreement • Implementation of new Depot in parallel – inter-dependency
Project Challenges - Contractual
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
Language – UK, Japan, Europe Understanding the lack of trust from customer – UK history. Performance contract, not detailed specification. Design for maintenance – interaction with maintainer Need for vandalism proof trains Acceptance process – documentation requirements Project driven by PR
Project Challenges - Cultural
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
• Design – Japan – assisted by UK • Manufacturing – Japan • Assembly – Japan • Reassembly and commissioning – UK assisted by Japan • Testing - Japan and UK • Safety and Approvals – Japan and UK • Acceptance - UK assisted by Japan • Maintenance - UK
Project Challenges – Fully Integrated Team
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
Process - Critical Steps to control • Design scrutiny from concept to detail • Trials and mock ups • Prototype build and review, scrutiny • Glass Case samples agreed • Type testing – static and dynamic • Safety and Approvals Acceptance • Customer Acceptance • Initial operation feedback • Lessons learned feedback
Making it Happen
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi, Ltd. 2009. All rights reserved. 13
Fully detailed mock ups
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Low risk solution for C395
Module
FSW 12 years
TMS IGBT Traction
16 years High speed Bogie 45
years
HVAC
Air tight Door 45 years
AL Car body 35 years anti-corrosion know-how
Well Proven Design
Applying established reliable technology
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TMS
Motor
Cables Filter
Transformer
HVAC
Data storage
IGBT
CPU
Bogie Al bodyshell
Display Converter
Li Battery
Low risk solution for C395
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Key features – Crashworthiness structure
Crashworthiness structure
RGS&TSI compliant Crashworthiness
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Key features – Crashworthiness structure
Energy Absorption Block Crashworthy Structure
Energy Absorption Block
High Performance Structure Developed by Various Analysis and Testing
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Key features – Crashworthiness structure
Crash Simulation – Train to Train
Crash Simulation to confirm the energy absorption performance
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Key features –Air tightness
Full Scale Pressure Pulse Testing following FEA
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Key features –Bogie
High-Speed technology
Good Ride performance
300km/h, Series 500 285km/h, Series 700
275km/h, Series E2 270km/h, Series 300
Running Stability
Bolsterless bogie based on Shinkansen Technology
Less damage to track
All Rights Reserved, Copyright © 2010 Hitachi Rail Europe Ltd. Page 21
Japanese Sliding Door European Sliding plug Door
MTBF: 33 x 10 6 MTBF: 18 x 10 3 ←
more than 1800 times Reliable
Simple slide door for reliable & fast open/close operation Air tight is achieved by door pressure device at 4 corners
Key features –Door
© Hitachi Rail Europe Ltd. All rights reserved.
GREAT BRITAIN Wheel sets Gangway TPWS/ AWS Rubber Flooring Cab Panels Cab Electrics HVAC Pneumatic Fitting Air Horn Brake Hose Fire Protection Internal lights External lights Door Sounders DSD Foot pedal Rail ramps Advert frames Catering locks SRS
SPAIN Toilet
BELGIUM Speed Indicator
FINLAND Gangway Door
DENMARK PIS SRS
CZECH REPUBLIC Reduction Gear
SWITZERLAND Cable
GERMANY Couplers Seats Damper Windows Carpet Flexible Conduits Luggage Stacks
Major European Suppliers Project Challenges - Procurement
France Signalling
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
Making it Happen Philosophy • Joint Understanding of the Contract and Specification
• No Surprises, Requirements capture
• Understand each others main priorities • Customer, Stakeholders, UK team, Japan team
• Understand responsibilities
• Customer, Stakeholders, Hitachi teams, Acceptance & Approvals bodies
• Understand and manage the Risks • Communicate
• Keep the contract in the cupboard
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
Mitigating Challenges and Risks • Continuity of Bid team into Project • Immediate “No Surprises” Review
• (Requirements Capture exercise) • Understand the intent of the specification
• Continuous programme reviews with all parties for risks, opportunities and
joint mitigating actions • Instigate special forums for key novel/risk items
• Wheel/Rail and bogie interface • Operation • Testing • Infrastructure
Making it Happen
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
Mitigating Challenges and Risks • Agree Strategy for Safety and Regulatory Approvals with relevant
bodies – and stick to it. • Keep stakeholders up to date with progress and emerging issues –
“No Surprises”. • Create and foster One Team approach with all Stakeholders –
Collaboration is better than Litigation • Start activities earlier than you think – training, manuals. • Instill the Hitachi “must do” attitude in all parties. • Utilise informal and formal communication processes.
Making it Happen
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
• Factory team transferred to UK, working in depot • Units assembled and interiors completed in UK • All systems and UK only tests carried out at Ashford • Detailed Acceptance process carried out with customers
• Fault Free Running – 2,000 miles on DC lines 2,000 miles on AC lines in 6 car & 12 car formations • Initial 4 Test units reworked to service standard • Units accepted at average of one per week • Final acceptance required 20,000 continuous fault free miles per unit
Making it Happen – in UK
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi, Ltd. 2009. All rights reserved. 27
The Right Maintenance Philosophy
May 2006 January 2007
28 June 2007 30 August 2007
© Hitachi, Ltd. 2009. All rights reserved. 28
5 x MAINTENANCE ROADS
WAREHOUSE
MAIN OFFICE
SHUNTERS CABIN
WHEEL LATHE
TRAIN WASH
HEADSHUNT
AUTOMATIC INSPECTION
TEST TRACK
BIO HAZARD PIT
STABLING AND CET
STABLING & CET
Ashford Train Maintenance Centre Site Plan
© Hitachi, Ltd. 2009. All rights reserved. 29
Strictly time based activity
Absolute standardisation of process
Continual improvement. (Kaizen)
Rigidly team based
Consistent reliable staff
Long term skills base
Japanese Fleet Maintenance
© Hitachi, Ltd. 2009. All rights reserved. 30
Data collection is key
Automatic Inspection
TMS Data
Electronic Job cards
Inventory Control
Staff and Attendance
Dashboard Reporting
© Hitachi, Ltd. 2009. All rights reserved. 31
Automatic train inspection system
Allows trend monitoring Brake pad wear Wheel profile wear Wheel damage.
Alarms and work orders automatically raised to supervisor.
Integration to Equinox suite pioneered by Hitachi Rail Maintenance at Ashford
Proven in use – by Hitachi and other
operators
© Hitachi, Ltd. 2009. All rights reserved. 32
Maintenance Support
Equipment drop allows two trains to simultaneously have equipment removed on adjacent roads
Sculfort double headed wheel lathe
Automated storage machines for small spares and exam kits
© Hitachi, Ltd. 2009. All rights reserved. 33
2004 2005 2006 2007 2008 2009 2010
Apr 04
SRA issued ITT for new high speed trains
Jun 05
Contract signed with Hitachi
Nov 05
Depot Contract
30 Aug 07
Unit 1 delivered (on time)
4 Sep 07
100 mph on DC testing
Sep 07 – Nov 08
Testing on HS1 and Network Rail including 12 car passing trials
Sep 07 – Mar 08
Units 2-4 delivered
Nov 07
Unit 001 participated in St. Pancras opening ceremony and entered station unassisted
Mar 09
“S” Stage certificate
June 09
Provisional Acceptance of Unit 1
13 Dec 09
Commencement of full high speed service
Project Timeline
© Hitachi Rail Europe Ltd. All rights reserved.
The first unit (6 cars) of the Hitachi CTRL-DS train arrived in the UK in August 2007 drawing huge media attention.
Delivery
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved. Development of the UK class 395
November 2007 Delivery
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
4 - Delivery, maintenance and early introduction June 2009 - start of preview service Delivery
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
© Hitachi Rail Europe Ltd. All rights reserved.
December 2009 – start of full service Delivery
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
All Rights Reserved, Copyright © 2010 Hitachi Rail Europe Ltd. Page 38
Achievement
Introduction of Class 395 for CTRL-DS, First A-train High Speed for UK HITACHI made contract to supply ‘Class 395’ high speed A-trains for Channel Tunnel Rail Link Domestic Service (CTRL DS), UK
Rail News
HITACHI completed delivery of all 29 train sets on time & budget.
HITACHI acquires high reputation owing to high quality & reliability train.
© Hitachi Rail Europe Ltd. All rights reserved. 39 7 May, 2012
Delivery
Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry
All Rights Reserved, Copyright © 2010 Hitachi Rail Europe Ltd. Page 40
“It was fantastic –very, very fast” Ian from Ashford
“I can’t believe how quick the new train is” Stephen from Ashford
“Train service amazing –very fast” Stefan from Westgate on Sea
“Comfortable, early, just perfect” Matt from Ashford
“It makes what was a long tedious journey…pleasurable” Joanna from Gravesend
What the fare paying public say - Fast -
© Hitachi, Ltd. 2010. All rights reserved.
All Rights Reserved, Copyright © 2010 Hitachi Rail Europe Ltd. Page 41
What the fare paying public say - Great Service -
© Hitachi, Ltd. 2010. All rights reserved.
“The service itself is extremely efficient” Gary from Gravesend
“The train is comfortable, the staff friendly” Gary from Ashford
“It’s really comfortable, it’s great, really clean. It’s like first class Diane from Bean
“The new high speed train is fantastic” Christine from Ashford
“This is how travel should be” Elizabeth from Gravesend
All Rights Reserved, Copyright © 2010 Hitachi Rail Europe Ltd. Page 42
What the fare paying public say - Good Value -
© Hitachi, Ltd. 2010. All rights reserved.
“Well worth the extra few pounds” Mike from Bethersden
“Even the extra £2.90 is worth it for this relaxing journey” Ian from Ashford
“I am loathe to say this but the weekly upgrade is phenomenal value” Guy from Westwell
“The quality of life is more important …if I can cut an hour and a half it’s worth it” Lisa from Darenth
All Rights Reserved, Copyright © 2010 Hitachi Rail Europe Ltd. Page 43
What the fare paying public say - Life Changing -
© Hitachi, Ltd. 2010. All rights reserved.
“Thank you so much for letting me spend an extra hour in bed and making it possible for me to turn up 30 minutes early for work” Heather from Kingsnorth
“Feels like leaping forward a century. It will change the way I can live” Leigh from Ashford
“I can get from St Pancras to Kent quicker than some Londoners can get about on the tube” Andrew from Ashford
“Awesome!” Mick from Sittingbourne
All Rights Reserved, Copyright © 2010 Hitachi Rail Europe Ltd. Page 44
C395 project has been awarded the “Project of the Year” based on commencing of passenger service 6 month early.
National Rail Award - September 2010