ERL Maintenance Support Sdn Bhd. KL Sentral. Bandar Tasik Selatan. Putrajaya Cyberjaya. Salak Tinggi KLIA

Transcription

1 ERL Maintenance Support Sdn Bhd KL Sentral Bandar Tasik Selatan Putrajaya Cyberjaya Salak Tinggi KLIA Express Rail Link, Malaysia s No 1 Railway Page 1 of 16 Ref No: G00.OMS.M11110.CY.1001.B / # March 2011

2 ERL Maintenance Support Sdn Bhd (E-MAS) E-MAS was established in 1999 as a joint venture between Express Rail Link Sdn Bhd (ERLSB) and Siemens AG In 2005 Express Rail Link Sdn Bhd became the sole owner of E-MAS. E-MAS operates and maintains the Express Rail Link Services. The Express Rail Link Services consist of the KLIA Ekspres and the KLIA Transit, with route length of 57 km from KL Sentral to KLIA. KLIA Ekspres was designed with the air travellers needs in mind, is a high speed, nonstop air-rail connection between Kuala Lumpur International Airport ( KLIA ) and Kuala Lumpur City Air Terminal at Kuala Lumpur Sentral station ( KL Sentral ). It has a journey time of 28 minutes at 15-minute frequencies (during peak hours) and 20-minute frequencies (during off-peak hours). The KLIA Transit is a commuter service that stops at three intermediate stations - Bandar Tasik Selatan, Putrajaya/Cyberjaya and Salak Tinggi - with a journey time of 35 minutes at 30-minute frequencies. Trains have a design speed of 176 km/h and operate at a cruising speed of 160 km/h using 25kV power supply and ATP signalling. The KLIA Ekspres commenced operations on 14th April 2002 and KLIA Transit service on 1st June Both services of KLIA Ekspres and KLIA Transit have a current total ridership of about 11,000 12,000 passengers per day. The first 1 millionth passenger was recorded in December 2002, the 30 millionth passenger in June Both services offer airline check-in facilities at the Kuala Lumpur Sentral station. E-MAS, with 320 staff, has successful and consistently operated Express Rail Link Services at 99.7% average on-time arrivals. E-MAS has provided Railway Expertise to other Railway Projects Express Rail Link Sdn Bhd is owned by well established shareholders, namely, YTL Corporation Berhad (50%), Lembaga Tabung Haji (40%) and Trisilco Equity Sdn Bhd (10%). Express Rail Link, Malaysia s No 1 Railway Page 2 of 16

3 Express Rail Link, The CONSISTENT PERFORMER Train On-time Performance 99.7%* World Class Performance supported by World Class Maintenance In 2004 Express Rail Link achieved this excellent service performance and has retained the same level of performance ever since. Express Rail Link has an excellent record in Railway Safety. Express Rail Link, Malaysia s No 1 Railway Page 3 of 16

4 The E-MAS story 2001 Set up workshops and Depot 2004 Preparation for 1 st overhaul of trains 2003 ISO 9001:2000 Dual Certification (DQS Germany and SIRIM Malaysia) 2002 Start of Operations Set up of Quality Management System 2000 Recruitment and Training Testing and commissioning activities 1999 ERL Maintenance was established JV of Siemens and ERLSB E-MAS is fully owned by Express Rail Link Sdn Bhd and is located at Kompleks Rel Udara in Bandar Baru Salak Tinggi in the district of Sepang, Selangor Darul Ehsan, Malaysia, located a mere 10km from Kuala Lumpur International Airport. Our staff are highly trained and qualified in Railway Operations and Maintenance. They have experience drawn from many different railway networks in Asia, Europe and Africa. We also have specialists in all technical and operation areas that handle all complex queries and problems. E-MAS also works closely with other recognised companies in the Railways of the world. Express Rail Link, Malaysia s No 1 Railway Page 4 of 16

5 The E-MAS story - continued 2011 Initiative ISO 14001:2004 Environmental Management System 2010 Install Green Washing Plant 2007 Energy meters fitted to trains 2009 ISO 9001:2008 re-certification 2nd round of fleet overhaul 2008 Green Initiative Cost Reduction for Building and Train Operations st overhaul completed on all trains Express Rail Link, Malaysia s High Speed - High Mileage Railway. Operated and Maintained by E-MAS One Train The Fleet of 12 Trains Daily km ,700 Yearly km 388, Million Ekspres Train: Transit Train: 136 Trips Daily 79 Trips Daily Express Rail Link, Malaysia s No 1 Railway Page 5 of 16

6 Our Business Maintenance: Rolling Stock & Workshop Electrification Signaling & Telecommunications Operations: Control Center Trains Stations Chief Executive Officer Safety & Security Management Representative Quality & Environmental Operations Maintenance Logistics Human Resource Transportation Rolling Stock Procurement Documentation & IT Operations Control Centre Signalling Material Management Business Development Operations Development Electrification Finance & Administration Express Rail Link, Malaysia s No 1 Railway Page 6 of 16

7 Why we believe that E-MAS staff are the best E-MAS Expertise E-MAS has staff with vast experience in the field of Projects, Operations and Maintenance, in Malaysia and in Europe, Africa and other parts of Asia. E-MAS has provided Railway Specialists to YTL, KTMB, DGR Malaysia, Siemens AG, Deutsche Bahn International and Siemens Thailand. Some of our staff Thomas Baake, Chief Executive Officer, E-MAS Thomas is a Railway Operation specialist with 35 years worldwide experience in railway operations and railway-related project management. After joined Deutsche Bahn (German Railways) he held various roles in railway operation, operation planning and operation management. In 1989 he joined DE-Consult and worked in numerous railway projects in Asia, Africa and Europe. Thomas joined E-MAS in Ir. Ham Mow Wai, Manager, Maintenance Ham railway experience started on 1996, initially in design, supply and construction of PUTRA systems and track-work before joining ERLSB in 1999 as a Senior Engineer. He joined E-MAS in 2001 and held various managerial posts within the company and is currently responsible for the overall maintenance of the trains and sub-systems. He holds a Masters degree in Railway Systems Engineering and is a professional mechanical engineer. He has presented working papers in international railways conferences. James Leonard Boudville, Manager, Operations His experience in railway operations started in 1991 with KTMB before moving to STAR LRT in He joined E-MAS in 2001 and is currently responsible for the operation of the KLIA Ekspres and Transit services. Barry Gardner, CEng. MIMechE, Manager Business Development, Railway Engineering and Management of Railway Maintenance Organisations and Projects in Europe and Asia. Started in 1966 as a British Railways apprentice progressing to Executive Manager of one of the new Rail Freight companies. Re-railing and Recovery expert. Degree in Mechanical Engineering, Chartered Engineer and a Member of the Institute of Mechanical Engineers. Independent checking engineer (ICE) and has set up maintenance organisations for new railways in Malaysia and Thailand. Mohd Jamil Alias, Manager, Rolling Stock Rolling stock maintenance activities started in 1990 at KTMB before moving to STAR LRT in Joined E-MAS in 2001 and is responsible for the maintenance repair and overhaul of ERL trains, ensuring the train fitness, safety and availability for operations. He is exposed to Rolling Stock construction with Japan East Railway. Holds a Exec. Diploma in Railway Permanent Way Engineering and currently pursuing his MBA. And 300+ others with extensive experience in all Railway Operation and Maintenance disciplines Express Rail Link, Malaysia s No 1 Railway Page 7 of 16

8 Skills Training E-MAS believe in, and practice, intensive training starting from day 1 in the company. Training is a process of learning a sequence of programmed behaviour. It is the application of knowledge & gives people an awareness of rules & procedures to guide their behaviour. It helps in bringing about positive change in the knowledge, skills & attitudes of employees. Thus, training in E-MAS is a process that tries to improve skills or add to the existing level of knowledge so that the employee is better equipped to do his present job or to mould him to be fit for a higher job involving higher responsibilities. It bridges the gap between what the employee has & what the job demands. Training is a continuous and never ending process. All employees are required to attend refresher training to remind them of the quality standards to which we work and to enable them to keep up with the new methods & techniques of work. Experience staff also play a role by imparting to the new entrants the basic knowledge & skills they need for first class performance. Staff are trained not only how to perform tasks but equally importantly why it needs to be done the E-MAS way. This produces high quality work with minimum supervision. It reduces wastage, reduce defects & minimises risk. The good working culture brings with it new skills to match the technology and high job satisfaction, helpful for the growth & improvement of both individual and company. Employee turnover in E-MAS is lower than in many comparable industries. A successful railway needs First Class Technical Equipment Supplier manuals that clearly describe full operation and maintenance Spares Selection of the right staff Intense initial Training Production of comprehensive procedures in all disciplines Re-Training Motivate staff for excellence Staff appraisal Recognise and Award staff excellence Re-Training Innovative action in all disciplines to improve system performance E-MAS can show you how! Express Rail Link, Malaysia s No 1 Railway Page 8 of 16

9 COLLABORATION, E-MAS staff providing Operations and Maintenance expertise. Suvarnabhumi Airport Railway Line, Thailand For Deutsches Bahn International and Siemens Thailand Maintenance Strategy Study for the O&M Company. Involvement in Testing & Commissioning. Writing Operations Procedures and Training for operations staff. Supplies of expertise Keretapi Tanah Melayu Berhad, (KTMB) Malaysia For YTL, who had the Construction contract of a new line. Participation in Design, Testing & Commissioning. Maintenance/maintenance support of the Railway Infrastructure and Systems. (KTMB is Malaysia s National Railway) Perak Hanjoong Simen, (PHS) Malaysia Railway Operations and Maintenance Advisor. PHS is part of the YTL Corporation, one of Malaysia s most prominent companies Department of Railway, Malaysia Joint Accident Investigation Technical committee for local new railway system Costa Rica Light Rail With Siemens AG, Light Railway Proposal Express Rail Link, Malaysia s No 1 Railway Page 9 of 16

10 QUALITY POLICY Express Rail Link, Malaysia s No 1 Railway Page 10 of 16

11 Examples of some of the E-MAS Rolling Stock Maintenance Initiatives Wheel Life Extension Wheel Flange Lubrication to identify the pattern of wear and reduce the wear on wheel flanges and rail Reprofiling Management to minimise the metal removed during wheel attention on the lathe Continuous Monitoring to ensure that wheel life improvements will be retained. Before 200,000 km After >2 Mil. km Wheels renewed would have been 480 per year. Now only 50 wheels required per year Dampers Life Extension Performance Test on Test Rig enables the service life of the dampers to be exactly predicted Recalculation of Life Continuous Monitoring to confirm validity of the calculations Before 1 Mil. km After 1.4 Mil. km Annual saving is RM80,000. Express Rail Link, Malaysia s No 1 Railway Page 11 of 16

12 Primary Suspension Life Extension Stiffness Measurement ensures that springs remain within their safe operational condition Recalculation of Life Continuous Monitoring which also checks the quality of manufacturers product. Before 600,000 km After 1.4 Mil. km Annual saving is RM560,000 Gearbox Life Extension Condition Monitoring Spectrographic Analysis of the condition of the oil allows the overhaul to be linked to the condition of the components in the Gearbox. Before 1.5 Mil. km After 3.0 Mil. km Annual saving is RM1.3mil per overhaul. E-MAS now overhauls many main components in ERL s Depot at Salak Tinggi Express Rail Link, Malaysia s No 1 Railway Page 12 of 16

13 E-MAS In-house Signalling Maintenance Initiatives Earthing Redesigned and Improved the earthing concept on the system resulting in 67% reduction in axle counter failures. Test Bench Designed and constructed Signalling Test Bench for the complete interlocking function for training, and testing individual components and whole system to determine cause of failure and minimise future system failures. By performing the testing in-house eliminates the need to return components to suppliers overseas for failure cause determination. Saves time and saves cost. Design changes for a better performance Install duplicate components in the train borne signalling system to reduce recovery time in the event of failure. This modification has eliminated any train delay from this defect. Supplier search Evaluate components from alternative international suppliers to effect improvements in the system reliability. One example was purchased for around 50% of the cost of the original and because of better design it produced a drastic reduction in time to repair from 5 hours to 10 minutes. Combat Vandalism Redesigning Line Side cabinets to eliminate vandalism, and thus eliminate train delays due to this vandalism. Thermography & Vibration Analysis Condition Based Maintenance Usually no downtime is required for testing as is it can be carried out in service. Real Time monitoring giving immediate assessment of condition. Permanent record of test results. Based on the assessment, action can be taken to predict and prevent breakdowns or failure. This maintenance supports the optimum overhaul interval and will extend the life of the equipment by eliminating damage before it Thermographic image happens. Maintenance is now based on the actual condition of the equipment. Cost savings will be in manpower and components due to damage prevention and optimum maintenance based on each individual item s condition. E-MAS D.I.Y. Thermographic Image Thermographic image Easier Access In house design and fabrication of equipment to facilitate access for maintenance Wheel assembly jig Etc Express Rail Link, Malaysia s No 1 Railway Page 13 of 16

14 Building the Operations Team E-MAS Operations staff are in the front line facing the customers/passengers. They have been cultivated with good attitude and etiquettes so that excellent performance can be delivered. Start the day off right. The staff practice positive greetings when beginning duty because it can set the tone for the rest of the day. Discuss feelings. Letting off steam with a dramatic outburst erodes relationship within the team and is a totally unacceptable fashion because it could eventually become a practice when the staff deal with customers. It will effect their work performance and the performance of others. They are advised to remain calm and to discuss E-MAS problems matter in private, never in front of customer. Try to do the right thing. When face to face with a customer with a grievance, advice to staff is to carefully listen and try to solve the issue amicably. Learn to listen, especially to customers. Staff are made to understand that they shouldn't interrupt their customers or jump to conclusions about what they're saying. Get to know the whole person. The senior staff need to know their staff and what they're up to in their lives. Celebrate noteworthy occasions and develop a relationship with their staff that is based upon respect for them as complete individuals, not just the results they produce. Thank the staff often. Be generous with compliments to staff and acknowledge their service skills when they've done a good job. An environment of recognition and appreciation encourages staff to maintain consistently high levels of service. Talking about good customer service. This will make great strides toward ensuring they will provides only the best in service. E-MAS can show you how! Express Rail Link, Malaysia s No 1 Railway Page 14 of 16

15 Energy Saving Initiatives from ERL and E-MAS Energy Meters installed in the trains to monitor Equipment and Driver performance Drivers operate ERL trains using energy saving techniques: Make sure that trains are switched off during stabling As much driving as possible in coasting mode Know to brake early, with not more than 40% braking force As much as possible, use the electrical regenerative brake No traction effort more than 80% 5.3% Reduction in energy cost per trip Reduce Building Energy Consumption Company wide use of Energy efficient lamps. Installation of electronic timer to control air condition and electrical installation. Savings of RM800k per year. Travel by Train instead of by Car and help reduce CO2 emissions Express Rail Link s Go LO-CO2 (Green Initiatives) Passengers that choose to travel to Kuala Lumpur International Airport using KLIA Ekspres and KLIA transit are responsible for saving of 3.5 million car journeys between the capital city of Kuala Lumpur and the airport. Savings of 23,000 tonnes of CO2 emission annually Express Rail Link, Malaysia s No 1 Railway Page 15 of 16

16 contact us at:- ERL Maintenance Support Sdn Bhd Kompleks Rel Udara, Bandar Baru Salak Tinggi, Sepang, Selangor, Malaysia Tel: Fax: Website: Facebook Address: Business Development Tel: Tel: Company for enquiries: Express Rail Link Sdn Bhd Level 2 KL City Air Terminal, KL Central Station, 50470, Kuala Lumpur, Malaysia Tel: Fax: Website: Express Rail Link, Malaysia s No 1 Railway Page 16 of 16