OPTIMISATION OF RAILWAY ASSET LIFE CYCLE PERFORMANCE THROUGH A CONTINIOUS ASSET IMPROVEMENT PROCESS Presented by Jackie vd Westhuizen e-logics Objectives Contextualise relevant asset management definitions and principles. Introduce the railway maintenance management principles focusing on track tamping related to substructure performance. Develop a maintenance decision model/process. Integrate the model into relevant technology to test usability/practicality. Compare results against standard strategies and tactics. Conclude with continuous improvement philosophy. Slide
What is asset management? Asset Management can be defined as the holistic approach within an entire business to improve its overall performance. Physical Asset Management has a single objective and that is to increase the value and return delivered by the physical assets. Physical Asset Optimization is a program that is a business initiative focusing on and determined by opportunities to create value in different areas. Holistic approach to realise value from Assets Slide 3 Areas/Opportunities to Create Value Increase stability and quality; Reduce cost; Increase effectiveness and productivity; Flexible and reliable processes; Improve capital effectiveness. Invest at the right time and right location/cost benefit analysis Slide 4
The Asset Centric Approach to Asset Management Operate Assets and resources should be planned and controlled to ensure optimal utilisation and profit. Operations planning considers the requirements for movement across the network within the associated constraints. Asset owner Physical Infrastructure Moveable assets and Operation Scheduling Assets Asset Base Integrated Operations and Maintenance Management Optimizing Physical Asset Management Maintain Maintenance of the asset base should ensure the safe, reliable, available and optimal (affordable) cost of the operation of these assets. Asset Care Ensure production capacity Minimize maintenance interference (Maximize Production) Material Management Minimize maintenance cost Increase Operation Profitability Slide 5 What is maintenance management? Maintenance can be defined as the care, correction and servicing of assets and their components, whether physical or functional, for the purpose of ensuring satisfactory operations of the assets and components before failure or major defects occur that will influence the operational ability thereof. In short, maintenance can be called asset care. It ensures the availability, reliability, safety and capacity of assets to deliver either a product or a service, depending on the business objective. Asset care need to provide capacity and ensure availability. Slide 6
Influence and Relevance of Maintenance Maintenance Areas/Opportunities to Create Value Reduce incidents; Increase availability and utilisation; Improve quality; Maximize effectiveness; Reduce and minimize failures; Reduce operating and maintenance cost; Reduce spares/inventory. Slide 8
Interdependencies of Operations and Asset Management in the Railways Infrastructure Availability Operate Functional Assets Equipment Availability Physical Asset Interface Importance of synergy/partnership (Asset Owner and Asset Care taker) to ensure operational objectives Demand Demand Operational Production Best Performance Breakeven Interruptions (Out-of-service) Operational Production Best Performance Breakeven Improved reliability extends intervals between interruptions and increase availability Time Demand Time Adopted: Mitchell et al. Operational Production Best Performance Breakeven Reduce out-ofservice duration to assist in delivery commitments e.g. Speed Restrictions Slide 10 Time
Maintenance Strategy Improvement Path Adopted: Hans Ahlmann High Quality & Performance Mode Hierarchy/Controlled Floworientated Slide 11 Accidental Mode APPLICATION IN RAILWAY MAINTENANCE MANAGEMENT
Maintenance Managers Dilemma Where should we work next?? Condition Measures Track Geometry Measures Rail Defects/Flaws/Wear Track & Turnout Inspections Contact Wire Measurements Track Circuit Failures Where and When do I Apply my Maintenance Resources? Work History Mechanised Maintenance Spot Maintenance Maintenance Costs Operational Interference Track Occupation Train Delays Speed Restrictions Slide 13 Maintenance Management Process Work Identification Work Planning Work Scheduling Know the asset and business requirements Asset Condition Monitor Infrastructure Management Data Work History (Feedback & Followup) Sustained Maintenance Work Execution Asset Configuration Emergency, reactive repairs
Continuous Improvement Process for an Effective Maintenance Management Asset Management Strategies & Policies (Network Requirements) Condition Assessment 1 Analysis 3 Feedback and Monitor 6 Execution Continuous Improvement 4 5 Planning + Budgeting Resource Scheduling Slide 15 Information Requirements What and where is it? What is its condition? What has it done? What has been done to it? Integration and Analysis Decision Making Setup Maintenance Plan What has it generated? What has it cost? Slide 16
Typical System information Flow Survey and create asset register Automated Condition Assessment Visual Condition Assessment Slide 17 Condition Data Track Geometry Slide 18 Slide 18
Condition Data Rail Defects Slide 19 Slide 19 Condition Data Rail Wear Slide 0 Slide 0
ANALYSIS METHODOLOGY DECISION MAKING MODEL/PROCESS Asset Performance Indicators and Limits Minimum Acceptable Roughness Level (Safety Limit) Roughness Increase (Condition Decrease) Minimum Allowable Roughness Level Cannot get the condition to its original level Rehabilitation Time between maintenance cycles decreases, impact on operations, asset availability and capacity Replacement (Maintenance Limit) Upgrade 0 30 60 90 10 150 180 Time/Traffic (MGT) Slide
Routine (Cyclic) Based Maintenance 48 Tamping Interval MGT / year sec tion Current = 18 MGT Tamping interval calculated at once a year Tamping total distance of track Routine Based Tamping Equivalent Tamping Unit Quantity Requirements Distance (Km) Tangent Track Km 41.88 41.88 Curved Track Km 55.518 111.036 Switches Number 81 3.4 Total Distance 185.318 Slide 3 Condition Based Maintenance Identify need Different analysis calculations Development of maintenance algorithm
Condition Based Maintenance: Maintenance Limit Intervention A selection of up to five track geometry condition assessment parameters to calculate a condition index. Each parameter can be multiplied with a weighted average, and the result of these values are added to one another A variable maintenance and/or safety intervention limit utilized to identify all areas that require maintenance. A variable cluster length, this length is utilized to cluster maintenance areas into one group if the areas not requiring maintenance between identified maintenance areas is less than this length. An option to include radius configuration data, to ensure that the result is applied to the extent of the curve. R + profile right = profile left R + alignment left R = profile tamp Ralignment tamp R R alignment right Slide 5 Maintenance Condition Limit From Gräbe and Maree (1997) Standard Deviation = 1.6mm for profile on coal line From frequency plot 86 th percentile profile on Durban line calculated at 4.mm Slide 6
Tamping Analysis Intervention Limit Analysis Clustering Analysis Radius Analysis extend Radius Slide 7 Condition Based Maintenance: Condition Performance Index (Rate of Condition Change) A further improvement to the condition based approach compares the rate of change in the geometry measurements. The rate of change is calculated by subtracting consecutive measurements of roughness data. The result can be used to identify areas were deterioration is high. Improvements can also be identified that will highlight effective maintenance. R R = n 1 R n Slide 8
Outcomes of different models Maintenance Intervention limit Delta Roughness limit Slide 9 Results comparison Condition Performance Routine Based Distance ( R ) Based Distance Tamping Further Requirements value (arguably more than Requirements the Savings Activity maintenance Equivalent cost saving) are created Equivalent through the additional (%) Type Capacity/Availability Tamping to Operations. The Tamping reduction in the Distance maintenance translates Distance Unit Quantity into 8 days of (km) track occupation. Quantity The same principles will also lead to the (km) Tangent reduction in Material requirements and Track km therefore 4 less inventory 4 17 17 60 Curved Track km 55.5 111 53 106 5 Switches Number 81 3.4 65 6 0 Total Distance 185.4 149 0 Slide 30
Continuous Improvement Process Slide 31 In conclusion Maintenance Management is a fundamental part of optimised asset management. Sound principles, processes with relevant data and tools assist in effective maintenance decision making. Continuous improvement process is the fundamental link for sustainable maintenance management and asset performance optimisation. Slide 3
THANK YOU Additional Information What's ideal for substructure management?
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