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Implementing and Managing a Maintenance Plan

Implementing and Managing a Maintenance Plan. The Maintenance Plan Ken Henman. The Maintenance Plan. What is a Maintenance Plan Why have Maintenance Plan How to develop a Maintenance Plan Implementing and managing a Maintenance Plan. What is a Maintenance Plan.

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Implementing and Managing a Maintenance Plan

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  1. Implementing and Managing a Maintenance Plan The Maintenance Plan Ken Henman

  2. The Maintenance Plan • What is a Maintenance Plan • Why have Maintenance Plan • How to develop a Maintenance Plan • Implementing and managing a Maintenance Plan DTE Rail Services, Inc. Maintenance Management Seminar

  3. What is a Maintenance Plan • Part of the total effective management of railcar assets • A structure under which railcar maintenance and repair can be proactively managed • Allows for aggressive control of maintenance costs and procedures DTE Rail Services, Inc. Maintenance Management Seminar

  4. Why Have a Maintenance Plan • Meet regulatory requirements • Improve and sustain reliability • Risk management and loss control • Avoid opportunity loss • Sustain asset function • Sustain asset value • Maintenance of assets viewed as contributor to business success DTE Rail Services, Inc. Maintenance Management Seminar

  5. How to Develop a Maintenance Plan • Understand objectives • Understand responsibilities • Evaluate • Organize • Develop • Implement • Measure effectiveness • Re-evaluate • Adjust DTE Rail Services, Inc. Maintenance Management Seminar

  6. Implementing and Managing a Maintenance Plan • Establish a scope of work- SOW • Selection of repair facilities • Logistics and scheduling • Commence maintenance activities • Evaluate- leading and lagging KPI’s • Adjust DTE Rail Services, Inc. Maintenance Management Seminar

  7. Establish a Scope Of Work • Objectives - State your intent • Goals • Types of maintenance • Overall expectations • List of specific cars involved • Individual, group or series • Repair scope • Focus of repairs according to objectives • Applicable attachments (i.e. prints, schematics etc.) • Overall car condition and other repairs DTE Rail Services, Inc. Maintenance Management Seminar

  8. Establish a Scope Of Work • Responsibilities • Maintenance responsible party • Who approves and pays the bills • Expectations of shop • Quality • Reporting • Estimating • Turnaround • Contact information • Maintenance responsible party and shop DTE Rail Services, Inc. Maintenance Management Seminar

  9. Distribution of the Scope of Work • Treat as a controlled document • Titled and dated per latest revision • Confirmation of receipt and understanding by shop DTE Rail Services, Inc. Maintenance Management Seminar

  10. Selection of Repair Facility • Capacity • Size suitable for level of performance and turn around expected • Capabilities • Meets quality and quantity expectations • Location • Within boundaries of serving railroad without off line transportation charges • Relationship • Familiarity of service expectations • Agreements covering rates and material DTE Rail Services, Inc. Maintenance Management Seminar

  11. Logistics and Scheduling Maintenance Activities • Car service demands • Loading schedule • Availability of railcars • Relationship of car location to shop(s) • Criticality of condition • Shop availability • Materials DTE Rail Services, Inc. Maintenance Management Seminar

  12. Maintenance Activities • Equipment inspection results • Inspection summary or estimate as needed • Distributed to maintenance responsible party for approval • According to SOW criteria • Adherence to stated objectives • Report of overall car condition • Estimate • Per SOW • Within expectations DTE Rail Services, Inc. Maintenance Management Seminar

  13. Maintenance Activities • Approval of inspection summaries- estimates • In process inspections • Status reports • Completed car inspections • Track all warranties and claims • Equipment return to service DTE Rail Services, Inc. Maintenance Management Seminar

  14. The Scope of Work as a Living Document • Inspection and repair results meet expectations • Flexible according to need • Revised as needed • Revisions distributed in controlled manner DTE Rail Services, Inc. Maintenance Management Seminar

  15. Maintenance Plan Evaluation-KPI’s • Leading KPI - Indicators that measure performance before problems arise • EHMS exposure • Last major repair event • Lagging KPI - Historical information measuring performance results • According to budget • Reliability – effectiveness measure • Maintenance costs to deliveries • Reactive to proactive maintenance • Unplanned to planned maintenance DTE Rail Services, Inc. Maintenance Management Seminar

  16. Evaluate-Leading KPI’s • Periodic maintenance • Time or mileage based maintenance • Component life cycle based maintenance • According to known component life expectations • Equipment condition base • According to baseline and periodic inspections DTE Rail Services, Inc. Maintenance Management Seminar

  17. Evaluate-Leading KPI’s • Estimated cost of repairs according to the SOW • Relationship to budget and expectations – meets objectives • EHMS exposure • Review current car information for open “Alerts” • Quality assurance • Avoidance of rework DTE Rail Services, Inc. Maintenance Management Seminar

  18. Evaluate-Lagging KPI’s • Quality control • Avoid after repair rework • Tracking actual maintenance cost • Estimate to final invoice audit • Final invoice to SOW • To budget • Gather information • Equipment inspection and performance information • Results measured against plan DTE Rail Services, Inc. Maintenance Management Seminar

  19. Evaluate-Lagging KPI’s • Repair facility performance • Quality • Quantity • Out of service –Turnaround time • Time the car is bad order or awaiting disposition • Time the car takes moving to shop • Time the car is in the shop for repair • Arrival to inspection and estimate • Approval to completion • Time the car takes to move back into service • Results measured against plan • All this “out of service” time decreases utilization DTE Rail Services, Inc. Maintenance Management Seminar

  20. Key Performance Indicators • Association of leading and lagging KPI identifies trends • Time between component failures or repairs • Per car per month • Life cycle cost to asset value • EHMS exposure • Actual cost to budget • Car status monitoring • Shopping performance • Continuous improvement DTE Rail Services, Inc. Maintenance Management Seminar

  21. Plan Effectiveness - KPI Reporting • Gather data and measure results • Provide results in detailed, summarized format • Periodic reviews • Internal • Contractors • Repair facility • Results used to adjust plan and SOW • Insure quality of work and cost control • Re-focus on specific problem cars or components DTE Rail Services, Inc. Maintenance Management Seminar

  22. Fleet Per Car Per Month Cost CAR SERIES DTE Rail Services, Inc. Maintenance Management Seminar

  23. Major Components, Contractor OnlyABCX 1000-1999 $78,531 $53,969 $25,003 $3,645 $1,786 DTE Rail Services, Inc. Maintenance Management Seminar

  24. Major Components, Contractor OnlyABCX 2000-2999 $11,093 $3,933 $1,803 $285 $536 $761 DTE Rail Services, Inc. Maintenance Management Seminar

  25. Budget Review DTE Rail Services, Inc. Maintenance Management Seminar

  26. Budget Review – YTD DTE Rail Services, Inc. Maintenance Management Seminar

  27. Yearly AAR Billing PercentageReactive to Proactive DTE Rail Services, Inc. Maintenance Management Seminar

  28. Wheel & Bearing Defects 870 792 781 792 552 541 485 312 315 271 183 184 183 180 157 155 149 143 119 82 *Total includes wheels changed for other reasons All Wheels Replaced by AAR & Contract Shop DTE Rail Services, Inc. Maintenance Management Seminar

  29. Average Wheel Set Mileage, by Group CAR SERIES DTE Rail Services, Inc. Maintenance Management Seminar

  30. EHMS Exposure DTE Rail Services, Inc. Maintenance Management Seminar

  31. Major Shopping Event, Last Air Brake Test DTE Rail Services, Inc. Maintenance Management Seminar

  32. Shop Process Cycle Times DTE Rail Services, Inc. Maintenance Management Seminar

  33. Evaluate- • Continuing evaluation of SOW according to maintenance goals • Did the plan accomplish the objectives? • Adjusted - revise • Determining revisions to Scope of Work • Select revisions to meet objectives • Process of continuing improvement DTE Rail Services, Inc. Maintenance Management Seminar

  34. Maintenance Types DTE Rail Services, Inc. Maintenance Management Seminar

  35. Strategic Proactive Planned Reactive Don't Fix It DTE Rail Services, Inc. Maintenance Management Seminar

  36. Maintenance Plan Cycle PLAN ANALYZE SCHEDULE EXECUTE DTE Rail Services, Inc. Maintenance Management Seminar

  37. Summary • Maintenance and value to assets • Risks of not maintaining • Maintenance philosophies • Technology • Maintenance plan • Measuring effectiveness DTE Rail Services, Inc. Maintenance Management Seminar

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