Sharing practice: OEM OEM prescribed maintenance ib d i t Peter - PowerPoint PPT Presentation

Sharing practice: OEM OEM prescribed maintenance ib d i t Peter Kohler / Andy Webb

Overview Overview 1. OEM introduction 2. OEM maintenance: pros and cons 3. OEM maintenance: key message y g 4. Tools to help 5. Example p 6. Takeaway thoughts 7. Summary 2

What is an OEM? What is an OEM? Prime system Prime system Types of Types of Original Original g g Commercial off ‐ the ‐ shelf Commercial off the shelf Commercial off the shelf Commercial off ‐ the ‐ shelf Equipment Equipment Manufacturer Manufacturer Component Component All have responsibilities under Work Health and Safety All have responsibilities under Work Health and Safety legislation and the Rail Safety National Law legislation and the Rail Safety National Law 3

OEM maintenance: pros & cons OEM maintenance: pros & cons   Pros Pros Cons Cons Unlikely to balance cost, risk, Unlikely to balance cost, risk, U lik l t b l U lik l t b l t t i k i k Provides a quick basis for building Provides a quick basis for building performance performance a maintenance plan a maintenance plan May not consider failure May not consider failure y y S Supports basic reliability Supports basic reliability S b b i i li bili li bili consequence: may not address consequence: may not address performance performance safety safety May not consider the asset’s May not consider the asset’s May not consider the asset s May not consider the asset s environment environment Not necessarily efficient for the Not necessarily efficient for the user user 4

OEM maintenance: key message OEM maintenance: key message Good basis but... • C Continual improvement drives ti l i t d i you to review initial maintenance plan • You need to understand f il failure consequence on your railway to ensure safety Source: Asset Management concept model, Asset Management Council 5

Moving forward Moving forward • Tools already exist to help us • FMECA: FMECA – a systematic way of assessing failure modes assess g a u e odes and their consequences – enables the build up of effective maintenance effective maintenance tasks to address known failure modes – IEC 60812: Application guide – Failure mode effects analysis 6

FMECA process overview FMECA process overview Identify how Identify how Break down into Break down into Define the asset Define the asset each part might each part might its key parts its key parts fail fail Identify the Identify the Identify and Identify and Identify Identify failure effects failure effects assess failure assess failure maintenance maintenance and failure and failure consequences consequences consequences consequences tasks tasks tasks tasks probabilities probabilities Risk assessment Simplified diagram: refer to Sharing practice paper for more detail of the FMECA process 7

Sample FMECA Sample FMECA – track circuit track circuit Rail IRJ Define the asset being analysed, Track feed Track feed Track feed Track feed Train detector Train detector Train detector Train detector including its boundaries including its boundaries Power supply Power supply Power supply Power supply Housing Housing As an example, consider the tail cables connecting the rails to the train Signalling system Signalling system Signalling system Signalling system detection equipment 8

Develop a FMECA (simplified example) Develop a FMECA (simplified example) Scenario 1: Consider the track circuit tail cable – on low use sidings Scenario 1: Consider the track circuit tail cable – on low use sidings Sample failure Sample failure Sample failure Sample failure Failure Failure Sample Sample Function Function Criticality Criticality Sample maintenance tasks Sample maintenance tasks mode mode effect effect Rate Rate consequence consequence Analyse causes, leading to a Analyse causes, leading to a Minor delay Minor delay Fails to Fails to task frequency for: task frequency for: task frequency for: task frequency for: Track circuit Track circuit Track circuit Track circuit to traffic to traffic to traffic to traffic connect connect Examine cable connections Examine cable connections shows shows electrically electrically Low Low Low Low Examine cable for damage Examine cable for damage occupied occupied Manual Manual (eg open (eg open Ensure cable securely Ensure cable securely when clear when clear operation operation circuit) circuit) fastened fastened mode mode Minor delay Minor delay To connect the To connect the Track circuit Track circuit to traffic to traffic rails rails Analyse causes, leading to a Analyse causes, leading to a shows shows task frequency for: task frequency for: electrically to electrically to Low Low Low Low occupied occupied occupied occupied Manual Manual Manual Manual the train the train the train the train Examine cables for damage Examine cables for damage Examine cables for damage Examine cables for damage when clear when clear operation operation Insulation test cables Insulation test cables detector detector mode mode (track relay) (track relay) Fails to isolate Fails to isolate electrical electrical circuit circuit Analyse causes, leading to a Analyse causes, leading to a Track circuit Track circuit shows clear shows clear Slow speed Slow speed task frequency for: task frequency for: Medium Medium Very low Very low when when collision collision Examine cables for damage Examine cables for damage Insulation test cables Insulation test cables occupied occupied 9

Develop a FMECA (simplified example) Develop a FMECA (simplified example) Scenario 2: Consider the track circuit tail cable – on a high use passenger main line Scenario 2: Consider the track circuit tail cable – on a high use passenger main line Sample failure Sample failure Sample failure Sample failure Failure Failure Sample Sample Function Function Criticality Criticality Sample maintenance tasks Sample maintenance tasks mode mode effect effect Rate Rate consequence consequence Analyse causes, leading to Analyse causes, leading to Minor Delay Minor Delay Fails to Fails to an increased task freq for: an increased task freq for: an increased task freq for: an increased task freq for: Track circuit Track circuit Track circuit Track circuit to traffic to traffic to traffic to traffic transfer transfer Examine cable connections Examine cable connections shows shows Low Low Low Low electrical electrical Examine cable for damage Examine cable for damage occupied occupied Manual Manual Medium Medium Medium Medium energy (eg energy (eg Ensure cable securely Ensure cable securely when clear when clear operation operation open circuit) open circuit) fastened fastened mode mode Minor Delay Minor Delay To transfer To transfer Track circuit Track circuit to traffic to traffic electrical electrical Analyse causes, leading to Analyse causes, leading to shows shows Low Low Low Low an increased frequency for: an increased frequency for: energy from energy from occupied occupied occupied occupied Medium Medium Medium Medium Manual Manual Manual Manual the rails to the the rails to the the rails to the the rails to the Medium Medium Medium Medium Examine cables for damage Examine cables for damage Examine cables for damage Examine cables for damage when clear when clear operation operation Insulation test cables Insulation test cables train detector train detector mode mode (track relay) (track relay) Fails to isolate Fails to isolate electrical electrical circuit circuit Slow speed Slow speed Slow speed Slow speed Analyse causes, leading to Analyse causes, leading to Track circuit Track circuit collision collision shows clear shows clear Passenger Passenger Medium Medium an increased frequency for: an increased frequency for: Very Low Very Low when when train collision, train collision, Very High Very High Examine cables for damage Examine cables for damage Insulation test cables Insulation test cables occupied occupied potential potential fatalities fatalities fatalities fatalities 10

Takeaways Takeaways • Do you understand how your assets fail? t f il? • Do you understand the consequence of failure q modes? • Can you improve your knowledge of how assets fail? knowledge of how assets fail? • Are there systems for recording defects and failures? • Do you know your critical assets? • • Will you try a FMECA on your Will you try a FMECA on your critical assets? • How can today assist you in maintenance planning? 11

Summary Summary OEM may provide a good OEM may provide a good initial base for planning initial base for planning maintenance but ... maintenance but ... i t i t b t b t Safe assets need you to: Safe assets need you to: Safe assets need you to: Safe assets need you to: Understand how they fail on Understand how they fail on your railway your railway your railway your railway Understand failure Understand failure consequences on your railway consequences on your railway consequences on your railway consequences on your railway Plan maintenance activities to Plan maintenance activities to mitigate against asset failure mitigate against asset failure 12