division locomotives vitins - zeljeznice.net...division locomotives - final assembly in three steps...
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Division Locomotives
Borderless locomotives
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23%
8%12%
57%
European market share 2005
Bombardier is leader in the market of electric locomotives
Bombardier
Alstom
SiemensOthers
Bombardier is the largest producer of electric locomotives in Europe
Average European market share 1997-2003
19%
28%
5%
48%
Siemens
Others
Bombardier
Alstom
Total 1’540 kEuro
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IORE KirunaBlue Tiger
140 250–350 km/h200
TRAXX PlatformAVE S102
(330 km/h)
80 speed
Locomotives for Europe
* With Patentes Talgo, S.A.
AVE S130(250 km/h)
The TRAXX Platform of interoperable locomotives is the core business of Division Locomotives
> 1040 locos sold, >500 locos in service
Heavy freight
Interoperable locomotives for Cargo, InterRegio and InterCity
HighSpeed
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Bombardier is supplier of the largest fleet of high speed powerheads in Spain. Max speed 250 / 330 km/h
AVE S102 92 powerheads 330 km/h 1435mmAVE S130 90 powerheads 250 km/h 1435/1668mm
AVE S102 AVE S130
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Bombardier has 100% market share of electric locomotives for passenger services in North America
AEM 7
Acela powerheadHHP - 8
ALP 44
The ALP 46 operates on catenaries for double stack containers!
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The IORE locomotive of MTAB, Kiruna
The IORE locomotive was designed for arctic conditions. It is the basis for the 6-axle heavy freight locomotive which will be built with Dalian in China (500 locos sold)
Single cabDriver’s cab
80 km/hMax. speed
1250 / 1150 mmWheel Ø
25 – 30 tons Axle load
15 kV, 16.7 HzCatenary voltage
1435 mmTrack gauge
600 kNStarting TE
5.4 MWPower at the wheel
Co’Co’Axle arrangement
IORECharacteristics
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Dalian Co’Co’ locomotive – It combines the technologies from the IORE and TRAXX locos
• Carbody adapted dual cab, couplers, weight
• Bogies adapted 120 km/h, wheel profile
• Pneumatics adapted dual cab
• Vehicle control dual cab
• Traction converters IGBT
• Traction motor ratings
• Aux. converters adapted
Application specific:• Transformer• Cooling equipment• Brake control• Signalling
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Division Locomotives – 1.400 employees* at 5 sites
Vado LigurePre-/ final assemblyTest and commissioningSalesPM* Pool 464EngineeringSupply Management
KasselPre-/final assemblyTest and commissioningWarranty/service stationSalesPM* Pool TRAXXEngineeringSupply Management
*PM = Projektmanagement
WroclawManufacturing of carbodySupply Management
MannheimSalesPM* Pool TRAXXSupply ManagementEngineering
ZürichSalesPM* Pool „Applications”EngineeringSupply ManagementTest and commissioning
* as at May 05
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Bombardier in Kassel – The LOC “Lead Factory“
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1810 Formation of the company by Georg Christian Henschel
1848 Steam locomotive „Dragon” marks the change to innovative locomotive factory
1899 Delivery of the 5,000st locomotives
1905 Beginning of the production of electric locomotives
1910 Beginning of the production of locos with combustion enginesDelivery of the 10,000 locomotive
1923 Delivery of the 20,000 locomotive
1925 Building of standardized steam locomotives for passenger andfreight transport
1947 Building of high power diesel locomotives
Bombardier in Kassel – A view into History
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1960 Delivery of the 30,000st locomotive
1962 Building of the first diesel electric locomotivewith DC power transmission
1965 Beginning of development of three phase AC power transmission (with BBC)
1976 Delivery of the 32,000st locomotive
1991 Delivery of the 33,000st locomotive
2001 Lead factory for locomotive production of Bombardier Transportation
2004 Delivery of the 34,000 locomotive
2006 Completion of TRAXX product family
Bombardier in Kassel – A view into History
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Highlights:
All production activities in onebuilding
Production Area 18.000 m²
Staff permanent 560
Staff temporary 0 - 300
Main Competences
Pre and Final Assembly
Testing
Mechanical Engineering
Project Management
Logistics incl. Procurement, Production Control
Homologation and Warranty Support
Division Locomotives - The Kassel Site
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Division Locomotives – Pre-assemblies
• Driver‘s desk
• Piping / cabling modules
• Rear walls
• Roofs
Pre-assemblies are synchronized with the final assembly by pull logistics
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Division Locomotives – Final AssemblyConcept:
• 3 - 4 flow lines• Max. 20 locomotives / month • Material on pull principle
Flexibility
• No fixed installations in the finalassembly area
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Division Locomotives – Production flows
offices
incoming major components,
A-parts
pre assembly
loco final assembly
pre assemblymech. / electrical
incoming
material
trav
ersi
ng ta
ble
test track (various gauge)
paint booth
pre / final assembly
test & comm.
test & commissioning
test &
commissioning
loco overhaul (Service) store
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painted carbody
Division Locomotives - Final assembly in three steps
Step 1
delivery to
test & comm.
Step 2 Step 3
trans
form
er
driver‘s desk
bogi
es
roof
cabling
center canal
buffe
r
MR-com
ponents
All the components / activitiesare controlled by following criteria: - value
- throughput time- hours
call signal(external / internal)
pipi
ng
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throughput time (days)
Sustained stabilized processes
Throughput time reduction: large steps, each by a factor 2
1993 1996 1998 2006
80 40 20 10Functional Organization
Project - / ProcessOrganization Product Innovation
Project orientated order execution
Process stabilizationBR101Abu Tartour (Egypt)
New modularized products ⇒ TRAXXConcept / Engineering innovationFlow manufacturingPull logisticsBR185
Division Locomotives – Reduction of throughput time
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TRAXX F140 AC2
TRAXX P160 AC1
TRAXX 140 AC1
TRAXX 140AC2
Key parameters are displayed in the factory:
Quality InventoryLevel
Throughput-Time
EnvironmentHealthSafety
in Project
Division Locomotives – Monitoring shop-floor performance
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Division Locomotives - Fleet Implementation Facilities
• 8 indoor test bays, 8 outdoor test fields
• Electrical multi system test for: 15 kV 16 2/3 c/s, 25 kV 50 c/s, 3 kVDC and 1,5 kVDC
• Load test stage for diesel locomotives
• 250 m test track on site
• 12 – 15 working days of throughput time
• direct connection to German Railways, including high speed track
We act without limits
Wrocław locomotive site in Poland
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Bombardier in Wrocław: a look into the past
1838 - G.Linke commences rolling stock manufacturing on the site
1912 - Linke Hoffman Werke established
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Wrocław: Today production of all steel structures for locomotives: carbodies, bogie frames, …
2001 - Bombardier acquired Pafawag from Adtranz
2004 - 500th carbody type BR produced
2004 – first 5 carbodies for Italian railways produced
2006 – first TRAXX 2E carbodies produced
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Bombardier in Wrocław:
Key site characteristics:
• core competence: welded steel carbodies• full time employees: 325• temporary employees: 110
• two shifts production• production area: ca. 28 000 sqm
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4000
35003300
3000 29002650 2550 2450
2000 2001 2002 2003 2004 2005 2006 2007
Efficiency improvement (normative hours for carbodies type BR)
56
120 122136 137
162 158
185
2000 2001 2002 2003 2004 2005 2006 2007
Number of carbodies production (all types)
Bombardier in Wrocław:
Production level increase and efficiency improvement 2000 - 2007
Vado Ligure locomotive site in Italy
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When was the Vado Ligure site founded?
19051905The plant of Vado Ligure was built by Westinghouse.It represented the main railways production plant in Italy
19191919Tecnomasio acquired the Vado Ligure factory
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Bombardier has a long tradition in Italy
1905:1905: Locomotive E550 Locomotive E550 ““GiganteGigante deidei GioviGiovi””
The first 3-phase electric loco manufactured in Italy
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Vado Ligure Production Site
SalesEngineering Supply managementPre and final assemblyTesting and commissioningProject managementWarranty support
Locomotives Vado Ligure (LOC)
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Main contracts in Italy
Contract value: >1’200 M€
E464 - 544 units ordered
Single-cab locomotive for regional passenger traffic
♦ Axle arrangement: Bo‘Bo‘♦ Service weight: 72 t♦ Gauge: 1.435 mm♦ Axle load: 18 t♦ Length over buffers: 15.750 mm♦ Starting effort: 200 kN♦ Maximum power: 3,5 MW♦ Maximum speed: 160 km/h♦ Line voltage: 3 kV ÷ 1,5 kV DC
♦ Flexifloat bogie♦ GTO, water cooled converter♦ IGA drive, with Double-Star motor