maximo implementation at network rail

1

Date 20.11.13

Maximo implementation

and experience at

Network Rail Stephen Bond

Date 20.11.13 2

Introduction Section number to go here

Maximo implementation and experience at Network Rail

Date 20.11.13 3

About National Delivery Service

• NDS provides a national logistics and procurement service to its customers, the

operating routes - supporting the delivery of maintenance, operations, renewals and

enhancements activity.

• NDS is well placed as a national function within Network Rail to leverage economies

of scale and Network Rail's buying power within the supply chain on behalf of the

whole business

• As an internal product and service provider its annual turnover is approximately

£900m per annum, which as a percentage of Network Rail's annual spend on

“bought in” goods and services is over 15 per cent.

• NDS is also responsible for the operation of ten Local Distribution Centres (LDC),

allocation of national resources (e.g. wagons and delivery trains), planning and

delivery of efficient logistics / loading between material suppliers, LDCs and

materials handling / recycling locations. The NDS also operates production / welding

facilities

Date 20.11.13 4

About National Delivery Service

• Maximo is just one of the key applications – also:

• Oracle Supply Chain

• Bespoke logistic ordering tools (NROL3)

• Bespoke control applications

• Train operating applications

• Red Prairie WMS (3rd Party)

Date 20.11.13 5

Facts & Figures on NDS

• 2400km of rail is purchased by NDS each year on behalf of Track Enhancements

and Infrastructure Maintenance – enough to lay a single line between London and

Edinburgh.

• 130,000 tonnes of rail per year is supplied by NDS to Network Rail.

• 1.3m tonnes of infrastructure derived waste is handled by NDS each year

• 92.3% of infrastructure derived waste is recycled, recovered or re-used by NDS

each year.

• £2.9m the savings achieved through the Road Haulage Planning Centre in its first

year, avoiding 550,000 miles of journeys

• £118m of savings expected over CP4 with the award of a seven year agreement by

NDS for the supply and maintenance of on track machine fleet.

Date 20.11.13 6

Objective & Principles

Section number to go here

Date 20.11.13 7

Why Maximo?

The fleet includes:

High output renewals system

Track monitoring trains

Rail Grinders

Stone blowers

Rail delivery trains

Seasonal treatment fleet

Delivery Wagons

Incident recovery fleet

• All maintenance, overhaul & repair is undertaken

by contractors on behalf of Network Rail

• Contractors hold vehicle records; maintenance &

failure history, condition monitoring & other

information needed to manage asset reliability &

performance

• Over 2500 rail vehicles, with an insurance value of circa £750m

Date 20.11.13 8

Key Design Principles

• Access to Comprehensive Asset Register

• Extensive Vehicle maintenance scheduling capability

• Parts Inventory Management

• Rostering labour & Scheduling workshop facilities, tools and equipment

• Condition Monitoring Data

• Technical Support for fault diagnosis and trouble shooting

• On-going performance information to drive continuous improvement

• Direct access on-line data for fleet managers & maintainers

• Cost data, financial analysis and estimating

• Management & demonstration of asset compliance

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What we hope to achieve

• Lower Unit Cost of maintenance

• Reduced inventory management cost via effective contract management

• Lower annual unit costs for each vehicle type or module type

• Increased fleet reliability at work (worked shifts)

• Shifts delivered over shifts delivered plus shifts failed due to asset failure

• Reduced risk of regulatory intervention

• Severity/impact of incidents & number of incidents

• Visibility and standardisation of data

• Improved decision making

• Improved operational data including accurate usage for consumables e.g. fuel,

grinding stones, Stoneblower stone etc

• Development of a Network Rail workforce of optimum size with real time access to

rail vehicle maintenance data.

Date 20.11.13 10

Implementation


Date 20.11.13 11

Implementation Approach

Date 00.00.00 Presentation title to go here 12

Rail Fleet

• Vehicles created as assets in the asset tr application

• Up to 3 levels of sub assemblies created as rotating items/assets

• PM’s and job plans currently set up against top and middle level assets.

• 7400 active PM’s using 2400 job plans

• Calendar and metre based PM’s

• One central storeroom integrated to NR Oracle purchasing and financial

system.

• Central storeroom automatically feeds 35 satellite stores around the country

• 73 storerooms in total

• 1 internal maintainer 15 external contracted maintainers

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Hierarchy of Grinders

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Maximo Integration

ERP

TOPS

EMS Hub

Goods Receipt

Purchase Requisition

Vendor Updates

Items

Purchase Order

Invoices

PR Status

Vendor Updates

Items

Purchase Order

Invoices

In Service Dates

Operation Meters

PR Status

e.g.

NROL

FTP

In Service Dates

Operational Meters

Fleet Availability

Purchase Requisition

Goods Receipt

Vehicle Available

Component Modification

Fleet Availability

Web

Service

FAMS

TOPS Entry

Message Flow

FAMS Entry

Message Flow

FAMS Exit

Message Flows

MQ (JMS)Pub

Sub

Pub

ERP Entry

Message FlowPub

Fleet Availability

Message Flow

Key:Web Service Exposed

Web Service Call

ERP Exit

Message Flow Sub

SOA

Suite

MQ (JMS)

MQ (JMS)

Inte

gra

tion

Fra

me

wo

rk


Rail Fleet Challenges

• Business Change & willingness to change

• Multiple 3rd party maintainers

• Expectations of Fleet Engineers

• Entity in Charge of Maintenance

• Knowledge of application

• Unrealistic view of what could be achieved in year 1

& 2 in the business case

– Highlighted the inefficiencies in our

maintenance regime and process that need to

be improved. Become proactive rather than

reactive

Date 20.11.13 16

Progression



Business Progression

• Road Fleet

• PT&RS

• NDS 24:7 Control

• Service Help Desk

• Upgrade to 7.5

• Introduction of Scheduler


Managing Our Road Assets Through Maximo

• Maximo has been used to manage our road fleet assets since March 2012

• Road fleet is responsible for managing the lifecycle of 8,000 road vehicles from

initial order to the assets decommission

• We have reconfigured service requests and asset applications to meet road

fleets challenges to;

– Capture vehicle and fuel orders and provide suppliers with order

requirements inline with contractual requirements

– Capture related fuel card and vehicle assets and manage their independent

lifecycles.

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• Maximo is used to maintain our asset information by;

– Providing expiry information for fuel cards and road fund licences

– Ensuring road fund licences are taken out of service for decommissioned

vehicles



• We have enhanced our customers experience to place orders for new vehicles

and fuel cards by developing bespoke PHP forms to work along side the

Maximo road fleet solution. This give the following advantages;

• Users do not require a Maximo account to place orders

– Web forms can be hosted on our intranet

– We can ensure that only orders that are authorised are data loaded into

Maximo

– We are currently looking at rest API to remove the need of data loads

between PhP applications and Maximo.

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• Everyplace is being developed to allow NR to audit vehicles through work order tracking (tr);

–This will enable auditors to carry out mobile audits across 360 locations

Date 20.11.13 22

NDS 24:7 Control Desk

• NDS 24:7 use Maximo for the Infrastructure Monitoring Fleet & the Seasonal Fleet.

• The current operating status of the Asset / Vehicle is monitored and updated in real time.

• Service Requests and Work Orders are created in emergency situations, allowing emergency spares to be ordered.

• Daily update reports are generated for contractors and route managers to help identify any potential impacts to an Operational Shift.

• Wheel wear warnings are captured against an Asset, which provides the opportunity for a more effective maintenance planning schedule.

Date 20.11.13 23

Maximo NDS 24:7 Control Desk

• The main list screen shows the current operating status: Green =

Operating, Amber = Maintenance, Red = Not Ready.

• The list screen also shows the route the Asset has been allocated to, its

base location, current location & whether there is currently a Wheel Wear

Warning assigned to it.

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Maximo NDS 24:7 Control Desk cont…

• This screen shows all related

work orders for this Asset /

Vehicle.

• This screen shows the history

of geographical movements for

the Asset / Vehicle.

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Fleet Engineering Management System

(FEMs)

• The main list screen shows a summary of the Task, its current status, the

priority within the team and who the task is assigned to.

• The system allows the team to introduce & manage SLA’s and will provide

Fleet Engineers with a transparent view of what work is being completed.

Date 20.11.13 26

PT&RS Team

• The team ‘owns’ the Preventative Maintenance and Job Plan applications in

Maximo.

• They ensure all Job Plans and PM’s are set up correctly and make any

amendments in terms of safety bulletins or re-issued documents.

• They ensure that PM frequencies are correct (time & meter based) and also add

any planned materials for a maintenance event.

•The team have recently launched a new system (Fleet Engineering Management

System) within Maximo, for the management of the tasks they undertake on

behalf of their customers; such as ECR;s, Document Review & NIR’s.

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What Next


Date 20.11.13 28

Next Steps

• Create PM’s, job plans and metres for over

9000 wheelsets and incorporate them into

the new tyre and wheelset configuration

functionality

• Roll out of scheduler and assignment

manager

• Creation of Mobile applications which will

be trialled on our Grinder Fleet with an

external maintainer. (EveryPlace)

• Introduction of HSE module

• Mobility proof of concept

• Integration with WMS

Date 20.11.13 29

Questions

maximo implementation at network rail

Documents