Case Study No. 9
Train Operating Company
Improving fleet reliability through improved battery performance
To support the fleet reliability improvement activity detailed failure analysis is conducted on a daily basis. One major repeating failure identified was associated with the battery system. The battery failures were causing disruption to the train service and costing the client more than £130,000 every year in abatement costs.
Additionally, £73,000 was being spent yearly on procuring new batteries with no logic to scrapping old batteries.
Project Solution
The target improvement was set at reducing the abatement costs by 80% through detailed analysis and root cause countermeasure identification. Areas identified as potential causes of the failures were:
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Incorrect shutdown of power prior to train stabling
Length of time stabled with power on prior to interior cleaning
Inconsistent maintenance procedures due to Staff training, and material availability
Insufficient number of power cables available to keep power on prior to cleaning process
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Solution Implementation
By detailed investigation the failures were attributed to three direct causes and root cause countermeasures identified:
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Inconsistent Maintenance procedures – new procedures written, staff re-trained to new standard and 5S activity conducted in battery maintenance facility
Battery drainage due to lights left on in stabling – additional power cables implemented, staff re-educated and visual signage to focus staff attention
Incorrect Shutdown procedure – new procedure written and staff re-trained to new standard
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Results
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Battery failure reduced to provide an abatement saving in excess of £100,000 per year
Improved Health & Safety performance through 5S in battery maintenance facility
70% reduction in battery procurement providing a saving of £50,000 per year |
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| Supplier On-Time Delivery Performance |
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