Maximo Implementation at Network Rail
Transcript of Maximo Implementation at Network Rail
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Date 20.11.13
Maximo implementation
and experience at
Network Rail Stephen Bond
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Introduction Section number to go here
Maximo implementation and experience at Network Rail
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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
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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)
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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.
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Objective & Principles
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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
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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.
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Implementation
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Implementation Approach
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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
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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
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Progression
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Business Progression
• Road Fleet
• PT&RS
• NDS 24:7 Control
• Service Help Desk
• Upgrade to 7.5
• Introduction of Scheduler
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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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Managing Our Road Assets Through Maximo
• 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
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Managing Our Road Assets Through Maximo
• 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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Managing Our Road Assets Through Maximo
• 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
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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.
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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.
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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
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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
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Questions