بسم الله الرحمن الرحيم. king saud university college of engineering department of...

الرحمن الله الرحمن بسم الله بسمالرحيمالرحيم

King Saud UniversityKing Saud UniversityCollege of EngineeringCollege of EngineeringDepartment of Industrial EngineeringDepartment of Industrial Engineering

Improve The Value of PM Activities of Passengers Coach at (SRO)

By

ZAKI ALAWI AL-ALWAYETZAKI ALAWI AL-ALWAYET

420001889420001889

Advisor: Dr. Adel Al-ShayeaAdvisor: Dr. Adel Al-Shayea

Examiner: Dr. Mohammed Zaki RamadanExaminer: Dr. Mohammed Zaki Ramadan

OutlinesOutlines• Introduction.

• The aim of the project.

• (PM) activities in(SRO).• The Selected PM Activities to be

Studied and Improved.

• Solution methodology.

• Conclusions

•Maintenance function is a set of activities that are performed in order to keep system’s equipment in their best working condition.

•The objective of maintenance is to maintain the capability of the system while controlling the resultant costs of performing maintenance function.

IntroductionIntroduction

IntroductionIntroduction

Studying and then improving the function value of the PM activities are vital for improving the way of doing these activities and in turn for reducing their costs.

The Aim of the The Aim of theProjectProject

This project is a study of the PM operations at SRO. The aim of the project is to improve the function value of the PM operation and activities by using the value engineering tools.In particular, improve value function in preventive maintenance program activities for passengers coach (Quarterly inspection, Semi-annually inspection, Annually inspection)

Maintenance activities at the Saudi Railway have an effective role in achieving the organization targets by ensuring operation demands and travel schedule achievements. Any problem in maintenance activities, especially PM activities, will decrease the number of travels, and therefore the organization will not reach the planned optimal schedule.

PM activities in PM activities in (SRO)(SRO)

The Selected PM The Selected PM Activities to be Studied Activities to be Studied

and Improvedand Improved •I selected preventive maintenance program of passengers coach to be studied and improved.

The reason behind this is:

• preventive maintenance program of the passengers coach and its activities help to restore the condition of passengers coach items to an acceptable level, which is in turn necessary to maintain the passengers coach average desired life.

Solution Solution methodologymethodologyOne way of studying and improving the function value of these activities is by using the value engineering technique.

The reasons behind this is:

1.The ability of this technique in improving the value of the activities function at a minimum possible cost.

2.Ability to balance the cost and the function in such a way that required quality and performance, are maintained at the right costing level

Solution Solution methodologymethodology

The value engineering technique involves six phases. These are

1.The information phase.

2.The function analysis phase.

3.The creativity phase

4.The evaluation phase.

5.The development phase.

6.The presentation phase.

Information Phase Information Phase::Coach Classification Coach Classification

Coach Classification

Number Of Coaches

TotalOn Use

Coaches GermanFrenchSwitzerland

1st Class604*106

2nd Class7138*2820

Restaurant333*96

Baggage33399

Royal11-22

Total2020185843

On Use Coaches2020343

Information Phase Information Phase : :Average times need to perform Average times need to perform PM Activities PM Activities

Summarizes the average times needed to maintain a single coach for each section and for each type of inspection:

Three MonthsSix MonthsAnnually

#WorkersAverage

Time #Workers

Average Time

#WorkersAverage

Time

Air Break1414211

Air Conditioning22.923.427.58

Bogie232538

Body Repair1626211.5

Electric1827.25110

Painting3739ـــــــــــــــــ

Carpenter151616.35

Pipefitting13.751517.5

Upholster12.5612.512.5

Total1035.41547.61673.7

Information Phase Information Phase : :Quarterly activities relationships and Quarterly activities relationships and dependenciesdependencies

Activity ID

Activity DescriptionDurationPredecessorType

ELCSElectrical Semi-annually Items 9

ACSAir Conditioning Semi-annually 3ELCSFinish-Start

BRSBody Repair Quarterly Items6

ABSAir Break Semi-annually Items4

BGSBogie Semi-annually Items 6

PFSPipefitting Semi-annually Items5ABSFinish-Start

CRSCarpenter Semi-annually Items6

HSSUpholstery Semi-annually

Items2.5CRSFinish-Start

PTSPainting Semi-annually Items7BGS-ELCSFinish-Start

Information Phase Information Phase : :Quarterly activities Gantt ChartQuarterly activities Gantt Chart

This means the real time that had consumed for quarterly inspection on the average is 1.56 days. Real time that had consumed for semi-annually

inspection on the average is 2 days. Real time that had consumed for annually inspection on

the average is 4 days. (The day in the Gantt chart represents the working hours which is

from 7:00 am until 2:00 pm).

Information Phase Information Phase : :Average times need to perform Average times need to perform PM Activities PM Activities


Air Break2.35.59.5

Air Conditioning

0.711.7

Bogie24.28.7

Body Repair0.30.50.8

Electric2.84.79.2

Painting-----------------------1.22.5

Carpenter0.311.5

Pipefitting11.73

Upholster0.31.21.7

Total10.520.838.5

Information Phase Information Phase : :Average Number of breakdownsAverage Number of breakdowns

Each breakdown in the passengers coach was happened it cause losses to the Saudi Railway Organization depend to the size

of failure and in which part was happened. For example, the failure is

happen in electric part is not like is happen in upholster part.

Information Phase Information Phase : :Average Number of breakdownsAverage Number of breakdowns

The total cost of preventive maintenance=spare parts cost + labor cost + tools cost + losses Cost.

The average hour salary for workers in the Saudi Railway Organization is SR. 28.5/hour. This means

the labor cost = hour work* 28.5. The tools cost is depend on the working hour and the cost of tool per

hour. In spare parts cost there are difference between the sections, which means the cost of spare

parts depending in which parts the spare parts was used. The losses cost include the cost due to the

passengers coach is stop, for the inspection or for repair the failure. And the costs for repair the

failure.

Information Phase Information Phase : :Average Cost in each PM ProgramAverage Cost in each PM Program


Total costTotal costTotal cost

Air Break292646579684

Air Conditioning4658563010870

Bogie327854608990

Body Repair211141507432

Electric7808874716580

Painting037607415

Carpenter124320904200

Pipefitting182226583986

Upholster116717863540

Total250133893872697

Information Phase Information Phase : :Average Cost in each PM ProgramAverage Cost in each PM Program

UNIT

ITEMFUNCTIONKIND

PRESENT(SR)

WORTH(SR)

P/WREMARKSVERBNOUN

1Air BreakMaintainAvailabilityB292630000.98

2Air

ConditioningMaintainAvailabilityB465833201.4

Problem in the way of

putting priorities

3BogieMaintainAvailabilityB327833000.99

4Body RepairMaintainAvailabilityB211120001.05

5ElectricMaintainAvailabilityB680854701.24

Workers skills

problem & Spear Parts

6CarpenterMaintainAvailabilityB124312001.03

7PipefittingMaintainAvailabilityB182219000.95

8UpholsterMaintainAvailabilityB116712000.97

Function Analysis Function AnalysisPhasePhase


UNIT

ITEMFUNCTIONKIND

PRESENT(SR)

WORTH(SR)

P/W

REMARKSVERBNOUN

1Air BreakMaintainAvailabilityB465746001.01

2Air


3BogieMaintainAvailabilityB546048701.12Problem of the way doing the

job


5ElectricMaintainAvailabilityB874773271.19Problem in the way of putting

priorities

6PaintingMaintainAvailabilityB376023401.6Problem in the way of putting

priorities





UNIT

ITEMFUNCTIONKIND

PRESENT(SR)

WORTH(SR)

P/W

REMARKSVERBNOUN

1Air BreakMaintainAvailabilityB968487501.11Problem in the way of putting

priorities

2Air


3BogieMaintainAvailabilityB899073001.23Problem in the way of putting

priorities


5ElectricMaintainAvailabilityB16580165001.00

6PaintingMaintainAvailabilityB741554301.35Problem in the way of putting

priorities




CreativeCreative& & Evaluation EvaluationPhasePhases s

#

FactorIdea

Simplicity of Implementation

Satisfying Safety

Measures

Satisfying Operation

RequirementsBenefits

Average Rank

1

Restudy the relationship between the air

conditioning section and electric section in the quarterly inspection

10910109.8

2Increase the number of

worker in the air conditioning section

69998.3

3Used other spare parts in

electric section79998.5

4Increase the number of

worker in electric section69998.3


# Factor

IdeaSimplicity of

Implementation

Satisfying Safety

Measures



Average Rank

1

Restudy the relationship between the air conditioning section and

electric section in the semi-annually inspection

10109109.8

2

Restudy the relationship between the painting section and electric

section in the semi-annually inspection

10109109.8

3Contract with company to inspection the bogie system 8101089

4Increase the number of worker in

electric section69998.3


the air conditioning section 69998.3


the bogie section69998.3


# Factor

IdeaSimplicity of

Implementation

Satisfying Safety

Measures



Average Rank

1Restudy the relationship between the air break section and bogie

section in the annually inspection10910109.8

2Restudy the relationship between the painting section and electric section in the annually inspection

10910109.8

3Restudy the relationship between bogie and electric section in the

annually inspection10910109.8


the air break section69998.3


the bogie section69998.3


the electric section69998.3

Development Phase Development Phase

After evaluation process, I selected the best idea (higher average rank) for develop.

The best idea is the restudy the relationship between the sections. This is done by breaking down the items in checking lists then fined the relationships and dependencies between sections and items.

Activity ID

Activity DescriptionDurationPredecessorType

ELCQ1Electrical Quarterly Items from 1 to 13 4.25ELCQ2Finish-Start

ELQC2Electrical Quarterly Items from 14 to 192.75

ACQ1Air Conditioning Quarterly Items2

ACQ2Air Conditioning Quarterly Items0.92ELCQ2Finish-Start

BRQBody Repair Quarterly Items6

ABQAir Break Quarterly Items4

BGQ1Bogie Quarterly Items from 1 – 121.5

BGQ2Bogie Quarterly Items from 13 – 181 BGQ1

BGQ3Bogie Quarterly Items from 19 – 210.5ABQStart-Start

PFQ1Pipefitting Quarterly Items 1 to 72.75PFQ2Finish-Start

PFQ2Pipefitting Quarterly Items 8 and 91ABQ

CRQCarpenter Quarterly Items5

HSQUpholstery Quarterly Items2.5


Cost Summary

Quarterly Inspection

Semi-Annually

Inspection

Annually Inspection

Original250133893872697

Proposed226003476063881

Total Cost Saving

241341788816


ConclusionsConclusions

1. Finding the value index for the preventive maintenance program activity is very important for service sector in order to maximize service equipment availability while keeping the cost of performing maintenance activities at the lower level.

2. The improvement of the preventive maintenance program activity by increase its value index helps in increasing the total cost saving.

3. Value engineering techniques are very useful in increasing value index for preventive maintenance activities such as quarterly inspection, semi-annually inspection, annually inspection.

Thank YouThank You

بسم الله الرحمن الرحيم. king saud university college of engineering department of...

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