Description:
A large number of Australian rail bridges were constructed over 80 years ago and the rail industry is suffering from their ever increasing maintenance costs and continued budget constraints. Making informed decisions for condition assessment, cost effective inspection, maintenance including repairs, upgrades and replacements with inadequate and sometimes inaccurate data and limited resource is a major challenge. Moreover, this limited access to actual data causes a great level of uncertainty in the management of railway bridges. In addition, bridge managers are expected to maintain these assets at specified performance levels with ongoing budget cuts and resource constraints. On the other hand, there is an increasing demand for bulk material transport leading to increasing axle loads to cope up with capacity constraints. Because of these reasons it is currently taking staff a longer time to plan and prepare maintenance budgets, analyse, interpret and take decisions for bridge life management. Most of the available bridge management systems are generic and analyse faults at the system level. In many cases, a detailed analysis at the level of individual components is needed to have a better understanding of potential root causes and focussed decision on bridge life extension. Consequently, a research project is being conducted on this issue and this paper proposes a practical bridge life management decision model using degradations, defect initiation and growth, maintenance options and relevant costs. The objective is to provide a practical, cost effective and user-friendly way to make maintenance decisions. The outcome of this research is a faster, more accurate system for informed decision making capability for cost effective life cycle management of railway bridges.
Description:
Trauma has a huge impact on the society and the economy. Large distances between the various human settlements in Queensland are a major challenge for the delivery of desired trauma care. In addition, health care budget has been struggling due to staggering costs. An integrated trauma management system (ITMS) is expected to maximise the appropriate and judicious use of available resources and deliver best possible services within budget constraints. A limited number of researches have been conducted to identify resource constraints and effective diversions for trauma cases in remote parts of Queensland. ITMS proposed in this paper covers activities, events and persons involved in trauma management. It analyses the impact of resource constraints and diversion rules for effective trauma care. Pre-hospital data are used for developing a process map. Simulation using Queensland scenarios assumed patients arrivals following the referral from regional/remote hospitals to regional trauma centres and to major trauma centres. Time stamps are used for the development and analysis of a simulation model using probabilistic approach for time to definitive care and patient outcomes. ITMS is able to further enhance quality of strategic planning. It can be extended to real time decision-making for better healthcare and reducing delays for arriving at definitive care. It is expected to further improve clinical outcome and transform the existing healthcare system into a more efficient, cost-effective and high quality healthcare service to the people living in remote areas.
Description:
Timber poles are widely used for distributing electricity in rural areas, mainly in developing countries. The improved reliability of timber poles is extremely important as the breakdown or failure of any one of these poles can result in millions of dollars in lost revenue and restoration costs. The losses can include production loss, loss of property, or even loss of life. The reliability of such poles depends on a complex combination of age, usage, durability of timber, environmental factors influencing the deterioration process, and most important, maintenance actions carried out through the lifecycle of the poles. This paper focuses on developing an optimal maintenance model that predominantly captures the inground decay of timber poles, and on developing a mechanism for measuring these factors. The developed maintenance model is then illustrated with numerical examples. Analysis of failure data shows that most of the failures of timber poles are due to a decrease in timber strength and peripheral dimensions at or below ground level. The results from this research could be useful for maintenance and replacement decisions regarding inground timber components used in the utility, construction, railway, and transportation sectors.
Description:
Overall Equipment Effectiveness (OEE) evaluates quantitatively how effectively a manufacturing operation is utilised. Total Productive Maintenance (TPM) was considered by Tibaldi, a leading food manufacturer in Australia for achieving OEE. This research project has identified performance gaps, developed plan and implemented it in Thermoforming area of the business. The developed methodology helped Tibaldi in improving productivity and quality through TPM involving machines, equipment, processes, and employees. This paper demonstrates how this can be achieved by reducing lead time and establishing lean environment. Productivity improvement through the devised methodology led to further enhancement of competitiveness of the organisation for domestic and international markets of processed food manufactured by Tibaldi Australia. Lessons learned from application of TPM in Thermoforming, a key asset area, is rolled out to other sections of the plat and results from this pilot study are presented in this paper.
Description:
Overall Equipment Effectiveness (OEE) evaluates quantitatively how effectively a manufacturing operation is utilised. Total Productive Maintenance (TPM) was considered by Tibaldi, a leading food manufacturer in Australia for achieving OEE. This research project has identified performance gaps, developed plan and implemented it in Thermoforming area of the business. The developed methodology helped Tibaldi in improving productivity and quality through TPM involving machines, equipment, processes, and employees. This paper demonstrates how this can be achieved by reducing lead time and establishing lean environment. Productivity improvement through the devised methodology led to further enhancement of competitiveness of the organisation for domestic and international markets of processed food manufactured by Tibaldi Australia. Lessons learned from application of TPM in Thermoforming, a key asset area, is rolled out to other sections of the plat and results from this pilot study are presented in this paper.
Description:
A large number of Australian railway bridges were constructed over 80 years ago and have become increasingly costly to maintain. Infrastructure managers are under pressure to maintain bridge structures to a specified performance level with less maintenance funding and fewer resources. Currently, some rail operators maintain bridges through generic asset management systems which are simplistic and only address immediate operational issues. This is despite the fact that a life cycle cost analysis is proven to strategically maintain bridge assets and reduce costs over their operational life. A new bridge management system (BMS) framework which consists of a life cycle cost analysis and strategy model is proposed in this paper. The model can provide solutions at the element, bridge and network levels. A brief background is provided on Australian railway bridge operational history. Finally, a new maintenance cycle is proposed and its components are discussed.
Description:
Introduction to Long-Term Warranty and After-Sales Service -- Lifetime Warranties : Policies and Cost Models -- Used Second-hand Product Warranty -- Extended Warranty -- Maintenance Contract -- Outsourcing Rail Maintenance through Maintenance Contracts - A Case Study. This volume presents concepts, policies and cost models for various long-term warranty and maintenance contracts. It offers several numerical examples for estimating costs to both the manufacturer and consumer. Long-term warranties and maintenance contracts are becoming increasingly popular, as these types of aftersales services provide assurance to consumers that they can enjoy long, reliable service, and protect them from defects and the potentially high costs of repairs. Studying long-term warranty and service contracts is important to manufacturers and consumers alike, as offering long-term warranty and maintenance contracts produce additional costs for manufacturers / service providers over the product{u2019}s service life. These costs must be factored into the price, or the manufacturer / dealer will incur losses instead of making a profit. On the other hand, the buyer / consumer needs to weigh the cost of maintaining it over its service life and to decide whether or not these policies are worth purchasing. There are a number of complexities involved in developing failure and cost models for these policies due to uncertainties concerning the service life, usage pattern, maintenance work and long-term costs of rectifications. Mathematical models for predicting failures and expected costs for various one-dimensional long-term warranty policies are developed at the system level and analyzed by taking into account the uncertainties in connection with longer coverage periods and the rectification costs over the warranty period. Failures and costs are modeled using stochastic techniques and illustrated by means of numerical examples for estimating costs to the manufacturer and consumer. Various rectification policies are proposed and analyzed. The models developed here can be used to aid in managerial decisions on purchasing products with long-term warranty policies and maintenance contracts or outsourcing maintenance.
Description:
Prognostic models for maintenance decisions have inherent limitations due to quality quantity of historical data, assumptions made, and time required in validating models. In this paper, Preventive Maintenance (PM) Intervals, Failure events, cost and maintenance records from Computerized Maintenance Management System (CMMS) are analyzed for reducing downtimes and Operating Expenditure (OPEX). The proposed methodologies for maintenance intervals and replacements with acceptable level of confidence are articulated to asset maintenance of a City Council of Australian Local Government organisation as a case of improved decision making under limited information.
Description:
IEEE International Conference on Industrial Engineering and Engineering Management
Description:
Prognostic models for maintenance decisions have inherent limitations due to quality quantity of historical data, assumptions made, and time required in validating models. In this paper, Preventive Maintenance (PM) Intervals, Failure events, cost and maintenance records from Computerized Maintenance Management System (CMMS) are analyzed for reducing downtimes and Operating Expenditure (OPEX). The proposed methodologies for maintenance intervals and replacements with acceptable level of confidence are articulated to asset maintenance of a City Council of Australian Local Government organisation as a case of improved decision making under limited information.
Description:
IEEE International Conference on Industrial Engineering and Engineering Management
Description:
Rail wheel service life and incurred cost significantly contribute to the economy and performance of Heavy haul railway operations. Effective wayside lubrication becomes part and parcel of steps to combat wear and improves service life multiple times compared to unlubricated rail and wheel. Currently three different types of technology of wayside lubrication are in practice throughout Australian heavy haul operation such as mechanical, hydraulic and electric lubricators. Older lubricator technologies i.e. mechanical and hydraulic, may be attractive from initial low investment point of view; however they harvest significantly lower benefits throughout their life cycle compared to enormous potential of latest technology ( i.e. electric) in the market. However, a proper economic analysis is essential to determine the cost effectiveness of these technologies which may help the heavy haul operators to have a clear understanding of the real benefits which may encourage establishing appropriate asset strategy they need. There are several closely related and commonly used methods for evaluating economic performance. These include life cycle cost analysis (LCCA) method, net benefits (net present worth) method, benefit/cost (or savings-to-investment) ratio method, internal rate-of-return method, and payback method. The basic concept of all these methods is to provide an indication on the cost effectiveness of a single technology. However, LCCA method is a preferred method amongst them because it provides most cost-effective design alternative over a period of life time that includes both the capital cost and ongoing maintenance and operating costs. In current heavy haul practice it is very rare to see any effective asset tactics and asset strategy in place which can evaluate asset performance and their incurred cost. Structured lubrication asset strategy and genuine practice can significantly contribute to heavy haul operations cost reduction, continuous improvement of human resource and sustainable lubrication practice. This paper presents a frame work and model of lifelong lubrication asset strategy and quantifies the benefits throughout incoming journey of Australian heavy haul using LCCA.
Description:
Fluctuating demands and increased competition in Australia and Asian countries have been putting more pressure on plants for packaged meat products in Australia. Total Productive Maintenance (TPM) was seen a solution and is currently being implemented within a major meat processing facility in Melbourne, Australia for achieving high Overall Equipment Effectiveness (OEE). Concerns were raised by board of directors due to OEE targets not meant. TPM was initially applied in key areas of the business, thermoforming and packaging for reducing wastes and further enhancing productivity and quality. It is now being rolled out to other sections of the plant. Data collected from fifty-two weeks of production has been analysed and recommendations made to achieve OEE targets for the R145 production line. Risk based maintenance was applied to control adverse effects of packaging quality which significantly influences shelf life. Shelf life of a modified atmosphere packaged product assures safety for consumption of meat products by consumers. Risk based maintenance considered asset failure probabilities, impacts on quality and availability of spare parts. Reliability Centred Maintenance (RCM) resulted in a Risk score for each maintenance activity and as a component was used for TPM program. Findings from this study have been passed on to the meat processing facility for implementation in the entire plant.
Description:
Fluctuating demands and increased competition in Australia and Asian countries have been putting more pressure on plants for packaged meat products in Australia. Total Productive Maintenance (TPM) was seen a solution and is currently being implemented within a major meat processing facility in Melbourne, Australia for achieving high Overall Equipment Effectiveness (OEE). Concerns were raised by board of directors due to OEE targets not meant. TPM was initially applied in key areas of the business, thermoforming and packaging for reducing wastes and further enhancing productivity and quality. It is now being rolled out to other sections of the plant. Data collected from fifty-two weeks of production has been analysed and recommendations made to achieve OEE targets for the R145 production line. Risk based maintenance was applied to control adverse effects of packaging quality which significantly influences shelf life. Shelf life of a modified atmosphere packaged product assures safety for consumption of meat products by consumers. Risk based maintenance considered asset failure probabilities, impacts on quality and availability of spare parts. Reliability Centred Maintenance (RCM) resulted in a Risk score for each maintenance activity and as a component was used for TPM program. Findings from this study have been passed on to the meat processing facility for implementation in the entire plant.
Description:
ISO55000 is the International Organisation for Standardization (ISO) standard for asset management published in 2014. It stipulates that effective control and governance of assets by organizations is essential to realize value through managing risk and opportunity, in order to achieve the desired balance of cost, risk and performance. It is a challenge to industries on how to address this. This paper is on the issues and challenges of balancing cost, performance and risk in heavy haul rail asset management. Illustrative example from heavy haul network is used for this and on how to address some of the important challenges faced by heavy haul sector for managing life of rail assets.
Description:
Managing the coefficient of friction at the wheel/rail interface through wheel flange/gauge face lubrication is an accepted practice in railway systems. However, the coefficient of friction between the top of rail and wheel tread is not well addressed using this method, with traction, braking and some steering forces causing significant rail and wheel damage. Top-of- rail friction management uses friction modifiers to control the coefficient of friction within a defined range, and is being used in some North American rail networks with beneficial results. In Australia, there has been limited use of top-of-rail lubrication and where it is applied, it is mainly utilised to improve steering forces and mitigate wheel squeal. This research project sought a holistic understanding of top-of-rail lubrication and management of wheel/rail friction in the Australian context. A systematic approach for experimentation and analysis of the application of a friction modifier was developed in this study. The approach utilised an engineering analysis based on experimental results and publications and a numerical study for three-dimensional analysis. Vehicle system dynamics and wheel/rail operating conditions were then modelled through GENSYS simulation to understand variations in wear index with respect to friction conditions at the wheel/rail interface.
Description:
Remote asset management are faced with additional challenges in monitoring conditions, coordinating logistics for maintenance crew, transport and spare parts for maintenance delivery and asset replacements. Recent trends in technologies, remote performance monitoring and risk-based decision making in Capital Expenditure (CAPEX) and Operations and Maintenance Expenditure (OPEX) decisions for asset management are being embraced by asset intensive industries around the world, where critical assets are located in geographically distributed remote areas or difficult to inspect and maintain locations. Industries are also pushing boundaries by reducing crew size, deferring capital expenditure and overhauling and decision making in inspection and in some cases relaxing Original Equipment Manufacturers (OEM) recommended maintenance schedules. This paper discusses some of the issues and challenges with remote asset management. Illustrative example from heavy haul rail is used to explain reduction in Life Cycle Costs (LCC) and further enhancing operational performance.
Description:
Remote asset management are faced with additional challenges in monitoring conditions, coordinating logistics for maintenance crew, transport and spare parts for maintenance delivery and asset replacements. Recent trends in technologies, remote performance monitoring and risk-based decision making in Capital Expenditure (CAPEX) and Operations and Maintenance Expenditure (OPEX) decisions for asset management are being embraced by asset intensive industries around the world, where critical assets are located in geographically distributed remote areas or difficult to inspect and maintain locations. Industries are also pushing boundaries by reducing crew size, deferring capital expenditure and overhauling and decision making in inspection and in some cases relaxing Original Equipment Manufacturers (OEM) recommended maintenance schedules. This paper discusses some of the issues and challenges with remote asset management. Illustrative example from heavy haul rail is used to explain reduction in Life Cycle Costs (LCC) and further enhancing operational performance.
Description:
Derailment is a business risk for rail operators. However, most of the derailments are due to a combination of several causes. This paper presents a derailment study, focusing on Australia, that categorizes a comprehensive set of factors causing derailment and current mitigation techniques. Finally, a risk gap is analysed and integrated model is proposed. Further, the opportunities to incorporate remote monitoring and data analysis technologies to ensure an eMaintenance management of derailment are discussed. A case study on eMaintenance of rail lubrication, which is highly related to derailment, is also demonstrated in this paper.
Description:
Abstract: Timber components are very popular due to its flexibility in use and therefore, widely used in bridges and building constructions, rail tracks and supply electricity throughout the world and in Australia. The main reason of this choice is for their high strength per unit weight, low cost and excellent durability. Reliability of these components is extremely important because a failure of these components may cause loss of money, loss of properties, injuries or even loss of lives. Reliability depends on various factors such as species of the timber, structural dimensions in design, environmental condition, human factors in installation, operations and maintenance. In general, the timber structure failures are due to the loss of load bearing capacity from the decrease in peripheral dimensions at or below ground level and loss of strength of timber fibre affecting bending resistance. Soil factors and related decays reduce the diameter and the strength of timber component affecting the safety in operation and service. Rotting of fibre can be from centre to outward or outward to centre by accelerating fungal and insect (termite) attack affecting reliability, availability, maintainability and safety of infrastructure assets. This paper is on investigating soil factors for modelling in ground decay and estimating parameters for failure distribution of timber poles. Real life data from electricity supply company in Australia have been used for modelling and validation. Results from this investigation can be used in optimal decision in maintenance and replacements for reducing the life cycle costs and risks of in-service failure of timber poles and infrastructure assets in similar environment.