THE ST. LOUIS PREDICTIVE MAINTENANCE PROGRAM Program Results & Application in Your Organization Ray Friem, Chief Operating Officer Metro Transit
STRATEGIC FLEET MAINTENANCE Strategic Vehicle Procurement Predictive Maintenance Program Lower Maintenance Costs & Greater Reliability
PRE-PROGRAM BUS MAINTENANCE COST PER MILE $2.00 $1.80 $1.60 $1.40 $1.20 $1.00 $0.80 $0.60 $0.40 $0.20 $0.00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Original Cost/ Mile
HISTORICAL BUS REPLACEMENT STRATEGY 160 140 120 100 80 60 40 20 0 Number of Buses Purchased Based On Funding (earmarks) 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Number of Buses
PROCUREMENT STRATEGY DRIVES OPERATING COST U n i t s P u r c h a s e d 160 140 120 100 80 60 40 20 0 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2011 2012 2013 2014 2015 2016 $35,000,000.00 $30,000,000.00 $25,000,000.00 $20,000,000.00 $15,000,000.00 $10,000,000.00 $5,000,000.00 $0.00 A n n u a l O p e r a t i n g C o s t Fiscal Year Units Purchased Annual Maintenance Cost
TRADITIONAL MAINTENANCE PROGRAM HISTORICALLY 1500 MILE PACE 1500, 3000, 4500, 6000, 7500, 9000, 10,500, 12,000 repeat Driven by the need to adjust brakes every 1500 miles 3000 MILE PACE 3000, 6000, 9000, 12,000 repeat Changed with the advent of automatic slack adjusters but synced with the need to change Oil at 6000, ATF at 12,000 and Diff lube at 24,0000 miles
TRADITIONAL MAINTENANCE PROGRAM Components changed as needed Bus to main rebuild center for major engine repair or replacement and body repairs (usually mid-life) Dwell time on major repairs of 100 days or more Low expectations
IN 2002 IT WAS CLEAR THAT WE ABSOLUTELY HAD TO BREAK THIS CYCLE IF THE TRANSIT SYSTEM WOULD BE SUCCESSFUL System had just completed the purchase of 260 new buses in the past two years for a bus fleet that was 415 buses (now 380 plus contingency). That meant that we had about 5 years before major work and cost for midlife activities would commence. Further, our work load was immediately lessened by the new buses, in other words, we had time, but time works both for you and against you. It was imperative that we do everything we could to break the cycle.
REDESIGNED BUS & VAN FLEET MAINTENANCE IN 2002 CMO MANDATE Design a Program that could: Control operating cost Manage life cycle cost Extend the life of a bus beyond 12 years / 500,000 miles. Required to stagger future procurement efforts. If necessary retire some buses early on mileage only to further stretch procurement cycle.
PROGRAM GOALS Budgeting should be consistent and predictable Plan our work so that both operating and capital costs are consistent from year to year This is a go-long strategy that may require more than one capital purchase cycle to complete
PREDICTIVE MAINTENANCE Basic Concept: Replace or overhaul parts before they fail in service Ensure your preventative maintenance is part of your fleet management strategy Rigidly enforce configuration management No sub-fleets within sub-fleets Measure, adjust, and measure again Perform replacement at regular intervals
MANAGE AND PROGRAM LIFE CYCLE AND COST Determine expected life for asset Bus 15 years and 800,000 miles Create a maintenance program in order to attain the expected life Condition based maintenance point every 50,000 miles PM inspection schedule at 10,000 miles Oil change only (Jiffy Lube) at 6,000 miles
PREDICTIVE MAINTENANCE PLAN Minor actions every 50,000 miles 50k, 150k, 250k, 350k, 450k, 550k Major actions every 100,000 miles 100k, 200k, 300k, 400k, 500k, 600k
PREDICTIVE MAINTENANCE PLAN
BASE VS. PROGRAM BUS MAINTENANCE COST PER MILE $2.00 $1.80 $1.60 $1.40 $1.20 $1.00 $0.80 $0.60 $0.40 $0.20 $0.00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Traditional Cost Per Mile Predictive Cost Per Mile
HOW EXACTLY DOES OUR PREDICTIVE MAINTENANCE PROGRAM SAVE US MONEY? We looked at when historical failures occurred and found: We would bring a bus in four times to replace four identical components as they failed individually. (Changing them all at once saved three trips into the shop). We were running components into the ground, for example transmissions: Complete Overhaul of failed unit costs between $10K and $16K depending on model. Providing overhaul of seals and bearings before failure costs $4K. By determining which components historically failed and scheduling them for replacement in the 50K mile increment before failure we could predict when we needed the part (Inventory reduction / Cost of $$$)
HOW EXACTLY DOES OUR PREDICTIVE MAINTENANCE PROGRAM SAVE US MONEY? Every failure that occurred happened with people on the bus! Reduce in route failures, save on in route replacements (less angry customers = more customer revenue). Reduction in Accidents: Zero claims of Brake Failure in Five Years Enhanced Schedule Performance Helped Improve adherence to bus schedules from 75% to 93%. Needed the Capital Component (Rational Replacement Strategy) to Assure Success..
BUS FLEET REPLACEMENT STRATEGIES Units Purchased $40,000,000 160 $35,000,000 Purchase As Funded Strategy Transitional Purchase Strategy Planned Purchase 140 Strategy $30,000,000 120 $25,000,000 100 $20,000,000 80 $15,000,000 60 $10,000,000 40 $5,000,000 20 $0 Annual Maintenance Cost 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 Number of Buses Cost 0
PRE-PROGRAM EXPENSE ($) VS. VEHICLE USAGE (MILES) $120,000 120000 $100,000 100000 $80,000 80000 $60,000 60000 $40,000 40000 $20,000 20000 $0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Old Annual Cost Old Annual Mileage 0
PREDICTIVE PLAN EXPENSE ($) VS. USAGE (MILES) 70,000 60,000 50,000 40,000 30,000 20,000 10,000 0 $70,000 $60,000 $50,000 $40,000 $30,000 $20,000 $10,000 $0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Predictive Annual Mileage Predictive Annual Cost
BUS LIFE-CYCLE UTILIZATION 800000 700000 600000 500000 400000 300000 200000 100000 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Old Cumulative Miles Predictive Cumulative Mileage
DIRECT PROGRAM BENEFITS: GREATER VEHICLE RELIABILITY 12.00 10.00 8.00 6.00 4.00 2.00 0.00 30000 25000 20000 15000 10000 5000 0 AVG AGE MDBF
DIRECT PROGRAM BENEFITS: REDUCTION IN STOREROOM INVENTORY REQUIREMENT $7,000,000 $6,000,000 $5,000,000 $4,000,000 $3,000,000 $2,000,000 $1,000,000 $0 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 250 200 150 100 50 0 Storeroom Value Complaints
INFLUENCES OTHER SYSTEM OUTCOMES Accident Rates Workers Comp Claims 5.00 4.50 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00 FY02FY03FY04FY05FY06FY07FY08FY09FY10FY11FY12FY13FY14 Year Measured 300 250 200 150 100 50 0 FY02FY03FY04FY05FY06FY07FY08FY09FY10FY11FY12FY13FY14 Call-A-Ride (Preventable) MetroBus (Total) Call-A-Ride MetroBus MetroLink On Time Performance Complaint / 100,000 Boardings 105.00% 100.00% 60 50 95.00% 40 90.00% 30 85.00% 20 80.00% 10 75.00% FY02FY03FY04FY05FY06FY07FY08FY09FY10FY11FY12FY13FY14 0 FY02FY03FY04FY05FY06FY07FY08FY09FY10FY11FY12FY13FY14 Call-A-Ride MetroLink MetroBus Call-A-Ride MetroLink Metrobus
INDICATORS OF INEFFICIENT MAINTENANCE PRACTICES Campaigns or Systems Approach The practice of moving through fleet to repair or install a single component Expensive and a configuration nightmare! Competitive or Cooperative Competition between locations fosters secrecy Objective or Subjective Do personnel appraisal programs include objective measures both on individual (cost center), modal (division) and system levels?