How Can We Make Fleets More Reliable Lessons from Training Our Best Managers and Redesigning Buses

What Causes More Reliable Fleets More Reliable Fleet from Better Bus Selections More Reliable Fleet from Better Problem Solvers

Ford Engine Choices 2003 7.3 2 valve per cylinder, 275 HP, 525 Lb/Ft, Fixed Turbo 6.0 4 valve per cylinder, 325 HP, 560 Lb/Ft, VGT Turbo, EGR

Ford 6.0 Lessons in Design, Testing and Purchases From 2003 to 2010, 6.0 in minibus E350, E450 (better EPA, power, noise) Ford techs not prepared, most issues had more than one cause IH had built 7.3 for years, switched to EGR (EPA), VGT turbo (power), these were tested components but transit applications (stop and go, low speeds) Ten problems hurt reliability. EGR valve, cooler, head bolts, oil cooler, FICM, HEUI injectors, VGT turbo, HPOP (ICP,IPR), wire chafe, oil seals TTY Head Bolts, Head Gasket Failures – out of service EGR Cooler soot - low power roadcalls EGR Valve sticks open - low power roadcall

Dissection of the Critical 6.0 Issues Problems Causes EGR Cooler Fail EGR Valve Fail Oil Filter Capacity Exceeded by 3-5k miles, then goes to bypass mode. Hot, dirty oil destroys injectors EGR Cooler flow restricted, then fails since gas is 500-1400 degrees, it slowly bakes, ruptures, oil-coolant mix EGR valve can clog, stick open-lose engine power Transit slow speeds not a fit for EGR valve clogging

Coincident Critical Issues TTY Head Bolts PCM, FICM, HPOP MY2003 6.0 used 10 bolts each head Torque To Yield bolts best for load frequency and amplitude found in high torque diesel engine, but the OEM bolts were M14 (not strong enough), and the design clamping the heads and the valve rocker pivots to the block was flawed. The 6.4 used M16 studs and the head and block were direct mating, with wider and thicker washer. Power Control Module and Fuel Injector Control Module had a variety of minor problems (vibration, chafing) caused hard start, rough run, stalling HPOP critical to injectors, power. PSI is 3,000 at speed, 600 at idle; below 500 will not start Injector Control Pressure and Injector Pressure Regulator sensors failed (chafing), oil O-rings common fail

How Did This Get So Bad How did the Ford 6.0 Implode? What replaced the 6.0? The 6.0 problems were each corrected, but often after misdiagnosis, repeats But so many problems, and so many confused diagnostics led to owners suffering repeated failures after warranty. Ford was reacting to new EPA regulations, and pushed International to improve exhaust (EGR was needed to reduce NOx). The EGR valve, EGR cooler were new. International replaced the 6.0 with the 6.4 to cure most of the problems, but not for transit. Introduced the DPF, compound turbos Introduced the common-rail fuel injection, no more oil pressure-injector But Ford had developed their own 6.7 Improved CGI block, 6 bolts/main bearing cap, 6 head bolts/cylinder, SCR, separate cooling for oil/coolant

How do we Redesign Buses An Example

Zion NPS Eldorado National RE August 2001 Bus Fire Power Unit – Total Loss, Fire in Engine Compartment Trailer Unit – Significant Damage Evidence Found - Hydraulic leak, Cooling fan Correction – Local maintenance team designed electric fan to replace and retrofit radiator Hydraulic fluid 17 gallon down to 1.5 gallon 3,000 psi down to 1,500 psi, Alternator no change Zion NPS Eldorado National RE

Conditions for Team to Solve Fan Problem Safety Expert General Manager Ingenious Maintenance Director, Team Trusting Client Steps Involved Solve Fire Source Source Electric Fan Design Mounting Test First Installation Prove to Owner/Client; Agree on Fleet Retrofit Conditions for Team to Solve Fan Problem Most important element was being sure the causation was analyzed accurately

How do we Build the Best Team for Fleet Reliability Part Training, Part Motivating, Part Scouting the Best Talent

Part Training ASE Certifications Mechanical systems NTI Training Courses Fundamentals of Management ENO or other coursework Leadership vs Management

Part Motivating Each position needs evaluation of skills, compensation balance (including benefits) Each position allows the incumbent to feel part of an important team Each position must have basic process of recognizing outstanding performance Each position becomes most valuable when the incumbent finds this career is his/her path to being all they can be

Part Scouting the Best Talent Within the organization, we must objectively determine the greatest performances Outside the organization it is important to assess who excels and why For those that may be promoted from within, morale improves if the promotion seems earned For those that must be found and brought into the organization, performance and morale improve if the new member is viewed as a star