1. بسم الله الرحمن الرحيم

2. King Saud University College of Engineering Department of Industrial Engineering King Saud University College of Engineering Department of Industrial Engineering Improve The Value of PM Activities of Passengers Coach at (SRO) By ZAKI ALAWI AL-ALWAYET 420001889 Advisor: Dr. Adel Al-Shayea Examiner: Dr. Mohammed Zaki Ramadan

3. Outlines Introduction. The aim of the project. (PM) activities in(SRO). The Selected PM Activities to be Studied and Improved. Solution methodology. Conclusions

4. 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. Introduction

5. Introduction 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.

6. The Aim of the Project 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)

7. 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 (SRO)

8. The Selected PM Activities to be Studied and 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.

9. Solution methodology Solution methodology One 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

10. Solution methodology 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.

11. Information Phase: Coach Classification On Use Coac hes Total Number Of Coaches Coach Classification SwitzerlandFrenchGerman 610*4061st Class 2028*81372nd Class 69*333Restaurant 99333Baggage 22-11Royal 43581820 Total 43320 On Use Coaches

12. Information Phase : Average times need to perform PM Activities Summarizes the average times needed to maintain a single coach for each section and for each type of inspection: AnnuallySix MonthsThree Months Average Time # Workers Average Time # Workers Average Time # Workers 1124141 Air Break 7.5823.422.92 Air Conditioning 835232 Bogie 11.526261 Body Repair 1017.25281 Electric 9373ـــــــــــــــــ Painting 6.3516151 Carpenter 7.51513.751 Pipefitting 2.51 12.561 Upholster 73.71647.61535.410 Total

13. Information Phase : Quarterly activities relationships and dependencies TypePredecessorDurationActivity Description Activity ID 9Electrical Semi-annually ItemsELCS Finish-StartELCS3Air Conditioning Semi-annuallyACS 6Body Repair Quarterly ItemsBRS 4Air Break Semi-annually ItemsABS 6Bogie Semi-annually ItemsBGS Finish-StartABS5Pipefitting Semi-annually ItemsPFS 6Carpenter Semi-annually ItemsCRS Finish-StartCRS2.5 Upholstery Semi-annually Items HSS Finish-StartBGS-ELCS7Painting Semi-annually ItemsPTS

14. Information Phase : Quarterly activities Gantt Chart

15. 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 : Average times need to perform PM Activities

16. AnnuallySix MonthsThree Months 9.55.52.3 Air Break 1.710.7 Air Conditioning 8.74.22 Bogie 0.80.50.3 Body Repair 9.24.72.8 Electric 2.51.2----------------------- Painting 1.510.3 Carpenter 31.71 Pipefitting 1.71.20.3 Upholster 38.520.810.5 Total Information Phase : Average Number of breakdowns

17. 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 : Average Number of breakdowns

18. 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 : Average Cost in each PM Program

19. AnnuallySix MonthsThree Months Total cost 968446572926 Air Break 1087056304658 Air Conditioning 899054603278 Bogie 743241502111 Body Repair 1658087477808 Electric 741537600 Painting 420020901243 Carpenter 398626581822 Pipefitting 354017861167 Upholster 726973893825013 Total Information Phase : Average Cost in each PM Program

20. REMARKSP/W WORTH (SR) PRESENT (SR) KINDKIND FUNCTIONITEM UNIT NOUNVERB 0.9830002926BAvailabilityMaintainAir Break1 Problem in the way of putting priorities 1.433204658BAvailabilityMaintain Air Conditioning 2 0.9933003278BAvailabilityMaintainBogie3 1.0520002111BAvailabilityMaintainBody Repair4 Workers skills problem & Spear Parts 1.2454706808BAvailabilityMaintainElectric5 1.0312001243BAvailabilityMaintainCarpenter6 0.9519001822BAvailabilityMaintainPipefitting7 0.9712001167BAvailabilityMaintainUpholster8 Function Analysis Phase

21. REMARKS P/ W WORTH (SR) PRESENT (SR) KINDKIND FUNCTIONITEM UNIT NOUNVERB 1.0146004657BAvailabilityMaintain Air Break1 0.9954005630BAvailabilityMaintain Air Conditioning 2 Problem of the way doing the job 1.1248705460BAvailabilityMaintain Bogie3 1.0141004150BAvailabilityMaintain Body Repair4 Problem in the way of putting priorities 1.1973278747BAvailabilityMaintain Electric5 Problem in the way of putting priorities 1.623403760BAvailabilityMaintain Painting6 1.0420002090BAvailabilityMaintain Carpenter7 0.9428002658BAvailabilityMaintain Pipefitting8 0.9918001786BAvailabilityMaintain Upholster9

22. Function Analysis Phase REMARKS P/ W WORTH (SR) PRESENT (SR) KINDKIND FUNCTIONITEM UNIT NOUNVERB Problem in the way of putting priorities 1.1187509684BAvailabilityMaintain Air Break1 1.031050010870BAvailabilityMaintain Air Conditioning 2 Problem in the way of putting priorities 1.2373008990BAvailabilityMaintain Bogie3 0.9975007432BAvailabilityMaintain Body Repair4 1.001650016580BAvailabilityMaintain Electric5 Problem in the way of putting priorities 1.3554307415BAvailabilityMaintain Painting6 1.0141504200BAvailabilityMaintain Carpenter7 0.9940003986BAvailabilityMaintain Pipefitting8 1.0135003540BAvailabilityMaintain Upholster9

23. Creative& Evaluation Phases Average Rank Benefits Satisfying Operation Requirements Satisfying Safety Measures Simplicity of Implementation Factor Idea # 9.810 9 Restudy the relationship between the air conditioning section and electric section in the quarterly inspection 1 8.39996 Increase the number of worker in the air conditioning section 2 8.59997 Used other spare parts in electric section 3 8.39996 Increase the number of worker in electric section 4

24. Creative& Evaluation Phases Average Rank Benefits Satisfying Operation Requirements Satisfying Safety Measures Simplicity of Implementation Factor Idea # 9.8109 Restudy the relationship between the air conditioning section and electric section in the semi- annually inspection 1 9.8109 Restudy the relationship between the painting section and electric section in the semi-annually inspection 2 9810 8 Contract with company to inspection the bogie system 3 8.39996 Increase the number of worker in electric section 4 8.39996 Increase the number of worker in the air conditioning section 5 8.39996 Increase the number of worker in the bogie section 6

25. Creative& Evaluation Phases Average Rank Benefits Satisfying Operation Requirements Satisfying Safety Measures Simplicity of Implementation Factor Idea # 9.810 9 Restudy the relationship between the air break section and bogie section in the annually inspection 1 9.810 9 Restudy the relationship between the painting section and electric section in the annually inspection 2 9.810 9 Restudy the relationship between bogie and electric section in the annually inspection 3 8.39996 Increase the number of worker in the air break section 4 8.39996 Increase the number of worker in the bogie section 5 8.39996 Increase the number of worker in the electric section 6

26. 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.

27. TypePredecessorDurationActivity Description Activity ID Finish- Start ELCQ24.25Electrical Quarterly Items from 1 to 13ELCQ1 2.75Electrical Quarterly Items from 14 to 19ELQC2 2Air Conditioning Quarterly ItemsACQ1 Finish- Start ELCQ20.92Air Conditioning Quarterly ItemsACQ2 6Body Repair Quarterly ItemsBRQ 4Air Break Quarterly ItemsABQ 1.5Bogie Quarterly Items from 1 – 12BGQ1 1Bogie Quarterly Items from 13 – 18BGQ2 Start-StartABQ0.5Bogie Quarterly Items from 19 – 21BGQ3 Finish- Start PFQ22.75Pipefitting Quarterly Items 1 to 7PFQ1 ABQ1Pipefitting Quarterly Items 8 and 9PFQ2 5Carpenter Quarterly ItemsCRQ 2.5Upholstery Quarterly ItemsHSQ Development Phase

31. Annually Inspection Semi- Annually Inspection Quarterly Inspection Cost Summary 726973893825013Original 638813476022600Proposed 881641782413Total Cost Saving Development Phase

32. Conclusions 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.

33. Thank You