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Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Lean Service Summit
Europe 2004
Dipl.Dipl.--Ing. Manfred RedekerIng. Manfred Redeker
Optimizing the Contractor Management
at
Eisenbahn und Häfen GmbH
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Services
Rail: • Management of plant and connecting rail networks
• Planning and implementation of rail-bound traffic on
public infrastructure
• Transshipment and storage of mass goods and piece
goods
• Quality control, commissioneering, distribution
• Planning, construction, and maintenance of technical
plant and equipment
• Repair of locomotives and railway cars (including
refurbishment of components)
Ports:
Engineering:
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Key Data/Figures
Infrastructure
and Equipment:
• 500 km track
• 1550 track points
• 100 engines/locomotives
• 2000 freight cars
• 15 cranes/loading bridges
• 2 port tugboats
• 72.8 million t transported via plant railroads
• 395.0 million tkm plant railroads
• 8.6 million t transported via public rail networks
• 22.3 million t transshipped
Performance:
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Current Situation
Division of duties in infrastructure maintenance
• Inspections
• Planning for maintenance/construction activities
• Providing materials
• Monitoring realization
Handled
internally
Outsourced
• Track laying and construction
• Welding
• Clearing points
• Signal equipment work
• Electrical repair
• Track points cleaning
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Strengths
• Flexible use of outsourcing and subcontracting
• Quick response to problems
• Good budget monitoring
Weaknesses
• Work to be performed is not completely covered in service specifications
• Orders for firms have lee-way for performance/invoicing
• No systematic monitoring of fault clearing and poor documentation by
subcontractors
• Planning of orders and capacity are insufficient (repair work determined by
events)
• IT in use is not customized to meet the needs of maintenance
• State of infrastructure is not generally known due to many system breaks.
Analyzing the Current Situation
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Contractor Management
Basic idea
10-20%
80%
-
90%
Inspection
Repair
Maintenance
Corrective
Maintenance
Servicing
Individuel
Actions
Often repeated
actions
Standardization of servicing processes of a repetitive nature
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Optimizing the Contractor Management
Measures taken
• Adaptation of the business
processes
• Reorganization of servicing and
establishment of a maintenance
management system
- Revising the service
specifications
- Establishment of a
management system for
clearing faults
- Customizing the IT system
Objectives
• Reducing the costs of
outsourcing and subcontracting
• Lowering supervisory/direction
costs
• Lowering the internal
processing costs
• Increasing quality in services
performed
• More transparency in creating
services and simpler controlling
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Business Process
Order Invoice
Analysis
Inspection
Service
processing
with
subcontractors
Invoicing
Order
planning
Service
perfomed
Order
?
=
Service
specification
Damage
Service
specification
Service
specification
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
• Definition of evaluation benchmarks
- Objectively recording the status
- Classifying equipment components
• Derivation of relevant measurment values
- Establishing measurment cycles
- Registration of the values found
- Establishing equipment history
• Integration of the status monitoring into
the activities
- Inspection
- Repairs
- Fault clearance
Establishment of a Maintenance Management System
Geschäftsfeldlinie
Modulnummer
Modul
<=Priorität
Beschreibung des Modulinhaltes
KalkulierteZeit(Fh)
LeistungSOLL-Prozeß
Modulzeit/Einheit(Fh)
Priorität =>
I 1 Massivbau
I 1.1 Mauerw erk herstellen und instandsetzen
I 1.1.1 Natursteinmauer herstellen C
Mörtel herstellen, auftragen; Natursteine im Verband setzen, Zwischenräume schließen
(einschließlich Vor- und Nacharbeiten und Transport auf der Baustelle)
6 Fh/m³Quaderst. / 8
Fh/m³Bruchst. ***
I 1.1.2 Natursteinmauer instandsetzen B Instandsetzungsarbeiten, z. B. ersetzen ausgebrochener Steine, etc. 6-8 Fh/m² *
I 1.1.3 Ziegelmauer herstellen C
Mörtel herstellen, auftragen; Ziegel im Verband setzen, Zwischenräume schließen
(einschl. Vor- und Nacharbeiten) 5-6 Fh /m³ *
I 1.1.4 Ziegelmauer instandsetzen C
Mörtel herstellen, auftragen; Ziegel im Verband setzen, Zwischenräume schließen
(einschließlich Vor- und Nacharbeiten und Transport auf der Baustelle) 7 Fh /m² *
I 1.1.5 Mauerwerksfugen ausspitzen (Abbauhammer oder von Hand) C Fugen ausspitzen, Abbruchmaterial verladen inclusive Transport auf der Baustelle 0,5 - 1,0 Fh/m² ***
I 1.1.6 Mauerwerk verfugen (Naturstein, Ziegel) B Fugenmörtel herstellen, Fugen schließen 0,75- 2,50 Fh/m² ***
I 1.1.7 Mauerwerk verputzen - Sanierputzen C
Untergrund vorbereiten, Mörtel herstellen, aufbringen (einschließlich Vor- und
Nacharbeiten und Transport auf der Baustelle) baustellenspezifisch
I 1.2
Herstellung Fertigbeton- und -stahlbetonbauteilen
(stationär)
I 1.2.1 Schalungsarbeiten (incl. ausschalen etc.)
I
1.2.1.
1 Brettschalung C
Schalung herstellen und montieren, ausschalen, reinigen, (inclusive Riegel und
Abstützung, Bretter ungehobelt/gehobelt, mit Dreikantleisten), inclusive Transport auf 1,5-2,0 Fh/m² *
I
1.2.1.
2 Fertigschalung C
Z. B. Peri-Handset montieren, ausschalen, reinigen, Abstützung herstellen, inclusive
Transport auf der Baustelle 1,0-1,5 Fh/m² *
I 1.2.2 Bew ehrung
I
1.2.2.
1 Bewehrung herstellen (Bewehrungskorb) C Bügel und Längseisen verbinden, zwischenlagern 20-40 Fh/t (10-16er Baustahl) *
I
1.2.2.
2 Bewehrung einbauen C Bewehrungskorb einbauen, anpassen, inclusive Abstandhalter baustellenspezifisch *
I 1.2.3 Betonieren
I 1.2.3 Betonieren (incl. abdecken, befeuchten) C Transportbeton mit Betonkübel (Kran) einbauen, verdichten,abziehen etc. 2-3 Fh/m³ **
I 1.2.4 Nachbehandlung
I 1.2.4 Nachbehandlung (beschichten, hydrophobieren) C Beschichtung mit Pinsel/Rolle aufbringen (eine Lage) systemabhängig
I 1.3
Herstellung von Beton- und Stahlbetonbauteilen (vor
Ort)
Measure-
ments
Analysis of the
measurements
Feedback on
orders
Inspection
results
Basis of periodic, status-oriented maintenance
Status report
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Revising the Service Specifications
Contents of a standard service specification
Service item
Construction
materials
Transport service
Description as
independent of
constructed form as
possible
Graduated
performance rating
Material disposal
Construction
equipment
Invoicing unit that
can be checked
Requirements :
- Complete description
of core services to be
rendered
- Calculable
- Contract security
- Managability
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Revising the Service Specifications
Procedure
Determining the activities
• Evaluating services performed over the past years
• Assessing the performed service for further use
• Prognosis for the expected performance
Generating the service
specification
Revising the introductory
notes
Drafting documents for
tender
• Summarizing services as overall items
• Clear description of activities required
• Drafting introductory notes
• Adding related documents to the notes
• Legal examination of the introductory notes
• Drafting the quantitative framework
• Putting together the added documents to the
tender documents
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Optimized recording of defect source
Managing Repairs after Defects
TKS
businesses
Railway
business
SAP
Defect
Repair teamYes
No
Planable
repairs
Feedback
Report Recording Clearing faults Repair
Control centerEngineer
Decision if imme-
diate action is
required
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Customizing the IT System (SAP R/3 PM)
Required functions
Equipment Structure
Finding objects and components assemblies easily
Support for evaluations and analyses
Notifications
• Overview of maintenance
tasks
• Establishing equipment
history
Order
• Planning maintenance activities
• Clear service order
• Transparency in service
performance
Analyses
• Weak point analyses
• Target vs. actual comparisons
• Controlling the maintenance activities
Ein Unternehmen
von ThyssenKrupp
Steel Eisenbahn und Häfen
ThyssenKrupp
Results
18
24
35
0
10
20
30
40
50
year 1 year 2 year 3
costsavingsp.a.as%oftotal
Measures
Business processes
Service specifications
Management of defect repairs
IT system use

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Optimising the Contractor Management

  • 1. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Lean Service Summit Europe 2004 Dipl.Dipl.--Ing. Manfred RedekerIng. Manfred Redeker Optimizing the Contractor Management at Eisenbahn und Häfen GmbH
  • 2. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Services Rail: • Management of plant and connecting rail networks • Planning and implementation of rail-bound traffic on public infrastructure • Transshipment and storage of mass goods and piece goods • Quality control, commissioneering, distribution • Planning, construction, and maintenance of technical plant and equipment • Repair of locomotives and railway cars (including refurbishment of components) Ports: Engineering:
  • 3. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Key Data/Figures Infrastructure and Equipment: • 500 km track • 1550 track points • 100 engines/locomotives • 2000 freight cars • 15 cranes/loading bridges • 2 port tugboats • 72.8 million t transported via plant railroads • 395.0 million tkm plant railroads • 8.6 million t transported via public rail networks • 22.3 million t transshipped Performance:
  • 4. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Current Situation Division of duties in infrastructure maintenance • Inspections • Planning for maintenance/construction activities • Providing materials • Monitoring realization Handled internally Outsourced • Track laying and construction • Welding • Clearing points • Signal equipment work • Electrical repair • Track points cleaning
  • 5. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Strengths • Flexible use of outsourcing and subcontracting • Quick response to problems • Good budget monitoring Weaknesses • Work to be performed is not completely covered in service specifications • Orders for firms have lee-way for performance/invoicing • No systematic monitoring of fault clearing and poor documentation by subcontractors • Planning of orders and capacity are insufficient (repair work determined by events) • IT in use is not customized to meet the needs of maintenance • State of infrastructure is not generally known due to many system breaks. Analyzing the Current Situation
  • 6. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Contractor Management Basic idea 10-20% 80% - 90% Inspection Repair Maintenance Corrective Maintenance Servicing Individuel Actions Often repeated actions Standardization of servicing processes of a repetitive nature
  • 7. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Optimizing the Contractor Management Measures taken • Adaptation of the business processes • Reorganization of servicing and establishment of a maintenance management system - Revising the service specifications - Establishment of a management system for clearing faults - Customizing the IT system Objectives • Reducing the costs of outsourcing and subcontracting • Lowering supervisory/direction costs • Lowering the internal processing costs • Increasing quality in services performed • More transparency in creating services and simpler controlling
  • 8. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Business Process Order Invoice Analysis Inspection Service processing with subcontractors Invoicing Order planning Service perfomed Order ? = Service specification Damage Service specification Service specification
  • 9. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp • Definition of evaluation benchmarks - Objectively recording the status - Classifying equipment components • Derivation of relevant measurment values - Establishing measurment cycles - Registration of the values found - Establishing equipment history • Integration of the status monitoring into the activities - Inspection - Repairs - Fault clearance Establishment of a Maintenance Management System Geschäftsfeldlinie Modulnummer Modul <=Priorität Beschreibung des Modulinhaltes KalkulierteZeit(Fh) LeistungSOLL-Prozeß Modulzeit/Einheit(Fh) Priorität => I 1 Massivbau I 1.1 Mauerw erk herstellen und instandsetzen I 1.1.1 Natursteinmauer herstellen C Mörtel herstellen, auftragen; Natursteine im Verband setzen, Zwischenräume schließen (einschließlich Vor- und Nacharbeiten und Transport auf der Baustelle) 6 Fh/m³Quaderst. / 8 Fh/m³Bruchst. *** I 1.1.2 Natursteinmauer instandsetzen B Instandsetzungsarbeiten, z. B. ersetzen ausgebrochener Steine, etc. 6-8 Fh/m² * I 1.1.3 Ziegelmauer herstellen C Mörtel herstellen, auftragen; Ziegel im Verband setzen, Zwischenräume schließen (einschl. Vor- und Nacharbeiten) 5-6 Fh /m³ * I 1.1.4 Ziegelmauer instandsetzen C Mörtel herstellen, auftragen; Ziegel im Verband setzen, Zwischenräume schließen (einschließlich Vor- und Nacharbeiten und Transport auf der Baustelle) 7 Fh /m² * I 1.1.5 Mauerwerksfugen ausspitzen (Abbauhammer oder von Hand) C Fugen ausspitzen, Abbruchmaterial verladen inclusive Transport auf der Baustelle 0,5 - 1,0 Fh/m² *** I 1.1.6 Mauerwerk verfugen (Naturstein, Ziegel) B Fugenmörtel herstellen, Fugen schließen 0,75- 2,50 Fh/m² *** I 1.1.7 Mauerwerk verputzen - Sanierputzen C Untergrund vorbereiten, Mörtel herstellen, aufbringen (einschließlich Vor- und Nacharbeiten und Transport auf der Baustelle) baustellenspezifisch I 1.2 Herstellung Fertigbeton- und -stahlbetonbauteilen (stationär) I 1.2.1 Schalungsarbeiten (incl. ausschalen etc.) I 1.2.1. 1 Brettschalung C Schalung herstellen und montieren, ausschalen, reinigen, (inclusive Riegel und Abstützung, Bretter ungehobelt/gehobelt, mit Dreikantleisten), inclusive Transport auf 1,5-2,0 Fh/m² * I 1.2.1. 2 Fertigschalung C Z. B. Peri-Handset montieren, ausschalen, reinigen, Abstützung herstellen, inclusive Transport auf der Baustelle 1,0-1,5 Fh/m² * I 1.2.2 Bew ehrung I 1.2.2. 1 Bewehrung herstellen (Bewehrungskorb) C Bügel und Längseisen verbinden, zwischenlagern 20-40 Fh/t (10-16er Baustahl) * I 1.2.2. 2 Bewehrung einbauen C Bewehrungskorb einbauen, anpassen, inclusive Abstandhalter baustellenspezifisch * I 1.2.3 Betonieren I 1.2.3 Betonieren (incl. abdecken, befeuchten) C Transportbeton mit Betonkübel (Kran) einbauen, verdichten,abziehen etc. 2-3 Fh/m³ ** I 1.2.4 Nachbehandlung I 1.2.4 Nachbehandlung (beschichten, hydrophobieren) C Beschichtung mit Pinsel/Rolle aufbringen (eine Lage) systemabhängig I 1.3 Herstellung von Beton- und Stahlbetonbauteilen (vor Ort) Measure- ments Analysis of the measurements Feedback on orders Inspection results Basis of periodic, status-oriented maintenance Status report
  • 10. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Revising the Service Specifications Contents of a standard service specification Service item Construction materials Transport service Description as independent of constructed form as possible Graduated performance rating Material disposal Construction equipment Invoicing unit that can be checked Requirements : - Complete description of core services to be rendered - Calculable - Contract security - Managability
  • 11. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Revising the Service Specifications Procedure Determining the activities • Evaluating services performed over the past years • Assessing the performed service for further use • Prognosis for the expected performance Generating the service specification Revising the introductory notes Drafting documents for tender • Summarizing services as overall items • Clear description of activities required • Drafting introductory notes • Adding related documents to the notes • Legal examination of the introductory notes • Drafting the quantitative framework • Putting together the added documents to the tender documents
  • 12. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Optimized recording of defect source Managing Repairs after Defects TKS businesses Railway business SAP Defect Repair teamYes No Planable repairs Feedback Report Recording Clearing faults Repair Control centerEngineer Decision if imme- diate action is required
  • 13. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Customizing the IT System (SAP R/3 PM) Required functions Equipment Structure Finding objects and components assemblies easily Support for evaluations and analyses Notifications • Overview of maintenance tasks • Establishing equipment history Order • Planning maintenance activities • Clear service order • Transparency in service performance Analyses • Weak point analyses • Target vs. actual comparisons • Controlling the maintenance activities
  • 14. Ein Unternehmen von ThyssenKrupp Steel Eisenbahn und Häfen ThyssenKrupp Results 18 24 35 0 10 20 30 40 50 year 1 year 2 year 3 costsavingsp.a.as%oftotal Measures Business processes Service specifications Management of defect repairs IT system use