Optimization of Pneumatic Overhaul Workflows in Rolling Stock Workshop for Increased Process Efficiency

Abstract

Train overhaul is of utmost importance to ensure the reliability and availability of train services. As most trains have reached the midway point of their expected useful life, additional mid-life overhauls are scheduled, hence extending the overhaul duration and potentially reducing the number of service trains and increasing the number of crowded train station platforms. This paper, therefore, attempts to optimize pneumatic overhaul workflows in rolling stock workshop through dynamic modeling, simulation, and analysis of workflows; implementation of effective working tools; as well as recommendation of ideal facility layouts. With the aid of FlexSim three-dimensional software package, the coupler overhaul process efficiency is found to improve by 3.9% after implementing a torque multiplier in the coupler overhaul. The pneumatic overhaul process efficiency also increases by 10.8%, equivalent to a reduction of 17.6 working hours, after relocating the brake overhaul station and redeploying idle technicians.