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© Hitachi Rail Europe Ltd. All rights reserved.

Delivery of Successful Rolling Stock Projects in a Competitive Railway Industry


• Adversarial approach to Project Management on all sides • Very prescriptive contractual requirements and punitive LD regime • Suppliers build contingency for penalties into their pricing • Led to a reliance on Variations and Lawyers • Customers sometimes forced to accept trains with many problems • Bad project performance, late deliveries, non-compliance, trains sat in

sidings awaiting approvals. • Many projects ended in legal challenges, litigation • Closing of open issues takes a long time • Operational performance of trains inadequate, non compliant, unreliable. • Unhappy customers

UK Rail projects – historical performance



Project Aims

• High Speed Commuter Service into London • Regenerate South East corner of UK • Link South East to North London & Docklands • Maximise use of High Speed 1 Route • Release capacity on Local Rail Lines • Increase capacity for London Olympic Games 2012 • Benchmark Reliability in UK

Hitachi Aims • Deliver what we promise



High Speed 1 route and domestic network

Hitachi Maintenance

Depot

Delivering High Speed Commuter Trains into the UK


Project Challenges - Technical

• First Japanese design to UK/EU standards and High Speed TSI • Complex train design

HS TSI Crashworthiness standards 225 kph operation on HS1 – French Network Dual voltage (25KV OHLE, and 750 VDC 3rd rail) 4 Signalling systems French TVM/KVB and UK TPWS/AWS Safety approvals required for NR AC, DC and Eu HS1 AC In cab Driver Only Operation using bodyside cameras 2 Infrastructures – High speed and local tracks Bogie design optimised to minimise track wear on Classic routes



• Complex train interface Rescue existing trains on both Networks Operate as 6 & 12 car and Split / Join en route. On Board Seat Reservation System Journey times necessitated high installed power (4Mw) Challenging Tunnel Fire standards

• Train operator not chosen at contract award • Integrate Maintenance into Design • Deliver on time and to budget • Deliver 55,000 MDBF reliability – performance contract

Project Challenges - Operation



Project Challenges - Design

DPTS1 Standard Seating Priority Seating Tip-Up Seating Total Seating

Wheelchair Accessible Toilet Wheelchair Area

24 4

13 41

1 2

MS1 Standard Seating Priority Seating Total Seating

60 8

68


Guard Panel

60 8

68

2


60 8

68


60 8

68

DPTS2 Standard Seating Priority Seating Total Seating

Standard Toilet

42 6

48

1

Delivering High Speed Commuter Trains into the UK


Hitachi (Manufacturer)

Safety & Approvals Manager

Independent Safety Assessor

(AEA Technology Rail)

3 rd Party Neighbours

Network Rail

CTRL

(Supervisory Authority)

HSBC (Owner)

Vehicle Owner and NoBo Contracting Entity

IKF/SRA (Operator)

Service & Test TOC

3

HSE (

(

Interfleet Certification

Independent Competent

Review Body

Notified Body / Engineering

Conformance Review

LR Rail

RAM Analysis Safety Case

Software Assurance

Vehicle Acceptance Body

Interfleet Technology

Project Challenges - Contract, Regulations and Approvals



• Project Procured by Government • Trains owned by ROSCO • Train Operator unknown • Transition phase for Standards - prototype • Transition phase for Regulatory bodies – prototype project • Owner and UK Consultancies lack of High speed experience • Inclusion of Maintenance contract – Train Service Agreement • Implementation of new Depot in parallel – inter-dependency

Project Challenges - Contractual



Language – UK, Japan, Europe Understanding the lack of trust from customer – UK history. Performance contract, not detailed specification. Design for maintenance – interaction with maintainer Need for vandalism proof trains Acceptance process – documentation requirements Project driven by PR

Project Challenges - Cultural



• Design – Japan – assisted by UK • Manufacturing – Japan • Assembly – Japan • Reassembly and commissioning – UK assisted by Japan • Testing - Japan and UK • Safety and Approvals – Japan and UK • Acceptance - UK assisted by Japan • Maintenance - UK

Project Challenges – Fully Integrated Team



Process - Critical Steps to control • Design scrutiny from concept to detail • Trials and mock ups • Prototype build and review, scrutiny • Glass Case samples agreed • Type testing – static and dynamic • Safety and Approvals Acceptance • Customer Acceptance • Initial operation feedback • Lessons learned feedback

Making it Happen


© Hitachi, Ltd. 2009. All rights reserved. 13

Fully detailed mock ups

All Rights Reserved, Copyright © 2010 Hitachi Rail Europe Ltd.

Low risk solution for C395

Module

FSW 12 years

ＴＭＳ IGBT Traction

16 years High speed Bogie 45

years

HVAC

Air tight Door 45 years

AL Car body 35 years anti-corrosion know-how

Well Proven Design

Applying established reliable technology


TMS

Motor

Cables Filter

Transformer

HVAC

Data storage

IGBT

CPU

Bogie Al bodyshell

Display Converter

Li Battery

Low risk solution for C395


Key features – Crashworthiness structure

Crashworthiness structure

RGS&TSI compliant Crashworthiness



Energy Absorption Block Crashworthy Structure

Energy Absorption Block

High Performance Structure Developed by Various Analysis and Testing



Crash Simulation – Train to Train

Crash Simulation to confirm the energy absorption performance


Key features –Air tightness

Full Scale Pressure Pulse Testing following FEA


Key features –Bogie

High-Speed technology

Good Ride performance

300km/h, Series 500 285km/h, Series 700

275km/h, Series E2 270km/h, Series 300

Running Stability

Bolsterless bogie based on Shinkansen Technology

Less damage to track


Japanese Sliding Door European Sliding plug Door

MTBF: 33 x 10 6 MTBF: 18 x 10 3 ←

more than 1800 times Reliable

Simple slide door for reliable & fast open/close operation Air tight is achieved by door pressure device at 4 corners

Key features –Door


GREAT BRITAIN Wheel sets Gangway TPWS/ AWS Rubber Flooring Cab Panels Cab Electrics HVAC Pneumatic Fitting Air Horn Brake Hose Fire Protection Internal lights External lights Door Sounders DSD Foot pedal Rail ramps Advert frames Catering locks SRS

SPAIN Toilet

BELGIUM Speed Indicator

FINLAND Gangway Door

DENMARK PIS SRS

CZECH REPUBLIC Reduction Gear

SWITZERLAND Cable

GERMANY Couplers Seats Damper Windows Carpet Flexible Conduits Luggage Stacks

Major European Suppliers Project Challenges - Procurement

France Signalling



Making it Happen Philosophy • Joint Understanding of the Contract and Specification

• No Surprises, Requirements capture

• Understand each others main priorities • Customer, Stakeholders, UK team, Japan team

• Understand responsibilities

• Customer, Stakeholders, Hitachi teams, Acceptance & Approvals bodies

• Understand and manage the Risks • Communicate

• Keep the contract in the cupboard



Mitigating Challenges and Risks • Continuity of Bid team into Project • Immediate “No Surprises” Review

• (Requirements Capture exercise) • Understand the intent of the specification

• Continuous programme reviews with all parties for risks, opportunities and

joint mitigating actions • Instigate special forums for key novel/risk items

• Wheel/Rail and bogie interface • Operation • Testing • Infrastructure

Making it Happen



Mitigating Challenges and Risks • Agree Strategy for Safety and Regulatory Approvals with relevant

bodies – and stick to it. • Keep stakeholders up to date with progress and emerging issues –

“No Surprises”. • Create and foster One Team approach with all Stakeholders –

Collaboration is better than Litigation • Start activities earlier than you think – training, manuals. • Instill the Hitachi “must do” attitude in all parties. • Utilise informal and formal communication processes.

Making it Happen



• Factory team transferred to UK, working in depot • Units assembled and interiors completed in UK • All systems and UK only tests carried out at Ashford • Detailed Acceptance process carried out with customers

• Fault Free Running – 2,000 miles on DC lines 2,000 miles on AC lines in 6 car & 12 car formations • Initial 4 Test units reworked to service standard • Units accepted at average of one per week • Final acceptance required 20,000 continuous fault free miles per unit

Making it Happen – in UK



The Right Maintenance Philosophy

May 2006 January 2007

28 June 2007 30 August 2007


5 x MAINTENANCE ROADS

WAREHOUSE

MAIN OFFICE

SHUNTERS CABIN

WHEEL LATHE

TRAIN WASH

HEADSHUNT

AUTOMATIC INSPECTION

TEST TRACK

BIO HAZARD PIT

STABLING AND CET

STABLING & CET

Ashford Train Maintenance Centre Site Plan


Strictly time based activity

Absolute standardisation of process

Continual improvement. (Kaizen)

Rigidly team based

Consistent reliable staff

Long term skills base

Japanese Fleet Maintenance


Data collection is key

Automatic Inspection

TMS Data

Electronic Job cards

Inventory Control

Staff and Attendance

Dashboard Reporting


Automatic train inspection system

Allows trend monitoring Brake pad wear Wheel profile wear Wheel damage.

Alarms and work orders automatically raised to supervisor.

Integration to Equinox suite pioneered by Hitachi Rail Maintenance at Ashford

Proven in use – by Hitachi and other

operators


Maintenance Support

Equipment drop allows two trains to simultaneously have equipment removed on adjacent roads

Sculfort double headed wheel lathe

Automated storage machines for small spares and exam kits


2004 2005 2006 2007 2008 2009 2010

Apr 04

SRA issued ITT for new high speed trains

Jun 05

Contract signed with Hitachi

Nov 05

Depot Contract

30 Aug 07

Unit 1 delivered (on time)

4 Sep 07

100 mph on DC testing

Sep 07 – Nov 08

Testing on HS1 and Network Rail including 12 car passing trials

Sep 07 – Mar 08

Units 2-4 delivered

Nov 07

Unit 001 participated in St. Pancras opening ceremony and entered station unassisted

Mar 09

“S” Stage certificate

June 09

Provisional Acceptance of Unit 1

13 Dec 09

Commencement of full high speed service

Project Timeline


The first unit (6 cars) of the Hitachi CTRL-DS train arrived in the UK in August 2007 drawing huge media attention.

Delivery



4 - Delivery, maintenance and early introduction June 2009 - start of preview service Delivery



December 2009 – start of full service Delivery



Achievement

Introduction of Class 395 for CTRL-DS, First A-train High Speed for UK HITACHI made contract to supply ‘Class 395’ high speed A-trains for Channel Tunnel Rail Link Domestic Service (CTRL DS), UK

Rail News

HITACHI completed delivery of all 29 train sets on time & budget.

HITACHI acquires high reputation owing to high quality & reliability train.


“It was fantastic –very, very fast” Ian from Ashford

“I can’t believe how quick the new train is” Stephen from Ashford

“Train service amazing –very fast” Stefan from Westgate on Sea

“Comfortable, early, just perfect” Matt from Ashford

“It makes what was a long tedious journey…pleasurable” Joanna from Gravesend

What the fare paying public say - Fast -

© Hitachi, Ltd. 2010. All rights reserved.


What the fare paying public say - Great Service -


“The service itself is extremely efficient” Gary from Gravesend

“The train is comfortable, the staff friendly” Gary from Ashford

“It’s really comfortable, it’s great, really clean. It’s like first class Diane from Bean

“The new high speed train is fantastic” Christine from Ashford

“This is how travel should be” Elizabeth from Gravesend


What the fare paying public say - Good Value -


“Well worth the extra few pounds” Mike from Bethersden

“Even the extra £2.90 is worth it for this relaxing journey” Ian from Ashford

“I am loathe to say this but the weekly upgrade is phenomenal value” Guy from Westwell

“The quality of life is more important …if I can cut an hour and a half it’s worth it” Lisa from Darenth


What the fare paying public say - Life Changing -


“Thank you so much for letting me spend an extra hour in bed and making it possible for me to turn up 30 minutes early for work” Heather from Kingsnorth

“Feels like leaping forward a century. It will change the way I can live” Leigh from Ashford

“I can get from St Pancras to Kent quicker than some Londoners can get about on the tube” Andrew from Ashford

“Awesome!” Mick from Sittingbourne


C395 project has been awarded the “Project of the Year” based on commencing of passenger service 6 month early.

National Rail Award - September 2010

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