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link to an detailed diagram (open in new window)

Putting total maintenance into effect

In order to actualize a highly efficient total maintenance, depot integrated management system is used, combining the ground based automatic inspection system, the train on-board self-diagnostic system, the parts/material control system and the vehicle utilization system (as detailed below). These systems promotes improvement in accuracy and labor saving in the maintenance process.

The depot integrated management system

The main points of the depot integrated management system developed by Hitachi are given in the upper figure. This system is a total depot management system that combines the maintenance management system, the vehicle utilization system and the parts/material control system. These systems are already used throughout Japan as a system that can greatly contribute to labor saving in maintenance, advancements in reliability, efficient usage of carriages and improvements to the components replacement process.
In maintenance management system , the data from tests of vehicles stock can be automatically collected by means of both the automatic measuring systems on the ground and on-board self diagnostic system as given below.

On-board self diagnostic system

We are currently in the process of implementing a system where the tests on the core parts of the rolling stock, including the propulsion system, brake system and safety signal equipment are, in combination with the Train Management System, automatically done at the touch of just one button and the results are then collected by the maintenance management system by such means as IC cards or radio signals.

Automatic measuring system on the ground

Wheel tread wear, brake pad wear, contact strip wear and wheel flats can all be inspected on the ground by means of ground equipment. Then these measuring data are automatically relayed online to the maintenance management system, which then offers a highly automated diagnosis monitoring system.

Parts/material control system

The real key to the efficient running of maintenance lies in both the security of the maintenance components and their timely supply. There should be no shortage of stock items and no wasteful overstocking. In order to ensure their requirements, there is an automatic computer based stock management system and a secure supply partnership with the original component supplies.

Training

However much the inspection becomes automated, the company must ultimately rely on the competence of the workforce. We place equal emphasis on the training of our staff as we do on the high degree of automation of the maintenance system. The reliability of the Japanese railways is down to the people. As well as technological training we also take care to teach all our staff about the great responsibility we have for the many human lives and vast capital investment involved in rail transport.
Hitachi has close work relationship with Japanese train maintenance providers that have a proven track record Japan's railway system.

• Features : PDCA Cycle-Japanese style of maintenance