GS1 standards on track and rolling!

Identification of components and parts in the railway industry

Naeem Ahmed | Solutions Architecture Manager

November 23rd, 2016

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Lack of standards in daily life is

inefficient and annoying

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GS1 an international standards

organisation

Not-for-profit
110+ Member Organisations
Over one million user companies
(from SME to global companies)
Member driven
150 countries served; 20 different domains/sectors
2,500 people helping us
Over 6 billion transactions a day

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GS1 an international standards

organisation

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GS1 Standards of Identification

Global standards for automatic identification

Rapid and accurate item, asset or location identification

Global standards for electronic business messaging

Rapid, efficient & accurate business data exchange

The environment for global data synchronisation

Standardised, reliable data for effective business transactions

Global standards for RFID-based identification

More accurate, immediate and cost effective visibility of information

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Introduction

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Rail in numbers

2,500

billion passenger-kilometres

9,500

billion tonne-kilometres

More than

1,000,000

kilometres of lines

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Source: UIC , The International Union for Railways

Infrastructure: International Rail lines

billion passenger-kilometres

billion tonne-kilometres

kilometres of lines

Source: http://data.worldbank.org/
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Source: UIC , The International Union for Railways

Who are the key stakeholders ?

1.

Railway infrastructure company

- Manages the fixed assets

billion passenger-kilometres

Rail tracks, switches, electrical infrastructure, etc

2.

Train Operator
- Manages the rolling stock

billion tonne-kilometres

Owners/Leasing companies of locomotives, railway wagons /

vehicles and vehicle components
3.

Cargo Owners - (End) Customers

kilometres of lines

- Parties making direct use of former (1 & 2) stakeholders services

against a financial compensation
Goods Manufacturers, Logistics Providers, (passengers,) etc

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Source: UIC , The International Union for Railways

What type of cargo is shipped by rail?

2 main
Entities

Containerized
- Closed / Open
- Dry / Refrigerated

Bulk

billion passenger-kilometres
+

(wagon & container)

billion tonne-kilometres

- Dry
- Liquid

- Gas

kilometres 1ofmain
lines
Entity
(wagon)

Transporting Unit (= asset) Transported Items (= cargo)

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Source: UIC , The International Union for Railways

A bird's eye view of the Zurich Railway

Station

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Rail a hi-tech sector

The railway industry manages Infrastructure & Rolling Stock and
needs to ensure Interoperability in a complex environment

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Rail in Europe

Transport & Logistics and Technical Industries

Figures for some of the companies:

SBB MRO activities: 200 to 300 suppliers
Siemens Mobility Schweiz: > 5.000 suppliers
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Siemens Mobility worldwide: > 50.000!
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Business Needs

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Business Needs MRO Challenge

Main challenges in the Manufacturing and
Maintenance, Repair & Overhaul (MRO) processes
Vast number (hundreds of millions) of MRO-objects
Complex, international network of companies

Increasing regulatory requirements to prove the

maintenance history for critical MRO-objects.
Lack of common definitions and vocabulary

No common standard to identify an MRO-object and

determine its history.

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Business Needs
external influences on the Rail sector

Legislation
Government laws
Regulatory operators
Regional pacts

Market Pressure
Cost Pressure

Supply Chain Globalisation

New Automotive
Technologies
Higher Reliability
Improved Service

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Business Needs: The Rail sector is in a

state of transition

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Business Needs

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Business Needs
Summarizing
The rail industry must;
- Improve service levels to customers (travellers and shippers)
- Improve rail safety, reliability and operating costs
- Guarantee safe and stable operations (often driven by legislation)
Requires improvements to manufacturing & MRO processes
For rolling stock as well as rail infrastructure
Identification, traceability and interoperability are a must

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Project Traceability in Rail Industry

Unique identification - Project Overview

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Project Overview
Who is involved?
Operator

Manufacturer

Solution Provider

GS1 MOs

SBB

Alstom

Beijing REN

Australia

DB

Bonatrans

Coriel

Austria

SJ AB

Harting

DevCSI

Belgilux

BB

HFG Transport

Learningwell

China

Network Rail (UK)

Knorr-Bremse

smart-TEC GmbH & Co

Finland

Siemens

SupplyOn AG

Germany

TE Connectivity

Vilant Systems

India

UGL Limited

4PL Central Station

Netherlands

Unipart Rail Limited

Norway
Sweden
Switzerland
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MRO/ID in Rail
A Standard for the Future
Rail operator and Infrastructure Manager

Require Improved Asset and Material Management

This requires, among other things, a new level of asset and material management in MRO value
added chains, as this is the basis for further process improvement and stability

For the supplier to customer interfaces it looks like a relatively easy fix.
Many elements already seem to be there or fairly quick to implement.

Serialization based
on supplier S/N
(where necessary)

Marking of part numbers

Today

(where missing)

Tomorrow
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At a Second Glance First Challenges Appear

because the solution toolbox is not complete
Including your part number (= the
customer part number) on a material is:
Feasible for parts manufactured for
you only

Costly for parts manufactured not only

for you.
Solution 1: Follow an industry
standard (like DIN)
And if there is no industry
standard?
-> no solution today

OK

OK
NOT OK
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At a Further Glance even more Challenges Appear

because the numbering conventions are not clear
Which one is the S/N?
Series?

How is it constructed?

10710
No description?
Nr.?
ID-Nr.?

Is it unique in my
asset mgmt. system?
How do I need to type the
data string in?
What AIDC-technology can be
requested to eliminate typing errors?

006-1-3026 04/07 01
No description?

101607

Fabr.Nr.?

0031

09A884

Reg-Nr.?
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What about Marking Parts Yourself?

By marking parts yourself you could do it your own way without relying on other parties

so marking yourself is clearly not the ideal solution

Marking parts yourself allows you to:
- Remain independent of your suppliers
- Use your own AIDC-standard
However:
- This is costly and time consuming
- Can be difficult
- Your label normally has a shorter life
expectancy than the part
- There may be no space
- This is a waste, as often
there already are AIDC markings
- Is impossible in a shared refurbishment pool

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What is the Benefit for Me?

For suppliers: Reduced number of deviating and contradictory

customer requirements. The standard protects you.
For customers: Increased buying power in regards to marking
As a consequence: Increased certainty for production and
IT-process planning in regards to marking
Therefore: Reduction of process complexity
A tool box for so far unresolved asset and material marking cases
After phase 2: A tool box for the standardized BOM/data exchange

FINALLY: the RAIL CLOUD, which will allow for sharing of configuration
data, maintenance data, part histories and a common, shared data basis
for ALL parties involved in the lifecycle of a part

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Project Overview
Phase

Jan Feb Mar Apr May Jun

Jul Aug Sep Oct Nov Dec

Build business case

Launch work group
Draft business
requirements (BRAD)
BRAD community review
BRAD approval ballot
Draft standard

Finalise standard
Standard community review

Approval ballot

Current
status

Ratify standard
Publish standard

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Application Standard

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Application Standard
Business processes and roles

Manufacturer

Operator

Service
provider

Regulator

System
integrator

Rail network
operator

MRO
workshop

Government

System
manufacturer

Rail operator

Project
contractor

Certification
agency

Component
supplier

Logistic
services
provider

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GS1 Standards of Identification

Global standards for automatic identification

Rapid and accurate item, asset or location identification

Global standards for electronic business messaging

Rapid, efficient & accurate business data exchange

The environment for global data synchronisation

Standardised, reliable data for effective business transactions

Global standards for RFID-based identification

More accurate, immediate and cost effective visibility of information

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Harmonization: GS1 Standards

GS1 standards: an indispensable basis for competitive railways!

Common language avoids

confusion and enables
collaboration.
Collaboration in MRO and
Manufacturing makes Rail
operations more efficient
and effective.

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Application Standard
Identification levels and GS1 keys
class-level:
GTIN

classdependent:
GTIN+lot

lot-level
classindependent:
GLN+lot

identification

classdependent:
GTIN+serial ID
serial-level
classindependent:
GIAI

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Application Standard
Marking scenarios

Direct
marking

Marking at time of production

Additional marking at time of receipt, installation or refurbishment
Repairing lost or damaged markings

Packaging
marking

Marking of primary packaging

Marking of secondary packaging

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Result of a long term strategy

2012
RFID in Rail

European guideline for the identification of

railway assets using GS1 Standards.
Delivered by GS1 in Europe in 2012

2015
EPCIS in Rail

GS1 Application Standard for exchange of rail

vehicle visibility data using EPCIS.
Delivered 2015

2016
AIDC standards
rail components

GS1 Application Standard for the identification

of components and parts in the Rail Industry
Ratification expected by December 2016

Next (2017...)
Data sharing
rail components

GS1 Application Standard for the exchange of

configuration, traceability and maintenance
data for rail components and parts
Development starting January 2017
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Business Cases
Perspectives from Stakeholders

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MRO in Rail:
Case study on component
maintenance service

INNOTRANS, Berlin, 22.09.2016

1. Company Profile HFG

Reconditioning of
wheelset bearings

Bearing assessment and component check

Refitting with new polyamide cages
Regeneration by grinding of raceway

1. Company Profile HFG

Approvals and references:
Deutsche Bahn AG
BB TS
SBB Cargo
PKP Cargo

VPI Hamburg
VTG / AAE
Touax

Vattenfall Europe Mining

Bochumer Verein / RAFIL
Villmann-Group

Railmaint (former Euromaint)

Ryko a.s.

2. Serialization of wheelset bearings

Direct part marking
(DPM) by laser

Laser engraving at the rim of component

Implementation of GS1 Application Identifiers
Datamatrix quality checks with VERIFIER

Approved marking technology

Durable and robust marking
High quality of Datamatrix Coding

Laser Engraving video

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2. Serialization of wheelset bearings

Implementation of the GS1 data identifier concept
Combination with GS1 Datamatrix
Optional: Additional GS1 Application Identifiers

Direct part marking

(DPM) by laser

Serialization of newly manufactured bearings: sGTIN

[01]04053063013841[21]241174FW
HFG Article number

HFG serial no.

Serialization of used bearings as a by pass operation

during the regular wheelset maintenance: GIAI
[8004]405822640000000901458951
Asset identifier given
by owner / operator

3. Benefits for wagon keepers and operations

HFG: Rail maintenance provider

Component-individual tracking of
operational
data

component
life cycle

maintenance
history

logistics
& storage

internal benefits

external benefits
Warranty periods:
Exact determination
per piece

Guarantee claims:
Exact backtracking

Procurement:
Automated
processes

5. Chances and prospect

HFG: Rail maintenance provider

In the case study

combination and analysis of information

about bearings condition with operational data
Operator:
e.g. conclusion
from events (e.g.
accident) to
component failure
(and vice versa)

Cause-and-effect chains

Service/MRO:
e.g. use-based
maintenance
(dependent on
mileage, route)

Producer/OEM:
Empirical
assessment of
OEM-related
product quality an
other features

vision of a new business model: Pay per use

THANK YOU

GS1KSA 2016

GS1 Saudi Arabia

Council of Saudi Chambers
Tel.: 011-2182420, 011-2182423
Mob.: 055-6236662, 050-2295830
Email: nahmed@csc.org.sa | gs1@csc.org.sa
Website: Saudi: www.gs1.org.sa | Global: www.gs1.org

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