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LavaCon 2017 - Case Study: Streamlining Maintenance at Siemens Rail by Linking Content and Engineering Data

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In Spring 2016, Siemens Rail began operating state of the art trains from a custom built depot. The information required to operate and maintain these trains needed to be accessible and technically accurate, so that drivers, maintenance technicians and engineers could keep trains available and running on a full-service contract.
This talk shows how Siemens identified waste in their existing processes and used the DITA standard to create an innovative publication system. The system featured a web-based maintenance portal and knowledge base that capitalized on interactive 3D models, and iPad apps for the driver’s manual. User feedback and technicial contributions at the point of consumption, coupled with interactive information, have contributed towards an estimated 30% saving in train maintenance effort.

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LavaCon 2017 - Case Study: Streamlining Maintenance at Siemens Rail by Linking Content and Engineering Data

  1. 1. Streamlining Maintenance at Siemens Rail by linking content & Engineering data Siemens Mobility uses DITA withTeamcenter and DITAweb to optimize train maintenance operations
  2. 2. Restricted © Siemens AG 2016 Page 3 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Introductions John Straw – Applications Manager Siemens Mobility john.straw@siemens.com Previously the Publications Manager driving this solution development. Julian Murfitt – CEO and joint founder of Mekon Julian.Murfitt@mekon.com www.mekon.com Providing Content Strategy and technical expertise in the documentation & XML publishing arena for over 26 years.
  3. 3. Realize innovation.Restricted © Siemens AG 2016 Automation Build Technology Drive Technology Energy Healthcare Mobility Financing Sevices Siemens Rail plc Part of Siemens Mobility Part of a large group of companies
  4. 4. Realize innovation.Restricted © Siemens AG 2016 Siemens Mobility Maintenance Work Instructions “Downtime caused by inadequate maintenance information is a long-standing issue” Dave Hooper Program Director, Siemens Mobility
  5. 5. Restricted © Siemens AG 2016 Page 6 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Total Service Logistics Business challenges Maintain Total Service Logistics • Keep trains running at optimal operating levels. • Improve the effectiveness of maintenance teams. • Capitalize on knowledge held in content and the service team technicians Scheduled overhauls on a fleet of 115 trains allow for only one train to be unexpectedly out of action at any time. Minimizing the time that a train spends in a depot is crucial. Customer Deployment Design & Manufacture
  6. 6. Restricted © Siemens AG 2016 Page 7 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Total Service Logistics Business challenges Customer Deployment Design & Manufacture Maintain Total Service Logistics “The traditional method of compiling maintenance instructions has been to pass information from the train supplier to a publishing company. This typically results in a first draft that requires substantial rewriting, plus an ongoing need for revision over the life of a train. Amendments are often done in batches to minimise cost, so manuals are frequently not up-to-date. Downtime caused by inadequate maintenance information is a long-standing issue across the rail industry.” Dave Hooper Program Director, Siemens Mobility
  7. 7. Restricted © Siemens AG 2016 Page 8 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Total Service Logistics Business challenges Customer Deployment Design & Manufacture Maintain Total Service Logistics “In my previous roles, it felt like we never had enough detail and were always identifying problems on the job. For example, some maintenance tasks were simply not possible and we often had to raise a non-conformance. It takes a lot of precious engineering time to agree how to handle and rectify such problems.” Ben Wardle Production Manager, Siemens Mobility • Manage technical query's TQs • Capture non-conformance using technician knowledge
  8. 8. Restricted © Siemens AG 2016 Page 9 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Total Service Logistics Keys to success Maintenance-manual documentation-creation processes that leverage: 1. Document creation and management as an integrated service lifecycle management solution; 2. Leverage core engineering data including 3D CAD in the creation of maintenance manuals; 3. Deploy work instructions as interactive, visual instructions to minimise text and allow technicians to clearly understand the required work tasks; 4. Capture real time feedback from technicians at the point of discovery
  9. 9. Restricted © Siemens AG 2016 Page 10 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Why DITA Flexible in its architecture • Specialisation Standards based for security and longevity of support • Teamcentre could support a number of options so they had choices Flexible Technology options • not tied to one supplier Allow decision on final deliver solution to be deferred • Not ready choose all the tools
  10. 10. Restricted © Siemens AG 2016 Page 11 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Integrated Service Lifecycle Management Solution • Traditional workflow means longer lead time before authors and maintenance teams can work on content Manufacturing readiness Publications readiness Workshop Manuals Parts Catalogues Owner Literature Wiring information Training Information Warranty Repair Times Work instructions Workstation s setup Parts supply and logistics Process information Maintenance Manuals Parts Catalogues Owner Literature Wiring information Training Information Repair Times Strategic planning R&D, systems development Systems integration & product development Product design and engineering Production 1
  11. 11. Restricted © Siemens AG 2016 Page 12 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Integrated Service Lifecycle Management Solution • improves collaboration and teamwork • engineering release integration • reduces time-to-market Manufacturing readiness Publications readiness Workshop Manuals Parts Catalogues Owner Literature Wiring information Training Information Warranty Repair Times Work instructions Workstation s setup Parts supply and logistics Process information Publications readiness Teamcenter-enabled authoring Maintenance Manuals Parts Catalogues Owner Literature Wiring information Training Information Repair Times Strategic planning R&D, systems development Systems integration & product development Product design and engineering Production Product Data (Teamcenter) EBoM Document Content (Teamcenter CMS) DITAweb Portal Maintenance Manuals 1 TEAMCENTER
  12. 12. Restricted © Siemens AG 2016 Page 13 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Manuals Delivery - Architecture Engineering BOM (A2V part numbers) CAD files (A6Z ...) Associated documents (A6Z...) SAP non-associated documents (A6Z...) Import scripts Engineering BOM (A6Z....) Associated documents (A6Z...) SAP non-associated documents (A6Z...) Documentation Structure Cortona Objects DITA MAPS DITA TOPICS
  13. 13. Realize innovation.Restricted © Siemens AG 2016 Content and process management: Teamcenter Content authoring: Teamcenter & Cortona3D “Teamcenter with RapidAuthor takes our solution to a whole new level” John Straw Publications Manager, Siemens Mobility
  14. 14. Restricted © Siemens AG 2016 Page 15 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Solution architecture CORE TEAMCENTER EBOM Publications EXTERNAL ASSETS CAD JPG, CGM XML CORTONA PROJECT XML VRML CGM •AUTHOR CONTENT • PUBLISH Variant Config- uration XML+ VRML+ CGM+ <xml /> XML Teamcenter Technical Publishing • Teamcenter – BOMs and 3D core data. • Cortona3D – 3D interactive authoring tool for technical publications documentation (xml, html, pdf, ios output). • Teamcenter Technical Publishing – management of publications content. • Cortona3D RapidAuthor: content creation • Teamcenter: workflows, DITA-compliant content creation, content management • DITAweb Content delivery INFORMATION PORTAL Modules/ Chapters/ Books
  15. 15. Restricted © Siemens AG 2016 Page 16 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Manual Deliverables Type Content Operating Manuals Driver’s Manual Drivers Manual App Maintenance Manuals Scheduled maintenance instructions Maintenance procedures Special engineering checks Overhaul and refurbishment instructions Spare Parts Catalogue Servicing and Cleaning Manual
  16. 16. Restricted © Siemens AG 2016 Page 17 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Information Structure – Commonality with Class 700 Pre-task – 707 Specific Applicability Competence Materials Special Tools Safety Conditions General Maintenance... Pre-task – 700 Specific Standalone fragments for Class 700 and 707 Task – Common 707 New / Revised Steps 3D Full commonality of validated steps (few exceptions – Sanding, Vehicle Level etc) PostTask – Common Testing Close up MMS Serialisation Full commonality but can be specialised later depending on operation
  17. 17. Restricted © Siemens AG 2016 Page 18 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Pre Task
  18. 18. Restricted © Siemens AG 2016 Page 19 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Task
  19. 19. Content management: Single source DITA content in Teamcentre Content Delivery: iPad mobile app Train Operating Manual Single source mobile app on an iPad
  20. 20. Restricted © Siemens AG 2016 Page 22 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30
  21. 21. Restricted © Siemens AG 2016 Page 23 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30
  22. 22. Realize innovation.Restricted © Siemens AG 2016 Cleaning Manual: New ways to repurpose content in DITA Spare Parts: Can be ordered Linked to Manuals Other Manuals Cleaning manual, Spare Parts Catalogue and fault diagnostics Fault Diagnostic: Growing knowledge base
  23. 23. Restricted © Siemens AG 2016 Page 26 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Fault code Knowledge base Knowledge base articles For Fault diagnostics
  24. 24. Restricted © Siemens AG 2016 Page 27 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Commenting feed back on Maintenance tasks Commenting and feedback
  25. 25. Restricted © Siemens AG 2016 Page 28 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Shop floor view by technicians RFBP070
  26. 26. Restricted © Siemens AG 2016 Page 29 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Video clip showing 3D procedure
  27. 27. Restricted © Siemens AG 2016 Page 30 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Siemens mobility authoring and job readiness gains 700 documents produced by team of four in 14 months Cost-effective data re-use from contract to contract “I have worked in technical publication for 20 years, and our progress is absolutely phenomenal. With Teamcenter generating accurate content and RapidAuthor for visualisation, we dramatically cut our preparation and research time. It has taken 50 percent less time to produce manuals, at significantly lower cost than previously, and we met our target to provide publications six months before the trains enter operation.” John Straw Publications Manager, Siemens Mobility • 50 percent less time to produce maintenance work instructions • readiness 6 months ahead of product launch
  28. 28. Realize innovation.Restricted © Siemens AG 2016 Content and process management: Teamcenter Content authoring: Teamcenter & Cortona3D “50% reduction in time to create manuals” John Straw Publications Manager, Siemens Mobility
  29. 29. Restricted © Siemens AG 2016 Page 32 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Siemens Mobility maintenance operations gains Clearer and up-to-date maintenance manuals avert delays Interactive publication deliverables allows feedback to product development and issue resolution avoiding critical product down time “If you speak to any technicians, they love the manuals. We estimate a 30 percent reduction in time spent on maintenance. With this project we have resolved many initial queries before they become an issue. We are not leaving any ambiguity; there will be no confusion, which is what causes delays.” Ben Wardle Production Manager, Siemens Mobility • technicians have the clear and correct information (in line with the latest engineering releases) every time • time spent on maintenance reduced by 30 percent
  30. 30. Realize innovation.Restricted © Siemens AG 2016 Teamcenter for work instructions Business benefits “We estimate a 30% reduction in time spent on maintenance” Ben Wardle Production Manager, Siemens Mobility
  31. 31. Restricted © Siemens AG 2016 Page 34 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Summarising • Improved collaboration and teamwork and, critically, reduces time-to- market. • Maintains technical publications data in sync with engineering releases and running changes, and avoids backlogs. • Improves right-first-time results and reduce text. • DITAweb dynamic delivery ensures that technicians, drivers and engineers all receive the consistent semantic rich instructions for the right product configuration in a format that suits their needs.
  32. 32. Restricted © Siemens AG 2016 Page 35 Julian Murfitt – Specialist consultants in XML publishing technology2016-10-30 Thank you for listening Your opinion is important to us! Please tell us what you thought of the lecture using the LavaCon app. For interested parties wishing to learn more about this case study, please email julian.Murfitt@mekon.com including the subject “LavaCon 2017 Staying on track” In response we will send you a set of speaker notes to complement the presentation slides and a link to a previously recorded video Or call the Mekon office +442087228400

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