Stéphane Guy Maintenance Director Africa Rail - Sandton 28 June 2016

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MAINTENANCE STRATEGIES
TO MINIMISE THE IMPACT
ON SERVICE DISRUPTION AND SECURE AVAILABILITY
Stéphane Guy, Maintenance Director | Africa Rail | Sandton | 28 June 2016

2. PagePage
AGENDA
1. Introduction
• our mandate
• our structure
• SA footprint
• project timeline
• economic development
2. Minimising service disruption and securing
availability
• design for serviceability
• make it local
• commit to parts availability
• invest in people
• set up performance-driven, long- term
partnership
3. Conclusion
28 June 2016Africa Rail, Sandton 2

3. Page
OUR MANDATE
Ourmandatehasthreeparts:
Africa Rail, Sandton 3
Foster rail as preferred mode of commuter transport for all South Africans
Build new, reliable, safe trains for SA’s 2.3 million daily rail commuters
Revitalise SA railway industry
Support customer with maintenance operations for 19 years
Build manufacturing/parts/maintenance/ training facilities
Create jobs
Develop skills
Achieve > 65% local content
Promote black economic empowerment
Support communities
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1
3
28 June 2016

4. Page
OUR STRUCTURE
• Structured to drive development and growth of BEE companies operating in the rail sector
• 61% Alstom Southern Africa Holdings
• 9% New Africa Rail: black-owned rail/infrastructure conglomerate
• 30% Ubumbano Rail: 100% black-owned
28 June 2016Africa Rail, Sandton 4

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SA FOOTPRINT
1 LOCAL FACTORY
(Dunnottar, Gauteng)
Gibela site for:
• manufacturing facility
• training centre
1 CENTRAL SERVICE FACILITY
(Gauteng)
Gibela site for:
• logistic platform
• technical support centre; 24/7 hotline
• repair, overhaul
• central technical support
2 REPAIR CENTRES
(Cape Town, Durban)
Gibela site for:
• local repairs, overhauls
• local warehouse
5 MAINTENANCE DEPOTS
• Braamfontein, Gauteng: 202 trains
• Salt River: 197 trains
• Wolmerton, Gauteng: 62 trains
• Durban: 101 trains
• Port Elizabeth or East London: 38 trains
Prasa sites for:
• 24/7 fault-finding support
• reliability engineering
• controls, monitoring
• materials requirement planning
28 June 2016Africa Rail, Sandton 5
1,400km
2.5 days
900km
1.5 days
600km
1 day
900km
1.5 days

6. Page
PROJECT TIMELINE
6
Design engineering
Production in Brazil
28 April 2014 Contract effective
September 2014
September 2015 First train shipped
November 2015 First train arrives in SA
Commissioning
First train in revenue serviceOctober 2016
Factory and Supplier Park construction
Maintenance support and material supply services 2035
Africa Rail, Sandton 28 June 2016
Maintenance project mobilisation

7. Page
ECONOMIC DEVELOPMENT
Refers to all initiatives and activities that result in:
28 June 2016Africa Rail, Sandton 7
Jobs, skills development
• 1 500 direct jobs within Gibela
• supply chain: 1000s of direct, indirect jobs
• skills development: R700m budgeted
• 19 000 skilled workers required over project life
Preferential procurement
• ~ R30bn: black-empowered entities
• ~ R5bn: qualifying SMMEs
• ~ R1.5bn: black women-owned entities
Local content
• develop robust, sustainable local supplier base
• >65% local content
• leverage Gibela expertise to equip emerging rail
enterprises with capabilities to be competitive
Enterprise development
• ~ R700 million for development of
rail sector enterprises
Socio-economic development
• ~ R300 million for community development

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MINIMISING SERVICE DISRUPTION
AND SECURING AVAILABILITY
28 June 2016Africa Rail, Sandton 8

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WHAT IS PREVENTIVE MAINTENANCE?
Imagine you had a car…
When would you refuel?
28 June 2016Africa Rail, Sandton 9

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WHAT IS PREVENTIVE MAINTENANCE? cont’d
28 June 2016Africa Rail, Sandton 10
Type of maintenance
CORRECTIVE SYSTEMATIC CONDITION-BASED PREDICTIVE
Preventive
When it fails Every day
Upon low fuel
indication
Upon a measurement
(gauge) and a prognostic
Number of refills Fewest Many Few Minimal and planned
Car availability Lowest Medium High High
Breakdown risk 100%
Low
(if no change in usage)
Low
Lowest
(if accurate algorithms)

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MAINTENANCE IN BRIEF: categories of maintenance
28 June 2016Africa Rail, Sandton 11
Corrective
Diagnostic
Palliative Curative
Temporary repair:
-provisional
intervention allowing
to allowing service
completion
MAINTENANCE
Preventative
Complete repair:
- restoring to original
condition according
to specification
Suffer failures (drive to failure)
SystematicOn-condition
Avoid failures
Task performed
just-in-time
scheduled or
continuous
monitoring of train
or components
condition.
Ad’hoc scheduled
intervention
Predictive
Data accumulation
and analysis allow
to adjust
programming of
maintenance tasks,
or even avoid
failures
Tasks performed in
accordance with
predefined
schedule (time or
km), organised at
train level or per
components
(estimated lifetime
or potential of
component)
Don’t understand these

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PERFORMANCE DECREASE CIRCLE
28 June 2016Africa Rail, Sandton 12
Higher pressure on available rolling stock from operator
Preventive operations get delayed
Fleet reliability drops
Weight of unscheduled visits increases
Fleet regularity decreases
More corrective operations
Spares not available on time
Decrease of fleet availability
Immobilisation of fleet increases

13. Page
DESIGN FOR SERVICEABILITY: life-cycle approach
• Design trains that are:
• safe, reliable, available
• easy to clean, maintain, operate
• cost-effective to maintain, operate
• supported by:
• solid documentation
• necessary spare parts
• tools
• backed by efficient supply chain
• compliant with environmental regulations
• supported on obsolescence issues
28 June 2016Africa Rail, Sandton 13
Cascade serviceability requirement
to all suppliers
Maintenance plan, life-cycle cost commitment
Reliability commitment
Testability, maintainability
Maintenance safety requirements
Maintenance documentation
Spare parts, tools
Training
Obsolescence management

14. Page
• Maintenance using 3D modelling
• accessibility of equipment
• inspection condition
• ease of dismantling
• ease of component replacement
• replacement of sub-assembly
or component
• use of standard tools
• handling conditions
• operating time
DESIGN FOR SERVICEABILITY: design verification
28 June 2016Africa Rail, Sandton 14
Brake
caliper
High voltage box HSCB accessibility
Operator
view

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• Data capture, real-time transmission
• Assess, monitor, analyse data
• Health status, diagnostics
• Condition monitoring
• Prognosis
• Real-time remote fault investigation
• Schedule corrective action
• Preventive maintenance
(condition-based)
• Round-the-clock health status,
reliability measurement
• Anticipated maintenance
• Reduced downtime
• More effective maintenance
• Less repeat failures
SERVICEABILITY BY DESIGN: condition monitoring
(TrainTracer™)
• TrainTracer™: train-borne system to maximise train availability by optimising
maintenance operation
28 June 2016Africa Rail, Sandton 15
ASSESSMENT TAKING ACTION OUTCOMES

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DESIGN FOR SERVICEABILITY: condition monitoring
for infrastructure
• Optional train-borne capabilities to monitor
infrastructure during commercial service
• overhead-line dynamic monitoring
• camera-based data capture
• wire and overhead line condition
• data processing, image analysis
• track dynamic monitoring
• beam mounted 3D cameras,
sensors
• track geometry,
condition
28 June 2016Africa Rail, Sandton 16

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MAKE IT LOCAL
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18. Page
Gearbox
Doors
Air conditioning
Traction
Motor winding
Pantograph
Interiorlighting
Auxiliary converter
Batteries
CCTV
Interior/panels
Suspension
MAKE IT LOCAL: manufacture, repair
• Local manufacture supported by
network of service, repair centres
• Integration facility at Dunnottar
• Supplier park for component
manufacture
• Main component repair, overhaul
facility in Gauteng
• Two regional repair centres in Durban,
Cape Town
• Highest design quality, international
standards
28 June 2016Africa Rail, Sandton 18
Wheelsets
Wheel bearing
brake system
Brake pads
Passenger
information system
Motor

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MAKE IT LOCAL: supplier development
• Develop local supplier network
• Support materials, components, services
• 69% local content by year two
• Development programmes ongoing
• existing local suppliers in rail or other
industries
• emerging suppliers, new local
entrepreneurs
• large international railway suppliers
committed to localise
• Local materials, components supplied
for first train
• Potential to supply industry with‘high-spec’
products of international standard
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MAKE IT LOCAL: skills development
• High training commitment (+19 000)
• Development focused on scarce skills
• Skills development to address entire
train life cycle
• Attract young people to railway industry
• provide real opportunities
• Skills reserve to benefit other manufacturing
industries
• In-house training centre to support
communities
• improve employment prospects for
unemployed people with limited skills
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COMMIT TO PARTS AVAILABILITY
28 June 2016Africa Rail, Sandton 21

22. Page
COMMIT TO PARTS AVAILABILITY
Supply chain at the core of maintenance efficiency
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Maintenance quality Vehicle reliability Maintenance costs Vehicle availability
• Spares supply
• Repairs
• Overhauls
• Parts quality
• Repair quality
• OEM warranty
• OEM suppliers
• Parts kit
• Optimised stock levels
• Availability service
• Reduced lead-time
• On-time delivery

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COMMIT TO PARTS AVAILABILITY cont’d
Localised service centres with necessary skills for repairs, overhauls
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Cape Town
Service centre
• Warehousing
• Local repairs
• Minor overhauls
Durban
Service centre
• Warehousing
• Local repairs
• Minor overhauls
Gauteng
Central services
• Logistics platform
• Technical centre
• 24/7 hotline
• Repairs, overhauls,
• Training centre
1,400km
2.5 days
900km
1.5 days
600km
1 day
900km
1.5 days

24. Page
Deliver:
• efficient systems
• data tracking enhancement
• advanced planning tools
Benefits:
• no train disruptions because of
spares shortages
• reliability guaranteed
• no inventory costs
• reduced supply chain costs
• less risk
Commitments:
• immediate availability
• reliability
• delivery closest to maintenance
• fixed price per km over 19 years
• maintenance parts, consumables
• repairable components
• component overhaul
• demand planning, forecasting
• managing obsolescence
• 70% localisation
• support for accident/vandalism
Adjust to:
• supplier capacity
• repair centres, distribution
capacity
• maintenance plan
Get it right:
• sourcing suppliers
• industrial strategy
• distribution network
COMMIT TO PARTS AVAILABILITY cont’d
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Information
systems and
technologies
Maintenance
efficiency
Lead time,
availability
guaranteed
Supply
chain
strategy
Operations
planning
5
Efficient:
• warehousing
• material requirement planning
management
• logistics
• transportation
Execution

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INVEST IN PEOPLE
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26. Page
• Knowledge-sharing
• support services to increase operation efficiency, train availability
• integrated on-the-job training: use of simulators
• obsolescence management: entire life cycle
• shared best practice, tools, processes
• manufacturer's expertise
• product post-design services, to customer needs, throughout
• Continued technical support
• training
• documentation
• obsolescence
• expert support
• reliability growth
• help desk
• accident/vandalism
INVEST IN PEOPLE
28 June 2016Africa Rail, Sandton 26
Documentation
Condition monitoring
Helpdesk 24/7Accident/vandalismReliability growthExpert support

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INVEST IN PEOPLE, cont’d
• Sustainable training
• training services, over 19 years, based on
modern support technologies
• train driver
• train maintenance
• fleet familiarisation
• expert training
• new starter training
• on-going training
• TrainTracer™ system
• maintenance information system
• combined classroom, on-the-job training
• supported by Gibela training centre
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Training course Web e-learning
Virtual reality 3D
On-the-job coaching Training on real equipment

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SET UP PERFORMANCE-DRIVEN:
LONG-TERM PARTNERSHIP
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SET UP PERFORMANCE-DRIVEN, LONG-TERM PARTNERSHIP
• Agree and share common targets
• prioritise train availability
• focus on passenger service
• developing common strategy
• Drive operational set-up towards performance
• upgrade maintenance depots
• customise facilities to deliver productivity
• adapt organisation, interfaces
• continuous improvement
• Adapt to change
• deliver customer requirement
• meet continuous, growing demand
2928 June 2016Africa Rail, Sandton
Wheel profile
Brake pads
Carbon strips
Train integrity

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SET UP PERFORMANCE-DRIVEN, LONG-TERM
PARTNERSHIP cont’d
3028 June 2016Africa Rail, Sandton
Share the vision:
common/shared
objectives
Deliver operational
performance:
priority to passenger
service
Define robust
interfaces, clear
processes
Anticipate, manage
co-activity
Anticipate, support
change
Build solid partnership,
joint team approach,
work as ONE

31. Page
CONCLUSION: reducing maintenance down-time
3128 June 2016Africa Rail, Sandton
Design for
serviceability
Make it local
Commit to parts
availability
Invest in people
Set up
performance-
driven, long- term
partnership

32. Page
CONTACT DETAILS
Pam Radebe
Communications Director
+27 (0)11 518 8235 (tel: reception)
+27 (0)11 518 8210 (fax)
+27 (0) 83 277 8766 (mobile)
pamella.radebe@gibela-rail.com (email)
28 June 2016Africa Rail, Sandton 32
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