RR-05 RR-05-02-03 — Locomotive Heavy Overhaul and Shop Operations
This process outlines the heavy overhaul and shop operations for locomotives at various US Class I freight railroad facilities, ensuring compliance with regulatory standards and maintaining high operational efficiency.
🗺 BPMN Process Flow
Click diagram to zoom & pan • Scroll to zoom • Drag to pan • Download SVG
📋 Process Attributes
| Process ID | RR-05-02-03 |
|---|---|
| Domain Family | OPERATIONS |
| L1 Domain | Mechanical & Rolling Stock |
| L2 Process Group | Locomotive Heavy Overhaul and Shop Operations |
| Trigger | Detection of a locomotive requiring heavy overhaul through routine maintenance checks or failure analysis. |
| Outcome | A fully overhauled and certified locomotive ready to return to service, meeting all safety and performance requirements. |
| Systems | Umler NetControl Wabtec Modular Control Architecture NEXSYS III-i EHMS TRAIN II |
| Regulatory Hooks | 49 CFR Part 231 49 CFR Part 229 AAR Interchange Rules (Rule 88 and related) |
📋 L4 Process Steps
| Step | Name | Role | System | Input | Output | KPI | Pain Point / Risk | Decision? | Exception? |
|---|---|---|---|---|---|---|---|---|---|
| 1.1 | Locomotive Identification and Classification | Manager-Locomotive Maintenance | Umler | Maintenance report from field crew | Work order for heavy overhaul | Time to identify locomotive < 2 hours | Incorrect identification leading to delays | Y | N |
| 1.2 | Locomotive Removal from Service | Train Dispatcher | NetControl | Work order for heavy overhaul | Service removal notification | Time to remove locomotive < 4 hours | Delays in service removal affecting train schedules | Y | Y |
| 2.1 | Locomotive Arrival at Shop | Service Operator | Wabtec Modular Control Architecture | Service removal notification | Arrival confirmation | Time to arrive at shop < 1 hour | Transport delays affecting shop availability | N | Y |
| 2.2 | Initial Inspection and Defect Detection | Electrician (locomotive) | Wayside defect detector network | Arrival confirmation | Defect report | Number of defects detected < 5 per locomotive | Overlooking critical defects | Y | N |
| 3.1 | Component Replacement and Repair | Machinist | Downing B. Jenks Shop | Defect report | Repair log | Time to complete repairs < 20 hours per locomotive | Delays in component availability | Y | Y |
| 3.2 | Locomotive Reassembly and Testing | Electrician (locomotive) | NEXSYS III-i | Repair log | Test report | Number of reassembly errors < 1 per locomotive | Assembly mistakes leading to further repairs | Y | N |
| 4.1 | Air Brake System Test | Manager-Mechanical Maintenance | EHMS | Test report | Brake test certification | Pass rate of air brake tests > 98% | Air brake failures causing safety hazards | Y | Y |
| 4.2 | Final Inspection and Certification | Senior Director-System Locomotive Facility | Umler | Brake test certification | Certification of readiness for service | Time to certify locomotive < 4 hours | Omissions in final inspection | Y | N |
| 5.1 | Locomotive Return to Service | Train Dispatcher | NetControl | Certification of readiness for service | Service return notification | Time to return locomotive < 2 hours | Delays in returning locomotives to service | N | Y |
| 5.2 | Post-Service Review and Documentation | Senior Manager-Mechanical Engineering | TRAIN II | Service return notification | Operational review report | Number of operational issues identified < 2 per locomotive | Neglecting post-service reviews | Y | N |
📊 KPIs & Risk Register
KPIs
Time to identify locomotive < 2 hours Time to remove locomotive < 4 hours Number of defects detected < 5 per locomotive Time to complete repairs < 20 hours per locomotive Pass rate of air brake tests > 98% Time to certify locomotive < 4 hours Time to return locomotive < 2 hours Number of operational issues identified < 2 per locomotive
Key Risks
Air brake test defect released to the road Delays in service removal affecting train schedules Transport delays affecting shop availability Overlooking critical defects Delays in component availability Assembly mistakes leading to further repairs Omissions in final inspection Delays in returning locomotives to service
Swim Lanes
Manager-Locomotive Maintenance · 1.1, 3.1 Train Dispatcher · 1.2, 5.1 Service Operator · 2.1 Electrician (locomotive) · 2.2, 3.2, 4.1 Machinist · 3.1 Senior Director-System Locomotive Facility · 4.2 Senior Manager-Mechanical Engineering · 5.2