Bogie Overhaul. World-class facility producing high performance bogie overhaulss SERVING THE WORLD S RAILWAYS

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1 Bogie Overhaul World-class facility producing high performance bogie overhaulss SERVING THE WORLD S RAILWAYS

2 Unipart Rail Bogie Overhaul Service Unipart Rail provides a complete depot to depot bogie overhaul service to train operators and owners, delivering highly reliable quality bogie performance across the complete overhaul cycle. Our extensive procurement and bogie overhaul experience enables us to take responsibility for managing the entire supply chain to ensure the overhaul programme meets our customers availability requirements and are completed on time within budget. Experienced engineers work with our customers to help solve any technical issues that arise during the programme. They are further able to add value, by assessing the condition of the assets and components with a view of extending life and maintenance periodicity, as well as re-engineering obsolete components. We have the capacity to overhaul all bogie types working to the exacting standards and engineering specifications laid down by the industry.

3 World Class Facilities and Workforce Situated at the heart of the UK Rail network, our world-class facility has the capacity to overhaul over 1200 bogies a year. In 2010 Unipart Rail overhauled and repaired over 960 bogies. The range of bogies is extensive with overhaul specifications dating back to 1932 vehicle types to present day high speed new era trains. Our workforce is the lifeblood of our business and are key to our success, the strong team ethic helps to produce a product to be proud of. Our workforce fully embraces our company s continuous improvement culture and are totally engaged in providing the best possible service and products to our customers. Unipart Rail Doncaster was the first UK bogie overhaul facility to gain RISAS approval as a standard supplier for bogie overhaul. Collaborative Approach We believe that the relationship we develop with our customers should be based on effective communication, close collaboration and co-operation. At Unipart Rail we understand that every customer s requirements can be different. It is only by working collaboratively that we can fully understand their maintenance needs and respond with a creative solution that delivers the precise benefits required. An integrated partnership approach provides the biggest benefits in optimising bogie overhaul performance. We jointly agree business aims and projects that will provide the desired breakthrough of improvements. Our highly experienced project managers will work with you to ensure that all your requirements are met. Our project managers will communicate with you every step of the way ensuring any issues are resolved in a proactive, structured and responsive manner allowing you to focus on your core business activity, confident in the knowledge that your project is in capable hands.

4 Key Stages of the Bogie Overhaul Process 1. Wash Oil, grease and soil are removed using two high pressure, hot water, detergent mix pressure washers enabling two bogies to be cleaned at once. The working environment is controlled by ventilation providing sixty air changes per hour. Waste is filtered off into an initial silt trap for settlement of solids and via a separator to collect hydrocarbons. 2. Dismantle Raised rails facilitate a comfortable effective working height. Bogies are stripped into component parts using mechanical and hydraulic pullers to maintain component integrity. All components are sorted and are placed directly into appropriate containers eliminating the need for re-handling and minimising lead-time and float requirements. 3. Shot Blast Components are blasted in our purpose-built shot blast facility. Two bogie frames can be processed simultaneously. G17 chilled cast iron grit gives an SA2 profile finish. Grit is filtered and recycled during operation enabling a continuous shot blasting process. 4. Manipulators Specifically designed and built for 360º rotation with changeable spigots enabling flexibility for mounting various bogie types. Manipulators lift and lower bogie frames to enable the inspection. Repair and assembly to be carried out safely and efficiently without risk of damage to the frames. 5. Bracket Alignment Axle box pivot brackets can be aligned on the bogie frame to tight tolerances to eliminate axial load in wheel bearings. 6. Secondary Suspension Air Bag Tester Designed and built specifically to test the air bag prior to final assembly, enabling any defects to be identified and rectified prior to reaching the later assembly stages.

5 7. Bolster Jig We use specially designed handling equipment, including the bolster jig, to ensure that bogie parts travel smoothly through the process to further protect component integrity. 8. Spring Tester This equipment is designed to measure both Chevron and Coil springs. With a maximum load of six tonnes, the force applied is displayed in kn on a digital readout to accurately determine spring integrity and packing heights. 9. Spray Booths Used for both paint application and curing with a low bake mode, the air assisted paint application system achieves high volume controlled spraying with Copon water-based paint. This produces a high class durable finish, accelerated drying times and low environmental impact. 10. Assembly Equipped with a manipulator, raised rails and a Faro Arm to complete the alignment process, our flexible assembly areas are organised with dedicated tools. Materials are provided as kits to reduce the amount of movement and transportation required during the assembly process. 11. Bogie Press and Wheel Weighting The bogie press comprises a twin ram hydraulic configuration with a seventeen tonne per ram max load. A twin ram and four identical wheel load cells are used to accurately set the wheel load distribution and enable the bogie height to be set to the individual vehicle type. 12. Dispatch and Delivery Prior to despatch all bogies are inspected, strapped and sheeted to prevent damage during transit. All relevant documentation are provided in a pack for the convenience of our customers. Our logistic partner, works in with us to deliver bogies to our customers schedules, ensuring a first class logistics service.

6 Comprehensive and Flexible Services Scope of Work We will work with you from the outset; agreeing the scope of work in line with your maintenance requirements. Our production process is designed to be tailoured to your requirements. We offer a quick turnaround of bogies to enable you to minimise the downtime of a your important assets and to reduce the float requirements. If a specification can be improved we will work with you to improve it. If you need to extend your overhaul periodicity, we will work with you to do so effectively and efficiently. In-house engineering support Our engineering support teams are able to solve any technical issues that arise during the programme. They are further able to add value by assessing the condition of the assets and components with a view of extending life, as well as re-engineering obsolete components. Our Engineers have many years experience working in the rail industry. This experience as we seek to implement improvements to the design that increase reliability, extend maintenance periodicities and extend the design life; without compromising safety. Re-engineering of obsolete components Components that are used in locomotives can rapidly go out of production or become obsolete (sometimes in five or ten years). Our specialist in-house engineering team is able to work with you to identify the origin of a particular part, even where this is not immediately obvious. We can work with our specialist supply base to re-engineer a component, for example if the production of a particular component has been made obsolete or the original manufacturer no longer exists. Access to a global supply base Our procurement teams source items required to meet any specific overhaul requirement in line with the customer specifications. Our procurement experts have many years experience dealing with major international suppliers building long-standing relationships. In many instances where we re-source a component from a supplier, it is not just a case of ensuring fit, form and function. We take advantage of improvements in technology to improve both the materials and the service to our customers.

7 Provison of specialist support services We have the skills base to offer any heavy engineering solution in including NDT (MPI/Ultrasonic), Coded Welding (MIG/TIG), precision measurement using FARO arm, shot blasting, painting and mechanical fitting. We have a large and highly trained workforce and we have invested in a structured apprentice training program to ensure new talent is brought into the business. Component Overhaul Our extensive rail industry experience and comprehensive network of approved suppliers ensures that the components are overhauled to the latest industry standards, delivering trouble free and reliable performance throughout the component life cycle. Our engineers also make improvements to the design of components and systems to prevent future failure. A continuous improvement and Lean philosophy Every business needs a set of principles that guides it. Ours is called The Unipart Way. It is more than a set of tools and techniques it is a way of working that engages our and your people, committing them to world-class performance and a culture of sustained continuous improvement. Using the Lean and continuous improvement expertise, our bogie overhaul process is designed to place quality and on-time delivery at the heart of its objectives. This enables us to supply on time, every time. Integrated depot to depot bogie transport service Working in partnership with our logistics partner we offer a full range of integrated bogie transport services. We help our clients to cut costs, drive year-on-year continuous improvement, focus on carbon reduction and create supply chain visibility. Our dedicated delivery fleets are equipped with the latest technology providing you with instant visibility of delivery progress.

8 About Unipart The Unipart Group is a leading UK manufacturer, full service logistics provider and consultant in operational excellence. Operating across a range of market sectors, including automotive, manufacturing, mobile telecoms, rail, retail and technology, Unipart offers a breadth of services to a wide range of blue chip clients internationally. Copyright Unipart Rail. July 2014 Unipart Rail (Traction and Rolling Stock) Jupiter Building, First Point, Balby Carr Bank, Doncaster DN4 5JQ Tel: +44 (0) Fax: +44 (0) Visit for details of our Worldwide Regional Offices

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