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11
Review of PTSB Issues
Henry SullivanChief Maintenance OfficerNYCT Department of Buses / MTA Bus / LI BusNovember 2011
CONFIDENTIAL, PROPRIETARY AND NOT FOR DISTRIBUTION
222
Agenda
Statistics
Overview
Actions Taken
Current Status
Maintaining the Improvements
Detailed Explanation of Failure Modes and Retrofits
Conclusion
1
2
3
4
5
6
7
33
PTSB CasesPTSB Bus Reportable Accidents
12
4
15
10
5
17
35
19
5
9
4
3
66
32
40
0
10
20
30
40
50
60
70
2010 (all) 2010 (to June) 2011 (to June)
0
10
20
30
40
50
60
70
Fatality
Multiple Injury
Mechanical Failure
Fire
4
Overview
• Increase in PTSB cases in first half of 2011.
• In June, met with Office of System Safety (OSS) and PTSB to explain the rise in PTSB cases.
• After meeting, established procedures to prevent accidents and sustain a lower rate of PTSB cases.
• Complexity of fleet is a major issue in resolving problems.
– 3 types of propulsion systems• Diesel• CNG• Hybrid
– 3 types of vehicles• 40-foot local• 60-foot artic• Express
– 6 different bus manufacturers
– Fleets range in age from 1995 to 2011, resulting in 23 variations in production models.
5
Actions Taken
• Established AGM Committee.
• Meetings to explain the causes and effects of the PTSB cases, as well as the procedures to prevent them.
• Made instructional CDs of the presentations for Depot Training Supervisors (DTSs) to hold training at all the depots (“PTSB Shop Gates”).
6
Fires – Current Status
1
2
1 1
3
2
1 11 1
3 3
5
4
1
3
2 2
0
1
2
3
4
5
6Ja
nu
ary
Fe
bru
ary
Ma
rch
Ap
ril
Ma
y
Jun
e
July
Au
gu
st
Se
pte
mb
er
Oct
ob
er
No
vem
be
r
De
cem
be
r
2010
2011
7
Mechanical Failures – Current Status
2
1
2
1 1
3
1 1
5
3
6
2
5
2
1
0
1
2
3
4
5
6
7Ja
nu
ary
Fe
bru
ary
Ma
rch
Ap
ril
Ma
y
Jun
e
July
Au
gu
st
Se
pte
mb
er
Oct
ob
er
No
vem
be
r
De
cem
be
r
2010
2011
88
Maintaining the Improvements
• AGM Committee meets weekly.
– Identifies short- and long-term solutions for issues.
– Identifies modifications to policies and procedures.
– Performs campaign tracking and updates.
• Depot management conducts a Quality Control check geared towards PTSB cases.
– 10 buses are checked per day at each depot.
• “Report Card” audits held at each depot.
– At the end of the audit, all depot management personnel ride a bus to look at it from the customer’s point of view.
• Customer Services conducts audits of PTSB issues at each depot to ensure that critical safety campaigns are completed.
• Bus Merger Team conducts quality audits.
• S.O. Re-Rack Audits are held each day and documented in SPEAR (1 bus per day per depot).
• Random inspections of depots are held jointly by the PTSB, OSS, and ACMO, Customer Services.
9
Detailed Explanation of Failure Modes and Retrofits
10
OEM Installation in Orion VII Bus
11
Issues with OEM UnitLoosening of Mounting to Panel
12
Issues with OEM UnitAssembly Components Falling Apart
13
Issues with OEM UnitMissing Rivets Securing Plate to Assembly
14
Issues with OEM UnitCracks in Blower Housing
15
NYCT Retrofit Kit
Frame Mount Bracket
Blower Assy. Mount Bracket
Cover-plate
Panel reinforcement Bracket (Upper)
Panel reinforcement Bracket (Lower)
Retainer Brackets
U-Clamp
Blower Assy.
16
ReworkShop Rebuilt Unit with Pre-Assembled Bracketry
New or repaired blower housing and blower plate
17
ReworkStep 1: Mount Bracket to Frame
18
ReworkStep 2: Reinforce Panel
19
ReworkStep 3: Mount Blower Assembly
20
ReworkStep 4: Install Upgraded Coverplate
21
ReworkStep 5: Install Grille & Retainer Brackets
22
Conclusion
• In order to keep focus and maintain the results we have achieved so far we will continue with:
– Depot management conducts Quality Control check geared towards PTSB cases.
– “Report Card” audits held at each depot.
– Customer Services conducts audits of PTSB issues at each depot to ensure that critical safety campaigns are completed.
– S.O. Re-Rack Audits held each day and documented in SPEAR.
– Random inspections of depots held jointly by the PTSB, OSS, and ACMO, Customer Services.
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