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Havelock Wheel Plant
NCTA Operations and
Maintenance Conference June 8, 2014
Overview
Introduction BNSF Havelock Shops Overview Havelock Wheel Plant Overview
Safety Quality Production Accomplishments (2008 – 2013) 2014 Initiatives
2
Havelock Shops: Overview
3
Havelock Shops: Overview (continued)
• Opened in 1891, Missouri River Valley Railroad • 315 acres in northeast Lincoln, Neb. • Currently employs more than 400 BNSF Employees • Havelock Wheel Plant • Current freight car operations include BNSF-owned
preventive maintenance: • Coal fleet • Grain fleet • Intermodal • Owned and foreign wreck repair • Many smaller programs include: capital, operating, and
preventive maintenance
Havelock Wheel Plant: Overview
History Opened in 1976 Was intended only as an automated wheel shop with very few employees Today: Currently employs 120 people Milestone: 2,000,000 wheel built Feb. 2008 Five union organizations represented:
Machinists, Electricians, Laborers, Pipe Fitters and Clerical
AAR M-1003 certified wheel shop to include: Wheel Truing Axle Lathe/Qualification Wheel Boring/Press Bearing Press
Havelock Wheel Plant: Safety
Safety most important aspect of all BNSF employees’ activities:
Culture of compliance and commitment; eliminating life-altering serious injuries and employee fatalities
Improve identification of exposure and risk in the workplace
Rules Compliance
Supervisor-with-Employee Safety
Contacts
Peer-to-Peer Interaction and Support
Havelock Wheel Plant: Quality
• Three full-time employees dedicated to quality assurance • 2 AAR mechanical inspections per year
• Internal audits
• Strong AAR WABL representation and involvement
• Havelock team supports the railroad industry with supplier product testing
and approval
• Involved with development/TR&D of industry technology. Examples: • Cracked-wheel detectors • Warm-bearing detection • TADS
• Automated ultra sonic of second hand axles by year-end 2014
• Full compliance with MD11 reporting and AAR Counter Billing
Havelock Wheel Plant: Production
88.1% 83.7%
88.7% 91.3%
77.8%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
2010 2011 2012 2013 YTD 2014
Per
cent
Whe
el P
lant
Pro
d to
Sys
tem
Usa
ge
Whe
el S
ets
Wheel Plant Production
Plan Actual System Usage Wheel Plant Production Prct
Havelock Wheel Production
Havelock Wheel Plant Production
BNSF CEPM
10
Wheel Set ID
1-D barcode
2-D barcode
Havelock Wheel Plant: Accomplishments
2008 • Converted locomotive wheel shop to freight car shop
2009 • New portal wheel lathe
2010 • Built new inbound/demount line to support additional production
2011 • Replaced an automated wheel UT Machine
2012 • Purchased two new axle CNC lathes • Installed and implemented CEPM
2013 • Purchased a new wheel manipulator for the locomotive shop
Havelock Wheel Plant: 2014 Initiatives
2014 • Install three automated axle UT machines
• Install an automated bearing mount at the Havelock locomotive shop
2015 • Continue install of automated bearing mount
• Various facility related upgrades