Railway Improves Engine Run Hours By 29% With GLSS
Canada
Transportation
Operations
29%
- The problem: Unscheduled locomotive engine downtime resulted in missing production goals and deadlines. Runtime time was at 70 hours, often less before an engine shutdown for maintenance.
- With GLSS’s Lean Six Sigma Green Belt Training & Certification, the company increased runtime to an average of 90 hrs between maintenance downtime—a 29% improvement.
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In the fast-paced railway industry, engine availability and reliability are essential for keeping operations on track. Downtime for maintenance disrupts schedules, affects customer satisfaction, and increases costs. A railway organization faced a critical challenge: reducing engine downtime and enhancing fleet performance.
To address this, the organization partnered with GLSS Green Belt Training & Certification, whose expert programs would help identify the root causes of downtime and guide the implementation of impactful improvements.
Frequent engine maintenance requirements hindered railway operations, reducing fleet availability and jeopardizing operational goals. Engines did not achieve the expected runtime between maintenance intervals, leading to more downtime and decreased reliability. This impacted the organization’s ability to maintain service schedules, resulting in delays and frustration.
A closer examination revealed two primary issues: clogged fuel filters and restricted air intake filters. Fuel filters clogged too quickly, while air intake filters caused unexpected engine shutdowns. These issues required more maintenance time than planned. Addressing these problems was critical to improving engine reliability and keeping operations running smoothly.
With the support of GLSS Green Belt Training & Certification, the organization implemented two key improvements:
- First, longer-lasting fuel and oil filters were introduced, allowing engines to operate more consistently with less frequent maintenance.
- Second, the engine derate codes were adjusted to be more tolerant, ensuring minor issues did not immediately trigger shutdowns.
This adjustment allowed engines to continue running safely for longer periods, significantly reducing unnecessary downtime.
GLSS’s training and process improvement guidance equipped the team with the knowledge and skills needed to implement these solutions confidently. The structured approach provided by GLSS ensured a smooth transition and lasting impact, making it easier for the team to adopt and sustain the changes.
The implemented improvements yielded significant results. By adopting longer-lasting filters and increasing tolerance in the engine shutdown codes, the organization was able to extend engine runtime to 90 hours, a 29% increase. This enhanced fleet reliability. Maintenance delays decreased, and engine availability improved, enabling the fleet to operate at peak efficiency.
These changes streamlined operations and positively affected the organization’s bottom line. Improved engine reliability enhanced customer satisfaction by ensuring more consistent schedule adherence, elevating the quality of service provided. Overall, the fleet now operates more efficiently, helping the organization fulfill its commitments to customers
with GLSS
This project demonstrated the value of strategic process improvements in maximizing performance and minimizing downtime. With GLSS Training & Certification, the organization rapidly implemented impactful changes that delivered measurable results. GLSS’s innovative instructional design and content empowered the team to adopt best practices effectively and efficiently.
With GLSS’s support, the organization is now better equipped to maintain a reliable and efficient fleet, positioning itself for long-term success in the competitive railway industry.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.
