Part 5 - Tab I.2 (Manufacturing Plan)

Transcription

M assachusetts Bay Transportation Authority
New Orange and Red Line Vehicles
RFP No. CAP 27-10
TAB I.2 MANUFACTURING PLAN
I.2
MANUFACTURING PLAN
This Section is presented in response to the Massachusetts Bay Transportation Authority’s (the
Authority/MBTA) Request for Proposal, Section B, Part B, Tab I.2 – Manufacturing Plan and all
Addenda.
I.2.a
Introduction
Kawasaki is committed to enhancing its established, successful partnership with transit
authorities in the United States, including the MBTA.
Kawasaki is an innovative carbuilder having gained its experience and reputation in the
following areas:
•
A long and well-established history in the United States rail industry, creating more than 17
designs for American authorities since 1979.
•
Proficiency in meeting regulatory requirements in the United States such as FRA, FTA,
ADA, AAR, APTA, AWS and NFPA.
•
Successful system integration of complete vehicles by experienced engineering resources.
•
Providing quality, reliable vehicles and achieving high availability.
•
Consistently meeting delivery schedules.
•
Strong commitment to further enhance American content.
•
Customer-oriented business approach, evidenced by its philosophy of “problem-solving first”
before discussion of responsibility assignments.
These strengths and advantages are combined in a proposal that satisfies the Authority’s
requirements for system safety, high reliability, passenger comfort, ease of maintenance and
superior customer support.
The following subsections detail Kawasaki’s overall approach to manufacturing and assembly of
carbody components, testing and commissioning and the availability of plant capacity at the
various locations, including Kawasaki’s subcontractors. These subsections also detail qualified
and/or certified personnel and other resources planned to perform the work, including the local
on-site staff. Finally, this Manufacturing Plan outlines options for transportation between the
various Kawasaki work locations as well as to the Authority. Details of Kawasaki’s compliance
with RFP Section C7.18, which requires that “Final Assembly of all Production (Non-Pilot)
Vehicles delivered under this Contract must take place in Massachusetts”, is also provided.
I.2.b
Final Assembly
For the New Orange and Red Lines Vehicle project, Kawasaki proposes to utilize the Hopedale
Railcar Manufacturing Facility (Hopedale Facility) in Hopedale, Massachusetts (MA).
Kawasaki’s proposed final assembly facility will meet the requirements of RFP Section C7.18 as
described in the following subsections.
Part B – Technical Proposal
Tab I.2 Manufacturing Plan.doc
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I.2.c
Prime Contractor Work and Locations
Kawasaki’s proposed work location assignments are presented in Table I.2-1, including the
areas of contract management, design, production, assembly, system integration, testing,
system assurance, warranty and field support.
The design of the vehicles will take place at the Hyogo Works facility at Kawasaki Heavy
Industries Ltd. (KHI), in Hyogo, Japan, as well as the manufacturing, final assembly and testing
of the pilot vehicles. Production of the subsequent production carbodies will take also place in
Hyogo, Japan. Final assembly and testing of the subsequent production vehicles will take place
at the Hopedale Facility.
Kawasaki will meet the Authority’s “Domestic US Content
Requirement” of RFP Section C.7.17 with final assembly, related production and testing of the
production vehicles in the Hopedale Facility.
For information, the manufacturing workflow for the carshell manufacture and final assembly is
shown in Figure I.2-1 and Figure I.2-2 respectively.
TABLE I.2-1: KAWASAKI WORK LOCATIONS
MBTA Project Allocations
Category
Contract Management
KRC,
Yonkers,
NY
KHI,
Kobe,
Japan
√
√
Pilot Vehicle Final Assembly
and Testing
√
√
√
√
√
√
Production Vehicle Testing
System Assurance
√
√
Warranty & Field Support
Testing &
Commissioning Site,
Boston, MA
√
Design
Carbody Production
Production Vehicle Final
Assembly
System Integration
Hopedale
Facility,
Hopedale,
MA
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Roof Frame
Side Frames
End Frames
Carbody
End Underframe
Installation of
Secondary
Structure
Floor Panel
Exterior
Installations
Windows & Doors
End Mask, Signs,
Lights
Water
Tightness
Test
Sealing,
Sound
Deadener
Cab Locker
Frames
Side Sill
Cross Beam
Piping
Thermal
Insulation
Inspection of
Thermal
Insulation
Insulation Holder
Wiring
Inspection of
Concealed
Portion
Piping
Pressure
Test
Brackets
Ceiling
Equipment
Floor Covering
Interior
Equipment
In Process
Inspection
Signs, Seats in
Passenger
Room
Transfer to
Hopedale, MA for
Final Assembly
FIGURE I.2-1: MANUFACTURING WORKFLOW AND STATIONING - CARBODY MANUFACTURE
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Receipt
Inspection
Undercar
Equipment
Installation
Measuring &
Appearance
Inspection
Packing
Completed
Underfloor
Inspection
Insulataion
Resistance
Measurement &
Hi-Pot Test
Wiring
Continuity
Check
Trucking
Inspection
Install Trucks
Car
Function
Test
Weighing
Low
Speed
Dynamic
Test
Water
Tightness
Test
Final Factory &
Pre-shipment
Inspection
Ship to
MBTA
FIGURE I.2-2: KAWASAKI’S MANUFACTURING WORKFLOW AND STATIONING - FINAL ASSEMBLY
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Kawasaki has a full complement of experienced, qualified and certified personnel which has
been instrumental in the successful completion of a large number of American rail contracts.
This includes an experienced management team, numerous engineers with many years of mass
transit experience, as well as certified welding, weld inspection and non-destructive test (NDT)
personnel. These personnel are typically resident at Kawasaki’s KHI and KRC facilities and
relevant personnel will be co-located at the Hopedale Facility before and during appropriate
stages of the final assembly process to work, train and supervise the staff at Hopedale.
Kawasaki understands the importance of job creation and retention in the United States, having
established two facilities in North America in the last 25 years, one in Yonkers, New York and
the other in Lincoln, Nebraska. Both railcar facilities have created over 1,500 sustainable jobs
in New York and Nebraska. This experience will be utilized in successfully establishing,
staffing, outfitting and operating the Massachusetts (Hopedale) facility described in this section
of Kawasaki’s proposal, to efficiently produce high quality Orange and Red Line vehicles on
schedule.
In 2013, KRC celebrated 25 years of manufacturing railcars at its Yonkers plant. During this
time Kawasaki has produced more than 2,500 railcars at the facility, making railcars and
component parts for a variety of transit systems, including New York City Transit, MTA Long
Island Rail Road, MTA Metro-North Railroad, Port Authority Trans-Hudson Corporation (PATH),
Connecticut Department of Transportation (DOT), MBTA and Maryland Transit Administration,
and also for non-North American customers such as the Department of Rapid Transit Systems,
Taipei City.
In the 1980s, when US manufacturing jobs were on the decline and other large companies were
closing, Kawasaki sustained hundreds of jobs at the Yonkers facility and contributed to the local
and state-wide tax base, in addition to having a front-row seat to the revitalization of Downtown
Yonkers. The economic implications from the Yonkers facility have been felt locally. Depending
on the size of the project, KRC has used on average, upwards of 100 New York-based
subcontractors and suppliers, creating an economic ripple effect throughout the State.
Kawasaki was a pioneer in building stainless steel subway cars (the NYCT R62, and
subsequent R142A and R160 models), which helped contribute to the battle against graffiti on
the New York City subways and also worked to develop cutting edge technology, including
electric multiple-unit railcars that draw power from both overhead and third-rail based power
sources.
The Yonkers plant is equipped for fabrication, assembly, rehabilitation and function testing of all
types of passenger rail cars. Employees number 250 to 500, depending on the work in
progress at the 380,000 square-foot facility.
The consumer products manufacturing facility in Lincoln, Nebraska, located on 335 acres of
land, has grown since its opening in 1974 from the original 286,000 square feet to nearly 1.3
million square feet of manufacturing, office and warehouse space.
In 2001, the railcar plant was completed at the Lincoln site, adding 437,000 square feet for light
rail car manufacturing. Over 1,000 people work at the Lincoln facilities, making Kawasaki
Motors Manufacturing Corp., USA (KMM) a major employer in the Lincoln area. In 1989 the
Maryville, Missouri plant was opened for production of general purpose engines. The Maryville
facility has grown to over 700,000 square feet on 113.7 acres of land, employing over 600
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people. KMM Research and Development Centers are located at the Lincoln and Maryville
facilities to meet customer demands as quickly as possible.
Kawasaki’s two existing US facilities (KRC and KMM) function in tandem to produce volume
orders for railcars.
Kawasaki anticipates that approximately 100 new jobs will be created at the Hopedale Facility,
as identified in Table I.2-2, in order to provide exceptional local economic benefits to the
Hopedale area. We are also investigating additional activities that could be performed in the
state of Massachusetts, to further increase the state content. Kawasaki plans to hire a national
transit services company to provide a significant amount of the labor force for the New Orange
and Red Line Vehicles. The labor force company is a registered Disadvantaged Business
Enterprise (DBE) entity in the state of MA. Kawasaki is committed to creating and providing
long-term value to the Authority using these technically-skilled employees.
Kawasaki has significant experience, credibility and skills in production management, quality
management and project management, to ensure that the new Hopedale Facility and the locally
hired personnel have the ability to manufacture high quality railcars, on time. This was gained
in part by Kawasaki’s performance on the MBTA Bi-Level Coach project awarded in 1989. For
this project Kawasaki utilized the Pittsfield Facility, located within the State of Massachusetts.
Bare carshells, manufactured in Japan, were brought to the Pittsville Facility for completion of
interior installation, including piping and conduit. Over 100 local workers were hired for this
work and were trained to be railcar manufacturing professionals by Supervisors from KRC’s
Yonkers, New York Facility. The Pittsville Facility delivered these high quality coaches on time,
which served commuters of the Boston region for more than twenty years. The Kawasaki
personnel taking an active role in managing the local workforce of the Pittsfield Facility are
currently a part of the core management force of the KRC Yonkers facility; therefore this
knowledge and expertise remains within KRC and has been carried on within the new
generation of Kawasaki management.
Kawasaki also successfully performed a full evaluation and created a comprehensive plan to
upgrade and staff a local facility for overhaul and final assembly work on the MARC III Kawasaki
Bi-Level Coach overhaul project at a new facility in Maryland, adjacent to Maryland
Transportation Authority’s (MTA) facility.
This labor force will work under the direct supervision of Kawasaki’s experienced team as
described above. Training will be delivered by Kawasaki staff from Japan as well as Yonkers
and Lincoln, in a “transfer of technology” approach and information on production, welding,
assembly and test processes and procedures will also be provided to this labor force. Staff
working in the Hopedale Facility will have the opportunity to train in the Yonkers and Lincoln
facilities in preparation for the work.
In addition to the labor force provided by a DBE national transit services company, Kawasaki
will utilize the many avenues available to hire the appropriate personnel and provide the
necessary support to their technical skills development.
Kawasaki has reviewed and understands and appreciates the importance of the Workforce
Initiative Now model and will make every effort to ensure that all potential employees,
regardless of community or background, have access to the open opportunities at the Hopedale
Facility.
Refer to Section I.2.e below for further details.
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I.2.d
Massachusetts Final Assembly Contractor and Location
Final assembly for all New Orange and Red Line Vehicles will be performed by Kawasaki in MA
at our proposed Hopedale Facility, as described in detail in the next subsection.
Refer to Appendix I.2-2 for sample assembly procedures and controls and a sample material
control program.
Kawasaki’s assembly procedures contain the necessary controls for
production personnel during their work and they are supplemented by quality controls which are
embodied in Kawasaki’s inspection plans.
Staff from Kawasaki Rail Car Inc. (KRC) in Yonkers, New York will be the group responsible for
preparation of workflow plans, schedules, procedures, quality control, material control, etc., at
the Hopedale Facility. Kawasaki’s experienced supervisory and management staff will co-locate
at the Hopedale Facility’s local area office.
Kawasaki envisions that any potential retrofit work that cannot be performed at Authority
facilities would be undertaken at the Hopedale Facility. There is ample space within the 85,000
square foot facility to accommodate assembly, acceptance and any required retrofitting of the
new vehicles. Refer to the proposed layout of the facility in Appendix I.2-1.
I.2.e
Massachusetts Facility Description
The Hopedale Facility is situated on the site of a former mill and foundry. The 30-acre property
is zoned industrial and is owned and operated by the Grafton and Upton Railroad, an
independent shortline providing rail service to the town of Hopedale. It includes an existing
85,000 square foot industrial building, rail yard and storage area. Acres of open space are
available for building expansion, component storage buildings and sidings for static testing and
completed car storage. The secure property is fenced and lit. The rail line that stretches
through the former mill property is also suited for active testing and can be modified to accept
third rail or catenary.
As the building was originally the foundry for a former mill, it therefore has exceptionally
heavy-duty construction throughout, including floors, structural components and high-capacity
electrical power provision. The open interior features 45-foot clear ceilings and provisions for
overhead cranes that can travel the length of the building. Office and worker spaces (locker
rooms and facilities) are at one end of the structure. Currently the building includes one interior
rail track, truck doors and a loading dock. This can be expanded to three tracks to provide
additional assembly area. Interior and exterior views of the Hopedale Facility are shown below.
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The building has 360-degree vehicular accessibility and because of the way the building is
situated on the property, it can easily and quickly be expanded to 300,000 square feet of
enclosed space. An expanded structure could include an enlarged manufacturing floor, final
assembly area, paint booth and parts storage warehousing. Rail capabilities can be increased
to include two or more run-through interior rail tracks. Additional tracks could also be placed
within the structure’s “shop floor” area, providing significant additional manufacturing space.
Reinstallation of overhead cranes will enable the movement of body shells and completed cars
from track to track within the structure.
Additional space is also available on the property for build-to-suit construction of support
structures, such as offices and long-term parts warehouses. These can be used during the
manufacturing of the cars, and also to provide facilities within easy reach of the MBTA after the
initial production phase of the contract has been fulfilled. The acreage surrounding the building
can provide extensive paved lots for lay-down space of parts such as trucks, carbody shells and
other major components. It also has the capability to hold multiple tracks for static and dynamic
testing of vehicles. Space is also available for a rail vehicle ramp, which would allow new transit
cars to arrive in Hopedale or to be brought to Boston via flatcar.
The Grafton and Upton Railroad is ready and available to welcome Kawasaki into the Hopedale
Facility. Their affiliate company, First Colony Group, has the experience and resources needed
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to quickly design and build quality 100,000+ square foot custom warehouses, flex buildings and
manufacturing facilities, as needed. First Colony Group has a skilled team whose experience
allows them to navigate efficiently through the zoning, permitting, utility infrastructure, and
roadway improvement requirements to quickly prepare a site for construction. They have built
over 3,000,000 square feet of commercial/industrial space.
Refer to Appendix I.2-1 for Kawasaki’s proposed facility layout based on the available space at
the Hopedale Facility.
Promptly following Notice of Award, Kawasaki will begin the process of converting the Hopedale
Facility in order to meet the schedule of the Contract. This includes the hiring and training of the
labor force and the transfer and acquisition of equipment to meet the Authority’s requirements
for manufacturing and assembly. Refer to Tab I.1.j for Kawasaki’s detailed schedule for the
design, manufacture, testing and delivery of each car.
FIGURE I.2-3: HOPEDALE FACILITY CONVERSION SCHEDULE
Kawasaki has initiated a dynamic and broad-based outreach program in Massachusetts
designed to reach potential employees, suppliers and sub-consultants in every corner of the
Commonwealth. Our program will utilize public and private resources to attract individuals and
companies to assist in the fulfillment of this procurement.
Kawasaki has contracted with Fort Hill Infrastructure Services; a Massachusetts based Service
Disabled Veteran Owned Business Enterprise, to assist in this effort. Fort Hill has significant
knowledge and experience in creating successful partnerships on projects and programs
supporting the MBTA and MassDOT.
Recognizing the importance of maximizing the amount of tax-payer dollars staying in
Massachusetts, Kawasaki has made arrangements with associations, schools,
quasi-governmental agencies, newspapers and on-line services, Chambers of Commerce and
subconsultants in order that we will be in a position to mobilize quickly to fulfill our extensive
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hiring needs. These entities, from all over the Commonwealth are enthusiastic about assisting
us in our outreach efforts.
Kawasaki has met with officials from the Commonwealth Corporation, a quasi-governmental
agency, in an effort to form a partnership to attract and train employees to work on the Orange
and Red Line car production. Commonwealth Corporation has established and extremely
effective programs and resources, such as the Workforce Training Fund Program, ready to be
utilized. Commonwealth Corporation will work with Kawasaki to determine the skill sets needed
on the project, the availability of those skills within the workforce, and develop a training
program to train individuals with the needed skills needed. Commonwealth Corporation has
also assisted Kawasaki in identifying organizations and individuals that can assist in our effort to
be as inclusive as possible in our goal to reach individuals, suppliers and sub-consultants. In
addition, Kawasaki will utilize the resources of the Massachusetts Job Quest Program run by
the Department and Labor and Workforce Development and the Massachusetts Operational
Services (OSD) to reach individuals and companies.
Kawasaki has coordinated with the Massachusetts Manufacturing Extension Partnership in an
effort to lay the groundwork for a partnership that will link Kawasaki to a Massachusetts-based
supply chain that draws from suppliers throughout the Commonwealth, using the SupplyPoint
and BuyMass systems. Kawasaki intends to work with MassMEP to create opportunities for
apprenticeships and skills training tailored to the workforce needs of this procurement.
The Central Massachusetts Workforce Investment Board (CMWIB) offers an array of services to
employees and employers. Representing 38 cities and towns throughout the Hopedale area,
CMWIB is an ideal partner for Kawasaki as we ramp up production on this procurement.
Kawasaki has made arrangements to utilize CMWIB’s Workforce Central Career Center as a
resource to reaching potential employees in the vicinity of the Hopedale facility. Kawasaki will
also use the other resources of the CMWIB such as their training and retraining programs.
In partnership with Chambers of Commerce and local economic development agencies,
Kawasaki will conduct five (5) regional outreach events presenting the opportunities for hiring
and subcontracting. We will conduct events in the Central, Northeast, South Coast, Western
and Eastern sections of the Commonwealth. We have contacted the following Chambers to
date and all are enthusiastic about partnering on this type of event:
•
•
•
•
•
•
•
•
•
•
•
Worcester Chamber of Commerce
Metro West Chamber of Commerce
495 MetroWest Partnership
Blackstone Valley Chamber of Commerce
Fall River Chamber of Commerce
New Bedford Chamber of Commerce
Greater Lowell Chamber of Commerce
Greater Lowell Workforce Investment Board
Pittsfield Economic Development Authority
The Urban League
Greater Boston Chamber of Commerce – Small Business Center
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There are a number of associations in the Commonwealth of Massachusetts that represent
individuals and companies that would be interested in and qualified for a partnership with
Kawasaki and the MBTA on this initiative. Kawasaki has contact many such organizations and
made various arrangements to outreach to their membership. Among these groups we have
contacted:
• Massachusetts Minority Contractors Association
• Women in Transportation
• Council of Minority Transportation Officials (COMTO)
• Associated Industries of Massachusetts
• Massachusetts Workforce Board Association Local Workforce Boards
Kawasaki has identified and been in contact with a number of schools and colleges in
Massachusetts, particularly in the area of our Hopedale facility, to discuss the opportunity for a
partnership benefitting students. We have sought out schools that offer technical and vocational
training most appropriate for the scope of skills that will be needed on this assignment for the
MBTA. It is our intention to offer “open-house” events with these institutions in order to
introduce Kawasaki and the opportunities for employment and internships. We will also offer
other learning and employment opportunities such as Hopedale site visits and in-school
seminars and lectures. Among the schools we have contacted are:
•
•
•
•
Blackstone Valley Regional Vocational Technical High School
Quinsigamond Community College
Worcester Technical High School
Assabet Valley Regional Technical High School
Kawasaki will utilize a number of print and online job posting services to spread the word on
employment opportunities created as result of this procurement. Kawasaki has researched
which of these will be most effective and inclusive and has made preparations to post job
offerings immediately upon the determination of need. Among the services we will utilize are:
•
•
•
•
•
•
•
•
•
•
•
The Boston Globe
Boston.com
The Boston Herald
The Fall River News
Worcester Telegram and Gazette
The Republican – Springfield
The Lowell Sun
Southcoastjobmart.com – New Bedford/Fall River Area
The Berkshire Eagle
Craigslist
Monster.com
Kawasaki has taken preliminary steps to permit the Hopedale facility for the change
in/expansion of use that may be required to conduct the assembly work envisioned for this
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procurement. Although we believe our operation will be a legally conforming use we have
reached out to local elected and appointed officials to begin the process of determining the
steps that will need to be taken. In addition, we have conducted a preliminary zoning analysis
and site plan review. We have scoped for the possibility that a traffic study will be required. We
have also researched the steps that may need to be taken to meet the requirements of the
Massachusetts Environmental Protection Act (MEPA) and local permitting needs.
I.2.f
Job Classification
In addition to the experienced Kawasaki Management and Supervisory staff that will be colocated to the Hopedale facility for initial training and continual oversight of the locally hired
personnel, Table I.2-2 shows the job classification details of the positions to be filled locally for
the Hopedale Facility.
TABLE I.2-2: JOB CLASSIFICATION DETAILS
Job Title
Initial
Hire *
Maximum
Number of
Personnel *
Anticipated Hours of Work
1.
Site Manager
1
1
Full time for duration of activity
2.
Production Supervisors
1
3
3.
Rail Car Technicians - Final
Assembly
5
20
4.
Rail Car Technicians - Trucks
3
12
5.
Function Test Supervisor
1
12
6.
Quality Control Staff
1
4
7.
Material Control Attendants
2
8
8.
Commissioning Personnel
-
6
9.
Warranty Personnel
-
8
10.
Facility Maintenance Personnel
1
2
11.
Administration Assistants
3
4
12.
Construction Personnel (for
Hopedale Facility upgrades)
-
20
18
100
Total
*
I.2.g
In reference to Table I.2-2, the initial hire of personnel will occur approximately 2 months in
advance of commencing actual work in the relevant areas of the project, in order to allow for proper
and effective indoctrination and training. This same approach will be used in the hiring of additional
personnel that will be needed as the Hopedale Facility’s work loading increases, as illustrated in
the “Maximum Number of Personnel” column. Once the project work at the Hopedale Facility
begins to ramp down as the project approach completion, the number of personnel will be reduced
from the maximum numbers provided above.
Kawasaki’s Ongoing Work and Available Capacity
Before making any contractual delivery commitment to any customer, Kawasaki first analyzes
their plant loading for existing projects and anticipated projects. Kawasaki then demonstrates to
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their senior management team that the delivery commitment is achievable. Once the senior
management team is satisfied that the customer’s delivery requirements can be met, the
decision to submit a proposal is made. For the MBTA Project, Kawasaki does not foresee any
workforce, facilities or financial constraints that could adversely impact the ability to deliver the
required cars on schedule.
Kawasaki proposes to manufacture and test the pilot cars at KHI in Hyogo, Japan as well as the
production carshells and some pre-assembly. The majority of final assembly will take place at
the Hopedale Facility. KHI has a number of projects underway; however there is more than
adequate capacity at Hyogo Works for the design activities and for the production and testing of
the pilot cars and the production carbodies for the MBTA Project. Refer to Table I.2-3 for a list
of current KHI contracts.
TABLE I.2-3: KAWASAKI CURRENT CONTRACTS
Customer
Type of Vehicle
Quantity
West Japan Railway Company
Hokkaido Railway Company
Commuter
Type 285
50
64
Delivery Dates
Mar 2018 – Feb 2019
Feb 2019 – Oct 2019
Production for the MBTA Project is scheduled to commence in early 2016. KHI has three
separate carbody manufacturing lines for construction of carshells which precludes any
production conflicts. Minor modifications will be made to re-tool the production line in time to
support the commencement of production for the MBTA contract as per the proposed delivery
schedule.
As the Hopedale Facility is being “purpose-built” for this project, it has no backlog of existing
projects and will be fully available for the final assembly and testing of the New Orange and Red
Line Vehicles.
I.2.h
Locations and Capacities for Major Subsystems
The table below lists the location and capacities of the proposed major subsystem suppliers for
the MBTA Project. Kawasaki will be the supplier of the carbody and trucks. Refer to Tab 1.3 for
details regarding Kawasaki’s carbody and truck experience as well as Tab I.1.c.5 Carbody and
Tab I.1.d Proposed Trucks.
Kawasaki has asked major subsystem suppliers to confirm their capacities and has analyzed
the responses and proposed work plans of the subcontractors for the MBTA Project. Based on
this, Kawasaki has determined that the subsystem suppliers’ current work force, facilities and
financial resources are adequate to support the proposed work and delivery schedules.
In the unlikely event of unforeseen impact from existing projects on the MBTA Project,
Kawasaki’s effective use and monitoring of the detailed contract schedule will provide sufficient
time to assess and mitigate these causes, so as to prevent schedule issues. In addition to this,
if and as required, Kawasaki will further alleviate unforeseen impacts by such mitigation
measures as hiring additional personnel and/or adding work shifts.
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TABLE I.2-4: LOCATIONS AND CAPACITIES OF PROPOSED SUPPLIERS
Subsystem
Potential
Suppliers
Location
Bombardier
West Mifflin, PA
NYCT (692 cars) for 10 years, with 300 more now on their R179 cars and at BART
(439 cars) for 11 years, with 300 more now on their D/E cars, WMATA 5000 series
(192 cars), PAAC stage II LRV’s (166 cars), CTA 5000 series (714 cars) and
Toronto “Rocket” (420 cars)
Melco
Pittsburgh, PA
LIRR M-7 (836 cars), MNR M-7 (336 cars), MNR/CDOT M-8 (405 cars) and
SEPTA (120 cars)
Freedom, PA
WMATA 7000 series cars (364 units), Metro North Railroad, series M-8 (162 units)
and New South Wales Rail Corp. in Australia, (314 units), Chogqing Monorail 1000
series cars in China (214 units), for East Japan Railway Co. series E231 cars (128
units) and other projects in Asia
Propulsion
Fuji
Auxiliary Power &
Low Voltage DC
Power
HVAC
Couplers / Draft
Gear
North American Experience
API - LIRR’s M-7 project (1266 units)
SEPSA
Ballston Spa, NY
LVPS - LIRR’s M-7 project, WMATA projects (538 units for series 1000, 2000,
3000, 5000 and 6000)
Merak
Westminster, MD
WMATA 7000, 6000, 5000 and 2000/3000 Series cars and MNR M-7 cars.
Melco
Warrendale, PA
100,000 HVAC units for vehicles in the US and worldwide, including 3,324 units for
NYCT’s R160 trains
Dellner
Charlotte, NC
50 years’ experience in supplying TS-compliant coupling systems, equipment
proposed based on equipment in service on the MBTA No.3 Red Line Cars
Wabtec
Duncan, SC
Extensive history of providing multiple designs throughout North America, serviceproven experience of providing couplers to MBTA for the existing No. 12 Orange
Line, supplied existing No. 2 Red Line coupler equipment
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Subsystem
Potential
Suppliers
Location
New Freedom, PA
Supplied MBTA with wheels for the existing Blue Line, Red Line and Orange Line
fleets, is OEM for Blue Line wheels, including wheel dampener, provided MBTA
with 16 wheels, with wheel dampeners for test on the Orange Line cars in 2009,
supplied MBTA with axles for the existing Blue Line, Red Line and Orange Line
fleets, is OEM for the Red Line axles, aftermarket provider for previous Red and
Orange Line axles
Osaka, Japan
Supplied significant number of wheels and axles to North American transit
authorities including W MATA 7000 series – 2,992 axles, 5,984 wheels (2012 –
2016), NYCT R188 - 584 axles, 1,168 wheels (2012 – 2015), NYCT R160 – 6,800
axles, 13,600 wheels (2005 – 2009), NYCT R156 - 112 axles, 224 wheels, (2008),
NYCT R143 - 848 axles, 1,696 wheels (2001 – 2002), NYCT R142A - 2,400 axles,
4,800 wheels (1999 – 2003)
Tipton, PA
Supplied wheels and axles to over 18 projects in North America including wheels
and axles for CTA 3800 Series 2007-2011, wheel set assembly for PATH PA-5
2007- 2010, wheel set assembly for NYCT R160 2008-2009 & 2004-2008, wheels
and axles for LA MTA P2550 2004-2008, axles for GE new locomotives 20072008, wheels and axles for NT Transit multi-levels 2004-2007, wheels and axles
for MNR M7 2000-2005, wheel set assembly for NYCT R142 1998-2003
UTCRAS
Morton, PA
Supplied wheels and axles to over 40 projects in North America including MBCR
2004-present, Amtrak Viewliner 2011-2012, SEPTA Silverliner V 2009-2012,
NCTID 2007-2008, NC DOT 2003-2007, WMATA 6000 Series 2004-2006, DART
2000-2005, TRI-RAIL 2000-2005, VRE 2005, WMATA 2000 and 3000 Series
2002-2004, Comet II-Comet IV 2001-2003
Knorr
Westminster, MD
Supplied the friction brake system to WMATA 5000 Series - 110 units, WMATA
6000 Series - 62 units, WMATA 7000 Series - 634 units, Toronto Rocket - 234
units
Wabtec
Duncan, SC
Brake experience in North America includes BART C2 – 80 units, CTA 5000 - 706
units, LACMTA Redline OPT - 74 units, MARTA CQ312 - 100 units, NYCT R142 1030 units, NYCT R142A - 600 units, NYCT R143 - 212 units, NYCT R160 - 1662
units, NYCT R188 - 26 units, PATCO - 120 units, PATH PA 5 - 350 units, TTC T 1
- 216 units, TTC T 1 OPT - 156 units
Alstom
Rochester, NY
More than 1,500 of proposed MC III ATP systems have been installed worldwide
since 1989, spanning the range from mainline railroads to driverless transit
Bonatrans/TSS
Wheel Sets Supplier
Nippon Steel
ORX
Wheel Sets Construction
Air Brake Equipment
& Controls
Cab Signal
15 of 20
May 15, 2014
RFP No. CAP 27-10
Subsystem
Potential
Suppliers
Location
applications including SEPTA, Metra, Amtrak, WMATA, MNCR, PATCO and
MARTA
Equipment
Ansaldo
Batesburg, SC
418 cab sets of similar equipment to LIRR, which have been in use since 2006,
218 cab sets are currently being delivered to Montreal Transit and 32 sets to
WMATA
Fuji
Plattsburg, NY
20,000 linear type door systems worldwide, including equipment for the NYCT
R160B and WMATA 7000 Series vehicles, as well as vehicle projects in Japan
Vapor
Plattsburgh, NY
NYCT R142, R142A.R142S, R143 and R160A cars, LIRR M-7 cars and PATH PA5 cars, which in total represents over 46,000 units in service from 1999 to 2013
KHROME
Drummondville,
QC
MNR for M-7 and M-8 cars, PATH for the PA-5 cars and NYCT for the R-188 cars
Kustom
Bellwood, IL
Chicago Transit Authority for 300 cars from 2010 to 2013; to San Diego
Metropolitan Transit System for 65 cars from 2010 to 2013; to Calgary Transit for
38 cars in 2011; and to Metropolitan Transit Authority, Houston for 19 cars in 2013
Recaro
Auburn Hills, MI
In service for over twenty years at transit agencies throughout North America,
including MBTA
Melco
Pittsburgh, PA
405 Kawasaki MNR/CDOT M8 Electric Multiple Unit cars (2009-2014); and 40
Hyundai-Rotem Vancouver Canada Line Light Rail Transit cars (in service 2009)
Quester
Victoria, BC
100 units for Bombardier (NJT) (2010-present), 75 units for Hyundai-Rotem
(SEPTA) (2009-2013), 160 units for Bombardier (AMT) (2009-2012),120 units for
Hyundai-Rotem (SEPTA) (2007-2010),120 units for Ansaldo-Breda (SFMUNI)
(2004-2007).
Axion
Plattsburgh, NY
405 M-8 and S-cars for MNR (2008-16), 1172 M-7 cars for MNR (2002-10), 706
5000-Series cars for CTA (2008-18), 420 Rocket cars for TTC (2008-17), 329
Multi-Level cars for NJT (2007-12)
SEPSA
Ballston Spa, NY
192 S5000 Married Pairs for WMATA, 364 S2000/S3000 Married Pairs for
WMATA, 184 S6000 cars for WMATA, 39 LRV trams for WMATA Houston
Luminator
Plano, TX
WMATA 7000 series (528 cars) and the CTA 5000 Series (714 cars)
TDG
Niagara Falls, NY
GO Transit, Bi-Level I, II and G9 (287 cars), ART Mark III (88 cars), Skytrain (54
cars), Tri-Rail (26 cars) and Amtrak Superliner I (65 cars)
Door Systems
Seats
Vehicle Monitoring
System & Network
Equipment &
Integrator
Communications
Equipment
Lighting
16 of 20
May 15, 2014
RFP No. CAP 27-10
I.2.i
Shipping
Hopedale’s strategic location, only 40 miles from Boston, features some of the best multi-modal
connectivity available in an MA location. Route 495 and the MassPike, both major truck routes,
provide a fast and direct connection to Boston. Completed cars could make the journey easily
on lowboy trailers. Personnel would also be only a 45-minute drive from the Authority’s major
shops at Cabot and Wellington. The Grafton and Upton Railroad provides on-site switching
services that can be tailored to fit Kawasaki’s needs. They connect to the CSX and the MBTA
in both North Grafton and Milford. Both lines offer direct service to Boston. The CSX
connection in North Grafton offers a connection to all points in the United States, including west
coast ports. Refer to the map below.
Kawasaki is currently reviewing shipping options and will select the option that best benefits the
Authority, including factors affecting cost, scheduling and mode of transportation of vehicles.
Due to the very short distance between the Hopedale Facility and the MBTA delivery destination,
Kawasaki does not believe that there is any need to protect the cars while they are in transit.
Should interim storage of completed production vehicles become required, these completed
vehicles will be protected by placing them on storage tracks within the fenced-in area of the
Hopedale facility, in order to prevent unauthorized access and potential vandalism.
17 of 20
May 15, 2014
RFP No. CAP 27-10
I.2.j
Local Area Office
As described in the subsections above Kawasaki proposes to utilize the Hopedale Facility in
Hopedale, MA for Production Vehicle Final Assembly, System Integration, Production Vehicle
Testing and System Assurance.
Kawasaki does not intend to furnish a local office in the Boston Area for the New Orange and
Red Line Vehicles Project as we intend to use, as an alternative to a local office, our existing
production facility and project office in Yonkers.
The merit in locating the project office in the Yonkers Facility is the communication network
between our subcontractors. Over the past 25 years, the Kawasaki Yonkers Facility has
developed a communication system with KHI’s Hyogo Works in Japan. This will be the location
of vehicle design, as well as the manufacturing, final assembly and testing of the pilot vehicles.
Production of the subsequent production carbodies will take also place in Hyogo, Japan.
Kawasaki feels that it is in the best interest of all parties to maintain a simple yet strong
communication structure, so that all needs, including changes to the design will be implemented
promptly.
The concept above also applies to Kawasaki’s US subcontractors, as it ideal for the project
office to be located in the Yonkers Facility where all information and orders are generated, so
that the quality of the product is enhanced and maintained.
Kawasaki understands the need for the Authority and Kawasaki to develop a cohesive
relationship and work closely geographically, especially during the design phase, so that we can
promptly respond to the Authority’s needs. In order to achieve and maintain this relationship,
Kawasaki staff would be pleased to travel to Boston for meetings and discussions, any time as
requested. The MBTA office in Boston and Kawasaki’s Yonkers Facility is only a three-hour trip,
door to door.
Kawasaki has not provided a local office for any of the past four MBTA bi-level projects and
neither party has experienced any communication gaps or issues. Past experience shows that
the provision of a local office is not crucial to the success of the project due to the continued
responsiveness of Kawasaki. We plan to continue the use of our current warranty site, which is
equipped with contact personnel, for this project as well. Although Kawasaki does not intend to
locate the project office in Boston, we are confident that we are able to be more responsive than
other manufacturers who might intend to furnish one, especially with the utilization of the
Hopedale Facility.
18 of 20
May 15, 2014
RFP No. CAP 27-10
APPENDIX I.2-1: HOPEDALE FACILITY LAYOUT
19 of 20
May 15, 2014
RFP No. CAP 27-10
APPENDIX I.2-2: SAMPLE ASSEMBLY PROCEDURES AND CONTROLS AND SAMPLE
MATERIAL CONTROL PROGRAM
20 of 20
May 15, 2014
TITLE:
PROCEDURE NUMBER:
RELATED DRAWING
DATE:
PROJECT:
PA5
Installation of Seat Shell
PA5-CST-02
44601-03531
05/19/09
TYPE
REVISION
WORK
CENTER
C- CAR
WRITEN BY
TT
H.Kim
D
CHECKED BY
Alan
Suarez
APPROVED BY
Digitally signed by Alan Suarez
DN: CN = Alan Suarez, C = US, O
= Kawasaki Rail Car Inc., OU =
Production Engineering
Reason: I am approving this
document
Date: 2009.05.20 14:43:42 -04'00'
Location
AL
TI
EN
D
FI
N
O
C
Views
T
Notes: There are 2 type of seat shells for 8 locations and the general installation
process is the same for each type.. Ensure that you are using the proper seat shell for
each location and following the correct steps.
3 Pass. seat shell P/N:54067-03543
2 Pass. seat shell P/N:54067-03542
PROCEDURE NUMBER
PAF-AST-02b
REVISION
D
ISSUING DEPARTMENT
PRODUCTION ENGINEERING
PAGE NO.
Page 1 of 7
REVISION HISTORY
REV
DESCRIPTION
REVISED BY
DATE
CUT-IN
INFO
N/A
-
Initial release
H. Kim
05/19/08
A
ADDED NOTES TO SHELL INSTALLATION
B.NICHOLS
02/04/09
ALL
B
Combined with PA5-CCB-01 procedure
B.NICHOLS
04/21/09
ALL
C
Removed all combined procedures
B.NICHOLS
4/27/09
ALL
D
Changed qty of p/n 31001-06775 shim to reflect actual usage per car
B. NICHOLS
5/19/09
ALL
TOOL LIST
NO.
TOOL P/N
QTY
Nut Driver 7/16’
Rubber mallet
Screw Gun (clutch type)
Level 1’long
Level 3’long
Scissors
1
1
1
1
1
1
NO.
TOOL P/N
V90101-0040
D
FI
CONSUMABLES
N
O
C
DESCRIPTION
QTY
Rags
Adhesive
Paint brush(1/2”)
Blow gun
A.R
A.R
2
1
Vacuum cleaner
PERSONAL PROTECTIVE EQUIPMENT
TOOL P/N
DESCRIPTION
Knee Pad
QTY
1 Set
All KRC required P.P.E
PROCEDURE NUMBER
PAF-AST-02b
AL
NO.
1
TI
EN
DESCRIPTION
REVISION
D
ISSUING DEPARTMENT
PAGE NO.
Page 2 of 7
BILL OF MATERIALS
DRAWING
ITEM
PART NUMBER
DESCRIPTION
QTY
UNIT
44601-03531
3
54067-03542
Seat shell Ass’y
2
44601-03531
4
54067-03543
Seat shell Ass’y
10
44601-03531
9
28058-03514
36
44601-03531
10
28060-03508
44601-03531
11
31001-06775
Screw Interior
Equip.
Washer Interior
Equip.
Shim
108
44601-03531
12
31032-05592
Packing
24
36
AL
TI
EN
D
FI
N
O
C
PROCEDURE NUMBER
PAF-AST-02b
REVISION
D
ISSUING DEPARTMENT
PAGE NO.
Page 3 of 7
Detail locations of seat shells
O
C
AL
TI
EN
D
FI
N
Installation : Starting point at #1end R.H, all seats are to be installed using
same process as below
Step 1 Ensure the completion of all steps related to seat shell
installation as below.
1), belt rail install properly (level, proper height(799mm),gap)
2), no gap between top of cover plate ass’y and side wall
3) no gap between door post and wind screen
4), 90 degree between wind screen and side wall
5), cover plate ass’y and cover plate installation
6), floor heaters and brackets
7), seat frames install properly
8), cleaning on bottom pan of seat frame
9) etc.
No gap
Fig. #1
Level & proper height
Fig. #2
90 degree
Belt rail
PROCEDURE NUMBER
PAF-AST-02b
REVISION
D
ISSUING DEPARTMENT
PAGE NO.
Page 4 of 7
Fig. #3
Door post
Fig. #4
Wind screen
No Gap
Cover plate
Cover plate ass’y
Fig. #5
Fig.#6
Heater
D
FI
N
O
C
Remove foreign materials &
clean well before seat shell inst.
Front bracket
for grille
EN
No gap between belt
rail and seat shell
AL
TI
Step 2 Place and fit seat shells into position on seat frames one by one.
Note: Top of seat shell must be approx.12mm below the top of the
belt rail,and approximately 3/16” away from belt rail to allow for
adjustment.
Approx 12mm
\
PROCEDURE NUMBER
PAF-AST-02b
REVISION
D
ISSUING DEPARTMENT
PAGE NO.
Page 5 of 7
Supports on
seat frame
Clips on seat shell
Rear side of seat shell
12
O
C
Step 3 Apply rubber packing item#12(p/n 31032-05592) on top of all seat
shells inside to plug the holes between belt rail and seat shell.
Using adhesive p/n V90101-0040
Item #12 Rubber
Packing p/n 31032-05592
N
D
FI
Seat shell\
Side View
AL
TI
EN
Seat shell
Step 4 Secure the seat shells onto seat frames with special mounting screws
(p/n28058-03514) and washers (p/n28060-03508) thru the hole on
bottom pan of seat frame.
Seat Shell ass’y
Special Screw
p/n 28058-03514
¼-20
9
3, 4
11
Shim(s)
p/n 31001-06775
Seat frame
Seat Bottom pan
Washer P/n28060-03508
10
PROCEDURE NUMBER
PAF-AST-02b
REVISION
D
ISSUING DEPARTMENT
PAGE NO.
Page 6 of 7
Torque : 4.5-5.2 lb-ft
Note: Add three (3) shim(s) item#11(p/n 31001-06775) to adjust
the height of seat shell .
Close ups
Bracket on
Seat Shell
D
FI
N
O
C
Bracket on seat frame and
mounting hardware
AL
TI
EN
Mounting hole
on bottom of seat
frame
PROCEDURE NUMBER
PAF-AST-02b
REVISION
D
ISSUING DEPARTMENT
PAGE NO.
Page 7 of 7
Material Rejection Reporting & Nonconforming
DOCUMENT No.: 832P4-01
Material Control
REVISION: E
G.
T.
Smith
J.
Bruen
AUTHOR:
APPROVED BY:
PAGE 8 OF 9
TITLE:
Form:
Material Review Report
832P4-01-F1
MRR/Ref. Number:
Issue Date:
Issued By:
Supplier:
Occurrence Date:
Supplier Contact:
Supplier Fax:
TO:
Car Number:
CC:
Quantity Rejected:
Subject:
Reported By: (Print & Sign Name) Stamp
Part Name:
Inspected By: (Print & Sign Name) Stamp
Part No:
Serial Number(s):
Responsibility: (Circle the choice)
RSB RSA KHI KMM KRC Supplier
MRB Required: (Circle)
YES
Rejection Details: (List all nonconformance’s found and attach drawings, photo’s etc.)
Disposition: (Circle the choice)
Return to Vendor
Replace
Repair
Deviation/Waiver Use As Is Scrap
Disposition Comments: (notes for disposition attach additional notes)
Critical Yes NO
Signatures Of Material Review Board Members As Required
Department
Quality
Engineering
Purchasing
Production
Production Planning/Engineer
Customer
Date
Print Name
Signature
Signatures For Final Acceptance of Repair/Rework
Customer:
Supplier Corrective Action Required:
Date:
Yes No
Carbuilder:
Review of CA: Accept Reject
Date:
CA Reviewer Signature & Date:
NO
KRC CORRECTIVE AND PREVENTIVE
ACTION REQUEST FORM
DATE:
TO:
FROM:
REQUESTED BY:
REQUEST #:
PROJECT:
PART #:
RAIL CAR #:
The following request has been made to perform a complete CAPA Investigation into the following:
DESCRIPTION OF EVENT OR NON-CONFORMANCE:
POSSIBLE OR KNOWN CAUSE(S):
POSSIBLE AFFECTIVITY PART OR CAR NUMBERS DATES OF MANUFACTURE:
COMMENTS:
CAPA REQUEST STATUS
REVIEWED BY:
DATE:
ACCEPTED BY:
REJECTED BY:
PERFORM CAPA
DOWNGRADED BY:
INVESTIGATION
IMMEDIATE REMEDIAL ACTION, IF ANY/REASON FOR THE DOWNGRADE/REJECTION:
CAPA REQUEST CC TO:
852W4-01-F01 REV. A
NOTE: ATTACH ADDITIONAL INFORMATION AS NEEDED

Part 5 - Tab I.2 (Manufacturing Plan)

Transcription

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