Reliability Programme

PPP Co must implement a Reliability Programme.

The purpose of the Reliability Programme is to:

(a) provide a means of establishing a quantitative assessment of the compliance of the proposed design with Reliability and Availability targets established in the Contract and thus ensuring PPP Co can provide the Required Availability;

(b) identify areas of the design which require modification or improvement to meet the required Reliability performance;

(c) introduce design improvements and changes that will ensure that the specified targets are met; and

(d) measure the levels of Reliability achieved during the Through Life Support Phase and identify any corrective action necessary if performance fails to meet the requirements of the Contract.

4.8.2 Modelling and prediction

PPP Co must develop Reliability block diagrams and models to calculate the predicted Reliability performance of the selected design throughout the Contract Term.

Models must be developed to represent the System to at least the lowest replaceable subassembly level. Commercially available computer modelling tools may be used at the option of PPP Co.

Data for inclusion in the models must include:

(a) demonstrated performance for previously developed items, where available.

Such data must reflect the operation of equipment in an environment that must be shown to be representative of the environmental and dynamic performance conditions specified. PPP Co must provide evidence in support of the validity of operating performance data; and

(b) estimated performance for newly developed items, based on manufacturers' data or other method agreed by RailCorp’s Representative.

The results of the modelling are to be presented by PPP Co as a formal Reliability Predictions Report.

PPP Co must demonstrate:

(a) that the Reliability predictions for the Sets, in steady state, will achieve Reliability of not less than one Incident per 50,000 Set kilometres; and

(b) that the requirements for Reliability predictions are specified within their contractor agreements.

4.8.3 Failure Modes, Effects and Criticality Analysis (FMECA)

PPP Co must complete, document and maintain a Failure Modes, Effects and Criticality Analysis (FMECA), in accordance with the requirements of MIL-STD-1629A Procedures for performing a Failure Modes, Effects and Criticality Analysis.

The purpose of the FMECA process is to review and analyse the design to establish:

(a) potential or demonstrated failure modes for each significant item within the design. This will be carried out at least down to the replaceable subassembly level and below this level, as necessary, in order to analyse effectively the failure

modes to identify any single-point failures and to fulfil the safety and reliability analysis requirements of the Contract;

(b) the likelihood of failure for each identified failure mode, where possible expressed in terms of failure probability;

(c) the effect of failure in terms of the impact on safety, operating performance, environmental impact, human factors and economic consequences, including damage to other equipment; and

(d) the criticality of failure in terms of operation of the System, i.e. whether operation can continue after the failure has occurred.

The FMECA process is closely linked to the Reliability Programme and the Reliability modelling described in clauses 4.8.1 (Reliability programme – purpose) and 4.8.2 (Reliability programme –modelling and prediction) of these Contract Management Requirements. FMECA serves to identify potential failure modes which must be considered as part of the Reliability estimation process for a specific item and to provide information on those which should receive highest priority for Reliability improvement. FMECA also provides the basis for development of programmed maintenance requirements, and for identifying failure modes and effects for consideration as an input to the System Hazard Analysis (see clause 3.2 (System Hazard Analysis) of these Contract Management Requirements).

The initial analysis is to be completed in conjunction with the Reliability modelling and prediction activity and results are to be available for review as part of the Critical Design Review.

The results obtained from FMECA throughout both the Delivery Phase and the Through Life Support Phase must be used to update the Technical Maintenance Plan.

4.8.4 Reliability Demonstration

PPP Co must implement a Reliability Demonstration for the Sets, in accordance with the requirements of EN 50126 Railway applications – The specification and demonstration of Reliability, Availability, Maintainability and Safety (RAMS). The purpose of this demonstration will be to provide assurance to RailCorp that the Reliability predictions provided in the Reliability Predictions Report will be achieved in practice throughout the Contract Term.

The methods to be employed for the Reliability Demonstration of the Sets will be submitted by PPP Co for review by RailCorp’s Representative and include two separate phases, namely:

(a) the first phase, to be undertaken during Delivery Testing of Set 1, will be aimed at identifying any areas where there appears to be a substantial departure from the predicted Reliability for the Cars. Corrective actions will be identified and agreed between PPP Co and RailCorp as a result of this initial assessment, for incorporation in all Cars; and

(b) the second phase, to begin at the Date of Practical Completion of Set 1, will continue until the Date of Final Completion of the last Set. This phase will involve the continuous assessment of achieved Reliability under service conditions and

will also result in the identification and incorporation of agreed improvements to correct identified deficiencies.

PPP Co must document the process to be followed for both of these phases in a Reliability Demonstration Plan.

4.9 Maintainability Programme