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Lean Manufacturing Technologies at JSC “Russian Railways”

The Lean Production Project is one of the key ways to increase the efficiency of JSC “Russian Railways” by streamlining processes, increasing productivity and reducing overheads.

The scope of the implementation of the Lean Manufacturing Project was expanded by over five times in 2012 and now covers 553 business units throughout the railways and across all areas of economic activity of JSC “Russian Railways”.

In 2012, 1,628 improvement projects were implemented, and 1640 standards and technological processes were revised. The increase in economic benefit from the project implementation exceeded RUR 260 mln, but a key achievement is that a core of employees has been created which is now engaged and interested in efficiency improvements. Our work was highly praised at the VIII Russian Lin-Forum.

Main areas of lean manufacturing in JSC “Russian Railways”’ facilities

Principle of the production system Examples of rolling stock benefits Examples of track facilities benefits Examples of traffic management benefits
1 Load balancing Timely repair of locomotives Gap scheduling to reduce as much time as possible when sending track machines Seamless planning of locomotives and crews at the point of departure
2 Flow alignment Removal of counterflows One-stop shop principle for all business entities Managing planning streams, route dispatch
3 Organization of pulling Replenishment of material and technical resources as required Just-in-time supply of materials for the track superstructure Destination station pulls the train from the formation station
4 Autonomy Automatic operation of test stations without human intervention Automatic adjustment of station-to-station travel time and train parameter charts when setting restrictions Alternatives to the formation plan are provided in the technical process of the station and do not require a decision from the Railway Traffic Control Center
5 5S methodology Maintaining order in the workplace Maintaining order in the workplace Dispatcher workplace ergonomics
6 Visual control Job boards and labels Network repair diagrams Electronic displays and color indicators
7 Prevention of human error Devices and equipment Work scheduling Automatic control
8 Common equipment maintenance Preventive maintenance and scheduled maintenance cards Maintenance and repair of track machines
9 Standardization of technological processes Monitoring of compliance with flow diagrams Regulation of scheduling and approval of gaps Agreed time for the transfer of working plans between dispatchers