Design Concept Proposal : Computerized Maintenance Management System (CMMS)

The Cairo Air Improvement Project (CAIP), with assistance from the bus companies, studied the existing diesel bus operations and maintenance (O&M) organizations and practices to determine the baseline Egyptian diesel transit bus environment. CAIP then developed a proposed new organizational structure and reporting relationship for the Compressed Natural Gas (CNG) bus garages that is designed to enhance the current system, as well as provide the necessary new equipment and management practices. This effort also includes development of proposed staffing requirements for maintenance personnel and management staff.

The new program is based on CNG transit experience from around the globe, and uses straightforward requirements to allow efficient implementation into the Cairo Transit Authority (CTA) and Greater Cairo Bus Company (GCBC) organizations. Some technologically sophisticated systems are proposed, but they are being implemented with proper training and provide superior capabilities for monitoring and ensuring the success of the new CNG programs at CTA and GCBC. CAIP is assisting the bus companies with developing detailed management procedures for CNG bus O&M. These include schedules for inspections; procedures for routine and preventive maintenance; management of spare parts and supplies; and monitoring, reporting, follow-up, and resolution of maintenance problems.

Currently, all CTA and GCBC maintenance management activities are performed without the use of computers. Significant deficiencies exist, including delay in obtaining spare parts for needed repairs, minimum level of preventive maintenance, redundancies in maintenance functions, inability to track performance of buses, and low level of safety checks.
CNG buses and their support facilities are more sophisticated than their diesel counterparts. CNG is a gas and leaks are harder to detect than those from diesel. The fuel tanks that hold the compressed gas are of a high-tech design. The gas is under high pressure, sometimes exceeding 3,000 PSI. The bus engines and transmissions are computer-controlled and require complex preventive maintenance techniques to keep them operating at optimum conditions. An enhanced maintenance and safety program is essential for safe and economical operation of the buses and their support facilities.

For sustainability reasons, CAIP is providing the bus companies with a complete computerized solution for managing and maintaining their new CNG fleets. The system includes software and hardware packages suited for transit service. The system allows implementation of modern management practices, emphasizing preventive rather than corrective maintenance, and includes
enhanced quality control for spare parts, tools, and other resources.

The CMMS enables management to:

• Schedule preventive and predictive maintenance procedures, and parts and labor utilization for maintenance tasks.
• Project and monitor downtime and causes.
• Project and monitor costs, repairs, and usage of spare parts and labor.
• Analyze failures, costs, maintenance procedures, and resource usage.

CMMS usage helps in:

• Achieving high efficiency in fleet operation (by minimizing failures and maximizing operating time).
• Minimizing usage of parts and labor.
• Maximizing usage of buses and minimizing downtime.
• Maximizing buses’ lifetime and replacement period.
• Minimizing maintenance and operation costs.
• Maximizing profits.
• Raising performance levels.

The goal of this project is to establish a fleet computerized maintenance management system that allows the safe and efficient functioning of a CNG bus fleet for the CTA and GCBC.

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