Cyclical Track Replacement Process Improvements
For a railroad infrastructure owner in the United States, we led an effort to examine work constraints resulting in less than ideal throughput of cyclical track program rail and wood tie replacement in continuously-welded rail (CWR) territory by a mechanized track gang. We utilized an eight-step framework consisting of organization, procedure, personnel, time study, rate analysis, utilization analysis, rightsizing, and benchmarking to understand and improve the work process. In the current line-up of track machines, production throughput varied significantly depending on factors such as local track characteristics (e.g. spike versus Pandrol clips), and operator skill. We recommended addition of drilling and screw lagging machines, which could improve gang throughput on curve territory. In this setting, the root cause of low machine utilization are the daily setup/preparation and tear down burden, and mobilization and demobilization at each site. We further recommended task-specialized gangs to ensure optimal machine and personnel mix, sequential work planning to improve machine utilization, and establishment of extra lists based on craft rather than providing protect coverage within each gang.
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