CATA Bus Rebuild Projects: Why and How?

Transcription

1 CATA Bus Rebuild Projects: Why and How? Mark Kutzer, Director of Maintenance Centre Area Transportation Authority (CATA) 2081 W. Whitehall Road, State College, PA (814) ext. 160

2 CATA - Background Service Area State College, Penn State Approximately 135 Square Miles 61 Buses, 4 Paratransit Vans, Passenger Vanpool Vans 7 Million Riders Annually (32,000 average daily during semester) Active Fleet Comprised Entirely of Clean Natural Gas Buses

3 CATA s First Rebuild Overview: Rehabilitation of ten 1997 New Flyer low-floor buses Funding: Flex funding, one-time transfer from highway funds Timeline: Began project in Winter 2006 Completed Fall 2008 Results: 6 8 years of extended life

4 Current Rehab Project Overview: Rehabilitation of ten 1998 New Flyer low-floor buses Funding: $1.67 million, American Recovery and Reinvestment Act (ARRA) stimulus grants Timeline: Began project in November 2009, Pre-production meeting First bus took 16 weeks, initial and final inspection Remaining, 8 weeks each, 2 at a time Completion expected November 2010

5 What IS Rehabbing? Rather than purchasing a new bus once a current one had reached the end of its expected life, it can be sent away for rehabilitation. The process includes the rebuilding of: Air systems Seat inserts Drivers seat Front axle/steering Rear axle AC system New side body panels Complete paint job New bumpers New radiator/cac Assembly

6 Why Rehab? Why Not Buy? Life: Rehabbing a bus can easily extend its life by 6 8 years. Cost: The average cost of a new CNG-powered bus is $425,000. The average cost to remanufacture a bus is $175,000. Lead Time: The average lead time between order and delivery for a new bus is 18 months. The average lead time to remanufacture a bus is approximately two months. Environment: The average remanufacture process keeps 5,000 pounds of non-recyclable materials out of landfills.

7 Why Rehab? Why Not Buy? Philosophy: Forward-thinking Board realized that much of the fleet would come up for replacement at the same time, rehabbing would stagger.

8 Pros and Cons - Rebuilds Pros: Like-new bus for less than half the cost Shorter lead time Warranty Can help stagger bus replacement Cons: Down a piece of equipment for 2 4 months Process is not perfect

9 Project Overview Phase 1: Procurement Process

10 Project Overview Phase 1 CATA staff plans project and develops specifications. Technical specifications Quality Criteria/standards Schedule requirements Project goes out for bid. CATA evaluates bid proposals and awards contract Total Time: 3 4 months

11 Choosing a Company A number of options: Midwest Bus, Coach Crafters, Perfect Body, Complete Coach Works, Chicago Truck & Bus, etc. Evaluations: Experience, price, etc.

12 Project Overview Phase 2: Build Buses

13 Disassembly Process Begins

14 Disassembly Process As pieces are removed from each bus they are catalogued and stored together in our warehouse. Undercarriage is pressure washed, de-scaled and sandblasted.

15 Disassembly Process Major Components Removed HVAC System Skirt Panels Battery Box Wheelchair Box Side Windows Sidewall Skin Engine Coolant Components

16 Disassembly Process Oh, the things you find Hidden Accident Damage

17 Disassembly Process Oh, the things you find Rusted Under Panels

18 Disassembly Process Differential rebuild

19 Repair Process Structural repairs are made and inspected

20 Repair Process Undercoat Under-Carriage Install Engine Cooling System Components Radiator Charge air cooler Fan clutch assembly Fan drive gear box Surge tank

21 Repair Process Install Air System Components Height Control Valves Brake Pedal and Relay Valves Windshield Wiper Motor Assemblies Air Springs and Shocks Fire Suppression System

22 Repair Process CNG components installed Air systems tests performed

23 Assembly Process Begins Install HVAC Components Rear Module AC Compressor Heater Box in Dash

24 Assembly Process Install Axle and Steering Components Front Control Bushings All Slack Adjusters King Pin and Bushing Assemblies Steering Shaft Front End Alignment

25 Assembly Process Interior Inspection Install body exterior panels Sidewall Panels Skirt Panels Access Door Panels

26 Assembly Process Paint and Body Repairs Body Work Completed Body Work Inspected Paint Complete Bus Paint Work Inspection

27 Assembly Process Paint and Body Repairs

28 Final Inspection/Delivery Inspection Road Test CATA Inspection Trailor Delivery

29 Our Experiences Very positive experiences The more you spell out in the RFP the less gray area you will have in completion of the project.

30 Questions? Mark Kutzer, Director of Maintenance Centre Area Transportation Authority (CATA) 2081 W. Whitehall Road, State College, PA (814) ext. 160