CSX Plan of Action

The CSX plan of action to improve quality involved the following six steps:

1. Commit to a quality program where everyone will become trained and involved.
2. Form a task force headed by upper management.
3. Identify problem causes.
4. Define solutions.
5. Implement a program.
6. Measure the results

An example of the application of such an action plan was the way in which CSX addressed roller bearing performance on their system. CSX was experiencing a rising trend of hotbox setouts and in-service bearing failures on their system. A quality task force led by Mr. L.A. McLean, Chief Mechanical Officer - Engineering and Quality Control and Mr. F. W. Althoff, Director - Quality Control, identified four possible causes for this rising trend in roller bearing incidents. Those causes were:

• Roller bearing aging.
• Reconditioned bearing quality.
• Reconditioned specifications not adequate.
• Loose bearing failures resulting from inadequate clamp load.

Solutions to each of these possible causes were proposed, and actions were implemented to deal with each of these possible causes.

Roller Bearing Aging

Roller bearing aging was addressed by removing field lube bearings from service. Field lube bearings are older style original installation bearings which were applied to a wheelset prior to January 1, 1977, and have been continually in service since that time without benefit of a reconditioning cycle. CSX adopted a policy that stipulates that whenever a car equipped with field lube bearings is on a repair track, those bearings are removed from the car, and new or reconditioned bearings of the current NFL design are applied to the car in their place.

Quality of Reconditioning

The issue of the quality of reconditioned bearings was addressed by means of a program to monitor the vendors' reconditioned bearing quality. Implementation of that program involved review of each reconditioner's quality assurance program and a systematic audit of reconditioned bearings delivered by the reconditioner. Any deficiencies noted during these observations were relayed to the reconditioner so that corrective action could be taken and improvements could be made to the outgoing quality level of bearings being reconditioned by that facility.

Adoption Of A Premium Reconditioning Standard

CSX then reviewed the existing AAR bearing reconditioning standards and compared them with the CSX service environment. That review led to the conclusion that the AAR minimum standards for reconditioning were not adequate for the CSX service environment and that standards improvements were the necessary next step. After discussion with manufacturers, CSX decided to adopt a premium bearing standard, the specifications of which addressed recurring component failures that CSX had observed on their system (Figure 1 - below).

Field Inspection For Loose Bearings: Torque Test Program

The final cause of bearing failures to be addressed by CSX was loose bearing failures resulting from inadequate clamp load. CSX had closely followed BRENCO's research into bearing retention and was convinced that removal of the cap screw seal rings and use of lubricated cap screws were essential to obtaining adequate bearing clamp. CSX decided to identify bearings in service that were operating with diminished bearing clamp and were in danger of producing in-service bearing problems. CSX initiated a cap screw torque test program for bearings on their cars to determine if a bearing should be removed from service for disassembly and inspection, or if the bearings were suitable for continued service after removal of the cap screw seal rings and reapplication of the end cap using properly lubricated cap screws (Figure 2).

Bearings removed from service as a result of failing the CSX torque test were sent to reconditioning shops and inspected. The results of those inspections showed that 50% of the bearings contained AAR condemnable defects. The CSX torque test has been adopted and certified by the AAR and is currently being performed at 21 locations on the CSX system. (A detailed description of the procedures used by CSX can be obtained by writing Mr. F. W. Althoff, Director - Quality Control, CSX Transportation Incorporated.)

Measurement of Results

The final and most important step in the CSX action plan was to measure the results of these programs which can be seen in Figure 3.

Since the implementation of the plan in 1988, the downtrend in bearing related in-service incidents has been marked. There has been a 20% decrease in bearing incidents over 4 years on CSX cars. In 1990, CSX derailments caused by cars were down 47% compared to the previous year, and the 1991 data indicated that car related derailments on CSX were down 50%.

Figure 4 shows a comparison between CSX equipment and cars owned by others for bearing related incidents over the 4-year time period. As the number of incidents on CSX equipment was declining, the number of incidents was notably on the rise for foreign line equipment.

As the result of these diverging trends, CSX is promoting bearing performance programs with all car owners. The benefits derived by CSX on their equipment with such a program can also be realized by other car owners. Those benefits are reduced hotbox setouts and bearing related derailments, both of which translate into fewer train stops, improved equipment utilization, and improved delivery performance to CSX customers.

Summary of Actions and Benefits Gained

In summary, CSX initiated a quality action plan to bring about improvements in bearing performance that dramatically reduced hotbox setouts and bearing related derailments. The two most important features of the CSX plan were the introduction of a premium bearing reconditioning standard in the maintenance of its fleet, and an extensive in-the-field program to remove from service bearings that showed indications of loose components. We believe the substantial benefits of these actions will prove to be even greater in the years ahead as the nations aging bearing fleet continues to deteriorate, and as the rail industry moves to even higher service demands, especially with increased axle load limits.

We applaud CSX management for their innovative leadership and impressive results. The bearing related performance improvements achieved by CSX translated into improved safety and reliability of equipment, reduced service delays and downtime for unscheduled maintenance, and consequently lower total operating costs and a more competitive position for this quality conscious carrier.

The Technical Forum is an information resource for the rail industry and is provided as a courtesy of Amsted Rail Group. Suggestions, inquiries or comments are welcomed and should be directed to:

Editor, Technical Forum
BRENCO, Incorporated
P.O. Box 389
Petersburg, Virginia 23804
804-863-1713

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