Siemens light rail manufacturing site in Sacramento consists of 4 structures situated on 25 acres of land. Over 500 employees work at the facility in carshell production, finishing, electrical subassembly, vehicle assembly, engineering, project management, quality assurance and commissioning.
This facility features:
4 structures
75,000 sq.ft. which includes 15,000 sq.ft subassembly shop, 37,500 sq. ft stockroom and warehouse space and 15,000 sq.ft for engineering, purchasing and aftermarket departments
103,000 sq. ft. of carshell manufacturing and vehicle assembly space including 24,000 sq.ft office space for production management, project management, accounting, human resources, business development, and marketing
21,500 sq. ft. newly added carshell paint and final finish space
2 cladding booths
5 production areas: warehouse/sub-assembly, carshell welding, carbody painting/cladding, light rail vehicle final assembly/bogie assembly and testing
Warehouse and parts storage
The 37,500 sq.ft warehouse houses parts with pallet racks for storage of large parts and a two level high density area for smaller parts.
Special wheeled carts are used to store and distribute parts from the stockroom to the production floor for less handling of the parts, protecting them while on the shop floor. Special glass carts are used to store window glass, also for safe handling and storage.
Vehicle movement
Rails mounted in the concrete floor of the main assembly areas enable a vehicle on wheels to be moved between the north and south sides of the assembly area.
A 90 ft. custom rail vehicle transporter is used to move vehicles between buildings production bays or to the test track for dynamic testing.
Prior to shipping a vehicle, a covered loading shed is near the water test area and rail spur to accommodate the loading and packing of vehicles for shipment to the end customers.
Carshell production and assembly
Weld Process
Assemblies
Integration
Straightening
Inspection
Finishing and Cladding Process
Blast
Prime
Spackle
Final paint
Sub-Assembly
All harnesses, racks, panels and electrical lockers are pre-assembled and partially tested in our 15,000 sq. ft. of sub-assembly facility. The sub-assembly shop fabricates wire harnesses, apparatus panels and equipment racks, such as a driver's cab for installation into the light rail vehicles during the assembly process.
Bogie (Truck) Assembly
2 bays are allocated to assemble bogies, which includes traction motors, gearboxes, brake units, hydraulic or pneumatic piping, electrical harnesses and axles.
The assembled bogies are subject to a press test, which simulates the different load requirements and the settings associated with actual operating requirements.
Final Assembly Stations
Station 1: Floor panels, floor lining, insulation, joining the cars
Station 2: Cab, UC-piping/wiring, doors, windows, lights, mirrors
Station 3: Cab, roof equipment, wiring, ceiling, heaters, coupler
Station 4: Propulsion, UF-cabling, Sandbox, interior panels
Station 5: Seats, ceiling lights, stations, windshield, trucking
Testing
Continuity Test Area Once the vehicle is fully assembled, it is brought to the test area in the final assembly building for a wire continuity test to assure that all wire terminations are correct. The vehicle undergoes a HIPOT or voltage test in this area as well.
Static Test The static test area is also in the final assembly building where all control systems are powered up, software functions are downloaded and the vehicle receives a functional test and goes live.
Dynamic Testing Area A short variable voltage (600-750 Vdc) test track is situated at the rear of the facility. This quarter-mile test track is used for limited dynamic testing of the completed vehicles. Speeds up to 35 miles per hour can be reached on the track allowing most dynamic functions to be tested prior to shipment.
Water Test Booth A water test booth is located at the rear of the facility used for testing each vehicle after the completion of assembly to ensure water tightness of the vehicle as well as roof mounted equipment.
Quality assurance
Design quality Project management and design through a well-developed set of milestone actions and reviews
Supplier quality Three areas of supplier quality:
Supplier selection
Supplier development
Supplier improvement
are managed through an inter-departmental team whose focus is to optimize the supplier's capability in meeting Siemens requirments. Examples include: Systems-based supplier qualification, milestone reviews with suppliers during development and a thorough evaluation of supplier process and product capabilities.
Quality in production Quality assurance is integrated throughout the entire carshell construction and through final assembly phases, which include, production self inspection up to and including quality inspector hold points. Detailed records are kept providing full traceability of all work conducted.
