Approach / Solution
Asset Audit & Assessment:
- Performed structured system walkdowns and documentation reviews to verify installed base accuracy across all control panels, PLCs, network nodes, and rolling stock components.
- Cross-referenced existing parts lists against OEM lifecycle databases and supplier EOL notifications to map obsolescence status.
Maintenance Review & Gap Analysis:
- Analysed historical maintenance records, fault logs, and Mean Time Between Failures (MTBF) to determine degradation trends and recurring failure patterns.
- Compared current practices against PAS 55 / ISO 55000 asset management principles and IEC 62443 maintenance guidance for OT systems.
Maintenance Plan Redesign:
- Developed a revised risk-based maintenance strategy categorised by criticality, operational impact, and manufacturer supportability.
- Introduced predictive maintenance elements using condition monitoring potential where feasible.
- Created visual flowcharts and regime tables for engineering teams to deploy and maintain consistency.
Reporting & Stakeholder Delivery:
- Authored a structured engineering report with prioritised actions, strategic upgrade recommendations, and a 5-year phasing roadmap.
- Presented findings to Heathrow stakeholders and Ultra leadership with clear cost-benefit scenarios and risk mitigation outcomes.
Outcomes / Results
Improved Reliability:
- Identified and mitigated key points of failure, enhancing system resilience with targeted replacement and upgrade strategies.
Modernised Maintenance Regime:
- Delivered a structured, risk-aligned plan replacing ad hoc legacy routines, reducing unplanned downtime and reactive interventions.
Obsolescence Clarity:
- Produced a full obsolescence risk map enabling budget forecasting and lifecycle planning, supporting future system digitalisation goals.
Stakeholder Value:
- Recommendations adopted into Heathrow’s ongoing asset management strategy and aligned with broader OT modernisation planning.
Documentation Legacy:
- Supplied up-to-date asset registers, maintenance matrices, and documentation templates for operational use and future auditability.
Key Technologies & Methodologies
- OT asset management frameworks (PAS 55, ISO 55000, IEC 62443)
- Lifecycle and obsolescence assessment (OEM data, EOL bulletins)
- Maintenance strategy redesign (preventive, predictive, criticality-based)
- Failure analysis and MTBF metrics
- Engineering reporting and stakeholder presentation
- Systems covered: Autonomous vehicle control, PLCs, telemetry, fibre communications
Specialists in Rail, Telecoms, and Automation