WIT to Suppress Unintended Cab-to-Saloon Door Opening

(Modernization Train)

1. Background
There were occasions where cab-to-saloon door was reported open by its own; at rear
end, during train service at revenue line. Though the design from the safety point of
view is robust, it was understood that the complaints on an opened cab-to-saloon door
during revenue services may induced unexpected service issue and may catch press
and councilors’ conscious.

Having said, we observed there has been a significant reduction in frequency of

occurrence of such kind of fault in the recent two years, better than before after the
introduction of improvements which ensued from the detail study of designer, from
both ergonomic and hardware integrity of cab to saloon door operation process.

The hardware trials, which were put through trial EDOC to name a few, were, new
door glam locks1, moving locking columns2, and door leaf enforcements3. The
software, detection logistics upgrade on Train Information System4 has also seen the
door open alarm deviation being lengthen to 600ms and provide repeated alarm whilst
door still open.

Frequent user of cab to saloon door, i.e. the train captains, all were briefed on how to
be mindful and application of technique ensuring that door leaves could be properly
close before swapping ends.

This Work Improvement Team, with staffs from Rolling Stock, and Operating train
captains were formed again to specifically look into the performance of cab-to-saloon
door again. The review is necessary, injecting a “continuous improvement” element
to the PDCA process.

2. Team Introduction
The team consisted of staff members from Rolling Stock depot front line, and
Operating train captains. It is a cross sectional and departmental team. All are
experienced staffs with over 10 years of services.

3. Scope of Work
This working improvement was confined to those modernization trains, M-train

1
ZML10340; Cab to Saloon Partition Door Locking Improvement (M-Train); Jun-2012
2
ZML10456; Replacement of moving parts of locking column for M-train partition door; Dec-2012
3
YML10151; Trial of Cab to Saloon Partition Door Reinforcement for M-train; Feb-2012
4
ZML 9899; Modification of TIS MMI to Provide Repeated "Cab-to-Saloon Door Not Closed" Alarm for M-train;
Sep-2012

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WIT to Suppress Unintended Cab-to-Saloon Door Opening
(Modernization Train)

servicing on DUAT lines and on the cab-to-saloon doors. The prime aims and
objectives were as follows:

A) Check the statistic of unintended cab to saloon door operation over the last
two years,
B) Identify mode of “issue”,
C) Gap analysis to the improvements previously devised amongst staff members,
D) Continuous review for improvements

4. The Investigation
In the past 12 months, there were 130 numbers of cab-to-saloon partition opening
cases reported in the DUAT lines. The factual characteristic of this opening cases
were that:

- All reported cases were not under emergency environments

- All reported cases were happened when the concerned units were a rear
cab
- All reported cases at rear end cab, after being attended by Station staff or
RRU, could be closed immediately
- No reported cases of unintended door operation when units were acting as
Front Cab (i.e. when the cab doors are being “push” to close)
- No train service delay or interruption of train equipment was registered at
those cases

5. Findings
To eliminate risk of train service delay and accusation from press, the team would
look into every cases of cab to saloon door and put them into different groups of
failure classification. After the analysis, while the major contributors are identified, a
gap analysis to the series of past proactive trials will be checked to see its progress
and effectiveness. The summary of Cab to Saloon Partition Door opening cases in the
past 12 months for all DUAT lines is referred (Appendix I). All the cases are
classified into 4 groups namely,

I) “Cab to Saloon Partition Door not close properly”,

II) “Equipment fault” and,
III) “Passenger actions”

Case I – 70%

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WIT to Suppress Unintended Cab-to-Saloon Door Opening
(Modernization Train)

There are 86 out of 122 cases reported “Cab to Saloon Partition Door not closed
properly”, i.e. 70% of the total. No equipment failure could be identified in this mode
of failure; neither by station staff, RRU, nor in depth investigation by maintenance
colleague at depot. From sign of operation, it was likely due to door leaf not fully
latch and hence causing it vulnerable to overcome light lean forces of passenger or
resultant centrifugal forces when concerned unit propagate along service line.

Case II – 13%
For equipment fault of Cab to Saloon Partition Door, 15 cases (12% of the total) that
caused the opening of the doors were reported. The failure mode included door latch
faulty, detection switch failed, door catcher broken, door lock spring broken,
equipment alignment shifted, door rubber seal detached, micro switch (part of TIS
component to indicate cab-door-open logic) failed.

Case III – 17%

Passenger actions leading to the Cab to Saloon Partition Door opening were the
emergency access panel pushed out by unknown passenger and passenger leaned on
the partition doors. 21 cases were reported, i.e.17% of the total. As the passenger
actions due to the vandalism or misconduct are uncontrollable. It could only be relied
on advising passenger not to do so through warning note or the vigilance of our MTR
staff members to avoid such occurrence.

6. Improvement Actions
After the analysis of the cases, the team found out the major contributors on the Cab
to Saloon Partition Door opening. And hence, we would focus on those that were
controllable and the majority. These were Case I - “Cab to Saloon Partition Door not
closed properly” and Case II – “Due to equipment fault of cab-to-saloon door”.

During brain storming session, few members raised to install CCTV may also be a
solution for problem solving. However, the playback of CCTV images may identify
out the responsibilities but is helpless to occurrences. Under the objective we planned
and the appreciation of “respect” culture, this improvement suggestion was therefore
unanimously withdrawn by all members. Also posting a warning label to remind
passenger not to lean against the door on the Cab to Saloon Partition Door may not be
effective. Hence the team did not recommend this proposal.

6.1 Resolutions
With the installation of CCT and thoughts of new label out of the list, the team

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WIT to Suppress Unintended Cab-to-Saloon Door Opening
(Modernization Train)

resolved to the followings for solutions; which was a pragmatic approach covering
both aspects of Hardware (train borne improvement) and Software (training for users).
Table 1 below has the detail summary of WIT resolutions.

(A) (B) ‘C)

Hardware Improvement Software Improvement Remarks
(Cab door) (Training for users)
1 - Users Transparent to Users or ‘## Video on the proper method to Elements of cab close
Train Captain close cab door will be produced. at front end will be
This will be shared and further study and incorporate
disseminate to train crew function to this video to ensure
partners, to maintain a standard and the action / method
quality platform of a proper way to captured has been
close this unique cab door; 100% correct.
especially at rear end, or change end
‘## conduct random check at the RS depot will prepare
turn round station, such as SHW, the video.
CHW and TSW. (Completed)
2- **Depot staff will **Demonstrate to user, when
Maintainer enhance the checking required or as necessary proper
on the door locking method to operate Cab to Saloon
gear and mechanism on Partition Door.
cab-to-saloon Partition
Door in ALL front line
check.
Table 1 – Resolutions to Unintended Cab-to-Saloon Door Operation (Rear end cab)

In response to the suggestion of 1(B), a video was prepared for the demonstration of
the proper way of open and close of Cab to Saloon Partition Door, which would be
used as Training video as part of the training material for train crew functions. This
was shared and communicated on 24 February 2014 during the bi-monthly train
crew / depot communicate meeting.

The objective of this action is to refresh and demonstrate a proper method of Final
Check concept. On the other hands, communication to sister depots about the
proactive approaches and experience sharing has been conducted as well.
6.2 Resolutions (Designer)

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WIT to Suppress Unintended Cab-to-Saloon Door Opening
(Modernization Train)

As mentioned in the introductory chapter of this report, actually there has been a
series of reliability enhancement work on the Cab to Saloon Partition Doors proposed
by the designer. From the nature of modification, there is a definitive improvement to
Case II of 13% and certain % of Case I items. Depot will pursue its full
implementation within this year.

6.2.1 Modifications and Trials

a. ZML 10340 – Cab to Saloon Partition Door Locking Improvement for M-train
This modification is to replace the existing curve latch by a longer angled
latch to increase the lock engagement. Spring Mechanism device is also
installed such that train captains are aware of any incompletely closed door
situation. (Completed)

b. ZML 10456 – Replacement of Moving Parts of Locking Column for M-train Cab
to Saloon Partition door
It is found that some moving parts of locking column of M-train Cab to Saloon
Partition door worn out seriously and caused failure. Thus, a set of modified
moving part has been developed to improve the durability on the locking
column. Those include the replacement of Trigger Levers with the new design
ones and the replacement of the circular lock holder and circular lock
mounting bracket. (Depot will help expediting the modification for
completion this year)

c. YML 10151 – Trial of Cab to Saloon Partition Door Reinforcement for M-Train
As a number of moveable side panels of the Cab to Saloon Partition Door with
degraded strength that affecting the locking performance are found. It is
proposed to reinforcing this door panel with additional structural beams;
giving its additional strength of 30%. A service trial has been conducted for
the validation of the effectiveness of the improvement. The reinforcement
beams have been installed on two moveable door panels of A230 and A125
since October 2012. As reviewed in the Trial Report, it is validated with no
adversity on the operation of the Cab to Saloon Partition Door. Also, there is
no failure related to the reinforced Cab to Saloon door panels during the
service trial. (RSMD will raise C&R work to have this implemented for all
cab-to-saloon door of Modernization train)

7. Conclusions

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WIT to Suppress Unintended Cab-to-Saloon Door Opening
(Modernization Train)

This Work Improvement Team, with staffs from Rolling Stock, and Operating train
captains were formed to specifically look into the performance of cab-to-saloon door
again. There was similar approach done years ago but was at Designer and maintainer
level. The review at this time is necessary, with the objective of injecting a
“continuous improvement” element to the PDCA process.

With the joint efforts of Train Crew and Depots, the major contributors for the Cab to
Saloon Partition Door opening cases were identified. From the symptom and 100%
successful rate of rectification (re-close) at site by either station staff or RRU, these
were considered as controllable. Percentage contribution of unintended cab-to-saloon
door operation to the total number of reported cases were as follows:-

70% - “Cab to Saloon Partition Door not closed properly”,

13% - “Equipment fault” and,
17% - “Passenger actions”

The WIT members approached the process in a pragmatic manner. And it resolved to
two major approaches; (1) Training; aligning the understanding of “proper” way to
handle cab door, and (2) Further enforcement to Maintenance. Retrospective
improvements from these two elements were communicated and built in to processes
of respective functions, pursuing for further improvements.

As we work in a collaborative environment, with the joint commitment of Train staff,

Depots and T&ES colleagues, the team anticipates that the number of Cab to Saloon
Partition Door opening cases would be greatly reduced in the coming days after all the
improvement actions implemented.
END
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Prepared by:
1) Train Crew Function -
2) Rolling Stock Maintenance Department – URL Depots representatives
KBD – Chat Man Tai (member)
TWD – Nelson Wong (Facilitator), Yeung Tai Kwong (Leader),
Wong Kin Leung (member)
CWD – Leung Ho Yin (member)

Date: 15 March 2014 (Submitted to WIT)

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WIT to Suppress Unintended Cab-to-Saloon Door Opening
(Modernization Train)

Appendix I
The summary of Cab to Saloon Partition Door opening cases in the past 12 months for
all DUAT lines