When operating a fleet of locomotives, every delay, repair, or failure directly impacts your bottom line. Among the most persistent and costly challenges facing rail operators are battery-related start failures, commonly referred to as Dead-Won’t-Start (DWS) events. At first glance, the costs of these failures might seem limited to immediate repairs, but their hidden ripple effects can drain time, resources, and profitability.
This blog explores the true cost of DWS events, uncovering the unseen burdens they place on operations and offering strategic solutions like KickStart technology to eliminate these challenges and their associated expenses.
The Direct Costs of Start Failures
DWS events arise when locomotive batteries fail to deliver sufficient power to crank the engine, causing operational delays and disruptions. The direct costs, while burdensome, represent just the tip of the iceberg:
- Unplanned Maintenance Costs: Emergency technician dispatches and repairs are costly and time-consuming.
- Battery Replacements: Frequent deep discharges shorten battery life expectancy, amplifying replacement expenses.
- Downtime and Delays: Locomotives remain idle when they fail to start, impacting schedules and revenue flow.
But while these costs are apparent, the hidden consequences of DWS events can be far more significant.
The Hidden Costs of Battery-Related Start Failures
Battery-related failures cause operational inefficiencies and cascading effects that extend far beyond immediate repair bills. Here are the hidden costs every rail operator must consider:
🚦 Lost Operational Efficiency
Each failed start sends a disruptive ripple throughout the entire system. Schedules are delayed, rail yards are forced to juggle assets, and congestion builds up unnecessarily. This undermines the precision and reliability essential in rail operations, leading to lost opportunities to maximize productivity.
⛽ Increased Fuel Consumption
To avoid start failures, locomotives are often left idling for prolonged periods. While idling ensures engines remain operational, it consumes vast amounts of fuel—up to 5 gallons of diesel per hour—adding substantial fuel costs to overall expenses. Over a fleet of locomotives, this waste climbs exponentially, further straining profitability and derailing sustainability goals.
🔋 Reduced Battery Lifespan
Frequent start failures stress and degrade locomotive batteries. With every restart attempt, batteries endure deeper discharges, higher temperatures, and increased wear. Instead of lasting their full lifecycle, these batteries often require premature replacements, driving maintenance budgets upward while creating unnecessary waste.
👷♂️ Crew Downtime and Overtime Costs
When a locomotive won’t start, your crew is left waiting. This downtime leads to unplanned overtime expenses and disrupts carefully planned shift rotations. The result? Higher labor costs and decreased employee satisfaction.
📋 Customer Dissatisfaction and Penalties
Missed schedules directly impact customer trust, especially in time-sensitive shipping operations. Delays may result in financial penalties for failing to uphold service level agreements (SLAs) or the loss of valuable partnerships, eroding long-term business relationships.
🛠️ Strain on Maintenance Teams
Frequent DWS occurrences divert maintenance teams from proactive tasks like inspections and scheduled service. This strain results in delayed upkeep, which can snowball into more preventable failures across your fleet, further hindering reliability.
Understanding these hidden costs highlights the urgent need to address DWS events proactively, rather than reacting to them as they arise.
Why These Costs Matter
The hidden and visible costs of start failures add up quickly, severely undermining operational performance and profitability. Solving the problem isn’t just about reducing expenses—it’s about building an efficient, resilient system that keeps your fleet running smoothly. This is where KickStart solutions come into play.
How KickStart Eliminates Battery-Related Start Failures
KickStart addresses the root causes of DWS events by using advanced supercapacitor technology and intelligent battery management systems (BMS). Here’s how it works:
✅ Reliable Cranking Power
KickStart supercapacitors deliver an immediate, high-powered energy burst during start-up. This reduces the strain on batteries and ensures successful engine starts—even when batteries are partially discharged.
🔋 Optimized Battery Life
By reducing deep discharges and stabilizing voltage levels, KickStart extends locomotive battery life by up to 3x. Fewer replacement cycles mean lower maintenance costs in the long term.
⚡ Voltage Stabilization with Bus Boost™
KickStart prevents voltage drops during engine cranking, maintaining stability for critical onboard electronics. This eliminates brownouts, preventing electronics from cycling or resetting during starts.
🚨 Emergency Start with One More Crank™
KickStart systems provide a final start attempt by temporarily disconnecting non-essential loads when battery power is low. This emergency feature ensures critical operations can continue, minimizing downtime.
🚛 Reduced Idling Time
Improved reliability means operators can confidently use Automatic Engine Start-Stop (AESS) systems to shut down engines when idle, significantly reducing fuel consumption and emissions.
KickStart doesn’t just fix the symptoms of start failures—it transforms operations by eliminating the root causes altogether.
The Long-Term Benefits of Reliable Starts
Investing in KickStart technology delivers several measurable benefits, providing a strong ROI for rail operators. Here’s what you can expect:
🌟 Reduced Maintenance Costs
With fewer unplanned repairs, battery replacements, and technician dispatches, maintenance budgets shrink significantly.
🚆 Increased Fleet Availability
Reliable starts mean fewer idle locomotives, improving fleet availability and overall productivity.
⛽ Improved Fuel Efficiency
Decreased idle time can save over 1,000 gallons of fuel per locomotive annually, equating to thousands of dollars in savings per year.
🌎 Enhanced Sustainability
By reducing idling and enabling optimal starts, KickStart contributes to lower CO2 emissions, helping operators meet environmental goals and regulatory requirements.
📊 Greater Predictability
KickStart-equipped locomotives benefit from real-time diagnostics and monitoring, making it easier to predict and prevent maintenance issues before they arise.
Is Your Fleet Prepared for Smarter Operations?
Battery-related start failures represent more than momentary operational hiccups—they are ongoing drains on resources, efficiency, and long-term profitability. By investing in solutions like KickStart, rail operators can ensure consistent, reliable starts, extend battery life, and achieve significant cost savings.
With supercapacitor technology at its core, KickStart provides the power, reliability, and operational excellence your fleet needs to thrive, no matter the challenges on the track.Start transforming your operations today. Learn how KickStart can eliminate start failures, improve efficiency, and optimize profitability for your locomotives.