CONTENTS

S No Description Page No1. Introduction & Role2. Organisation & Borne strength3. Shop Lay Out4. Machinery Installed5. Training6. Quality Circle & Objective7. Honours of the center8. Material Handling9. Achievements of the center10 Major Tasks of the center11 Work Load of the center12 Age profile13 Education profile14 Marital Status & Family planning15 No of children16 Areas Requiring attention17 Way Ahead18 Welfare measures19 DCMAF Status20 ECS Status21 SWOT Analysis22 Follow up action on last inspection

APPENDICES

1 Appendix-A Organisation2 Appendix-B Shop Lay out3 Appendix-C Machinery/Equipments 4 Appendix-D Training status5 Appendix-E Work Load of the center6 Appendix-F Education Profile7 Appendix-G Marital status & FP8 Appendix-H No of Children

REPORT ON CENTER - 30

1. Introduction and Role. The Valve Repair Shop, C No 30, of Systems department carries out overhaul/repairs of various system valves (except for hydraulic and HP Air valves) fitted onboard ships, submarines and yard crafts. The centre also undertakes repairs of valves of other centres of the Yard and CTS inventory. On an average three thousand valves are repaired every year. The centre is one of the most important centres of the Engineering Division and plays a very vital role since the shop undertakes overhaul of all engineering system valves including underwater valves below 05 inches. The broad responsibilities of this centre are appended below:-

(a) All systems valves (except Hydraulic and HP air valves)

(b) Saturated and Superheated Steam Valves (except main steam range valves)

(c) Boiler Mountings.

(d) LP Air Valves.

(e) Expansion Tanks.

(f) Overhauling of CTS inventory.

2. Borne Strength and Shop Organisation. Cdr G Venkateswarlu is the senior Manager of Systems department, Lt Cdr Bharat Pande is the center manager, Shri SR Jaiswar, Foreman (Gaz) is the in-charge of Administration and Shri. RM Kunder, C/Man-I is the in-charge of Production with one Assistant Foreman and three other Chargemen as supervisors-in-charge of different groups. Organisation chart of the centre is placed at Appendix ‘A’.

3. Shop Layout. The centre is located in the Second floor of PRS building. The layout of the centre is placed at Appendix ‘B’. The location of facilities in the centre are as follows:

S.No OFFICES/FACILITY LOCATION (PIPE REPAIR SHOP BLDG)

(a) Centre Manager Second floor

(b) Foreman Office Second floor

(c) Local Control Cell Second floor

(d) Shop Clerk’s Office Second floor

(e) Supervisor’s Office Second floor

(f) Supervisor’s Change room Second floor

(g) Testing Bay Second floor

(h) Work Shop (Group– ‘A’, ‘B’, & ‘C’) Second floor

(j) Store Second floor

(k) Workers Change room Second floor

(m) Valve Store Second floor

4. Machinery Installed / held in the Centre. Details of material handling equipment, tools and chemical cleaning equipment are listed at Appendix ‘C’.

5. Training. Industrial and non-industrial personnel are being regularly deputed for training courses at various organizations. Details of personnel trained are mentioned at Appendix ‘D’.

6. Quality Circle and Objectives. There exists an active Quality circle in CNo.30 called “Parivarthan”. Quality circle meeting are held regularly to discuss the various difficulties encountered in the area of various production related procedures.

7. Honours and Awards Personnel of C.No. 30 have received various awards and commendations for their professionalism, workmanship and individual achievement. Details of the same are mentioned below.

SNo Year Name Rank / GradeASD cash award(a) 2006 S K Suman HSK(b) 2006 M S Jhadav SKL(c) 2007 J Pore HSK(d) 2008 A T Shinde HSK(e) 2009 RM Kunder C/Man-I

8. Material Handling Equipments. The center has the following material handling equipment in operational condition: -

S.No Description Qty held in Nos.

Qty ops in Nos.

Qty non ops in Nos.

Remarks

(a) Electrical Overhead Crane 01 01 Nil Ops(b) Portable Crane

(Capacity-2 ton)02 02 Nil Ops

(c) Lister Jumbo (Capacity-2 ton)

01 01 Nil Ops

(d) Valve Handling Trolley (Capacity-2.5 ton)

03 03 Nil Ops

9. Achievements of the Centre. The Valve Repair Shop is one of the frontline production centres of Engineering Division. The centre has effectively undertaken all work packages assigned to it and met all cardinal dates consistently. Some of the achievements to the credit of this centre for the past one year are enumerated below:-

(a) Repair and Overhaul of Various System Valves. The centre successfully undertook overhauling/repairs of a total of approx. 1650 system valves during the Medium/Normal Refit of following ships:-

(i) INS Viraat - (ii) INS Shankul - 450(iii) INS Shalki - 550 (iv) INS Sindhuratna - 500 (v) INS Ganga - 600 (vi) INS Gomati - 700 (vii) INS Godavari - 800

(a)

(b)

(c)

(d) Liquidation of CTS inventory. In addition to the refit package of ships, the Valve Repair shop has also been instrumental in timely overhauling of Repairable Inventory received from CTS.

(e) Rotable Valve Inventory. The concept of rotable valve inventory has been introduced in valve repair shop to meet very urgent requirements of operational steam ships. Valves of decommissioned ships have been repaired and kept ready for replacement. The following category of valves are stored in the rotable inventory:-

(i) Aux. Sup. Master valve(ii) Aux. Sup. Cross- connection valve(iii) Steam Drain valve(iv) Re-circulating valve(v) Rack Operated valve(vi) Soot Blower Master valve(vii) Aux. Feed Check valve(viii) Aux. Machinery Master valve(ix) RFT System valve(x) TA Master valve(xi) Boiler Safety valve(xii) Exhaust to Atmosphere valve

10. Major Tasks of the Centre. The centre in presently involved in undertaking work packages onboard refit and operational ships. Few major tasks in hand are listed below:-

(a) Medium refit and midlife update of INS Gomati and Nashak.(b) Normal refit work package of INS Sindhuratna, Akshay, Vindhyagiri and Delhi.(c) Short refit work packages of IN ships Shishumar and Sindhuvijay. (d) AMP work packages of IN ships Aditya, Brahmaputra and Alleppey.

11. Work Load of the Centre. This center undertakes jobs of planned refits. However, large quantum of operational jobs is also undertaken in addition. The work load analysis of the centre is placed at Appendix ‘E’.

12. Age Profile of the Staff. Around 51 personnel in the center are above 40 years of age. Out of 08 Supervisors (including 01 F/M(G)) borne) 05 are in the age group of 50 to 55 years. A detailed chart showing the different age group among industrial and non-industrial staff is appended below:-.

AGE GROUP NO. OF PERSONNEL PERCENTAGE

18 – 30 YEARS 08 10%

31 – 40 YEARS 24 29%

41 – 50 YEARS 19 23%

51 & ABOVE 32 38%

13. Education Profile of the Staff. All supervisors are SSC. Out of 75 Industrial personnel 04 have completed Graduation, 41 are above SSC, 25 are Non-SSC, 05 personnel are below VIII Std. The detailed chart placed at Appendix ‘F’.

14. Marital Status and Family Planning. Out of 83 personnel 08 personnel are un-married. 75 are married. 41 out of 75 have adopted family planning norms. Detailed chart placed at Appendix ‘H’.

15. Number of Children. A detail showing the number of children of personnel (age group wise) is placed at Appendix-‘H’.

16. Areas Requiring Attention. Center No.30 is the back bone of Systems department which is the one of the main Valve Repair Shop in the Yard. As the experienced personnel in this center are retiring in the existing increasing work load conditions there is an inevitable limitation to augment the depleting manpower. However, the centre has the best record for overhauling and maintenance of various system valves and thus retained its motto as “Assuring quality valves, anytime”. The areas which are required to be addressed so that productivity of the centre can be enhanced and better working conditions can be achieved are as follows: -

(a) Unskilled Manpower. The available manpower comprises of 75 Industrial workers and 08 Supervisors including One Foreman(G). Almost 38 % of the borne strength is in the age group of 51 years and above. The centre is handling overhaul/repairs of various system valves (except for hydraulic and HP Air valves) fitted onboard ships, submarines and yard crafts. The centre also undertakes repairs of valves of other centres of the Yard and CTS inventory. On an average three thousand valves are repaired every year. The centre is one of the most important centres of the Engineering Division and plays a very vital role since the shop undertakes overhaul of all engineering system valves including underwater valves below 05 inches. As there is low induction rate of personnel in the yard, available skilled manpower are either retiring or getting promoted which leaves with diminishing unskilled manpower, consequently resulting in long term production constraint. Additional unskilled manpower needs to be augmented with the existing trained and skilled manpower to overcome this alarming constraint.

(b) Special Repairs. There are various special repairs that is being attended, mainly water leakage from the roof of PRS building, resulting water accumulation in the shop floor. This adversely affecting the productivity of the centre. The defects are being attended by MCM department on regular basis however, special repairs on the roof of the building needs to be approved at the earliest. Reference of this office letter DYT/SYS/041 dated 14 Aug 09 and 06 Jan 10 relevant.

(c) Skilled Manpower. There is reduction in the strength of skilled manpower with every passing year due to retirement of personnel. In the next five years, the strength will drop by 20% and further, by the year 2020, the strength would have dropped by 47%. It is therefore mandatory to recruit pipe fitters through DAS school to enable continuity of the trade.

17. Way Ahead. The way ahead plan for the centre is as follows: -

(a) Cross training of personnel to achieve multi-skilling (b) Computerisation of Control Cell and Store operations(c) Training of employees in eliminating the rework factor.(d) Special repairs on roof of PRS building(e) Streamlining and refining the various procedures adopted and practiced in the center for to achieve greater productivity.(g) Enhance awareness about safe working procedures while working shop floor, healthy and green environment, alcoholism and its ill effects and family budget (savings/investment) amongst all personnel.

18. Welfare Measures. The details of the welfare measures adopted by the centre since the last inspection are as follows:

(a) 100% employees completed their annual medicals.(b) All personnel of CNo30 applied for the membership of DCMA Fund.(c) Procurement of new furniture / dining tables for the centre. (d) Procurement of productivity enhancement tools.(e) Additional personnel trained on computers for office and store.(g) Conducted of lectures on health awareness.(h) 100% employees opted for crediting wages through bank.

19. DCMAF Status. All personnel of this center are a member of DCMAF.

20. ECS Status. All personnel of this center are a member of ECS.

21. SWOT Analysis. The various area of SWOT for the center has been analysed. Details of the same are as follows:-

(a) Strengths.

(i) Expertise for repairs/renewal of all types of valves.(ii) IMS certified (iii) Process level quality control.(iv) Pressure Testing facilities upto 1000 PSI.

(b) Weaknesses.

(i) Long lead time for procurement of spares especially rubber components.

(ii) Inadequate documentation.(iii) Limited work shop area.

(c) Opportunities .

(i) Availability of expertise in local industry. (ii) Cross training of personnel and merging of trades.(iii) Training of personnel on technological advancements.

(d) Threats.

(i) Growing age profile.(ii) Less promotional prospects leading to inadequate motivation.

22. Follow up Action on Last Inspection. The centre was last inspected by the ASD on 30 Apr 08. Actions taken on the observations made by the Admiral Superintendent during the last inspection are mentioned below.

(DK Goswami) Captain

Feb 2010 Dy. General Manager (Engineering)

Sl.No Observation Follow Up Action(a) Maintain adequate stock of

rotables/repairable inventory of various types of valves

(b) Create a library of drawing of valves with suitable details of its subcomponents manufactured by Yard

(c) Enthuse workers to undergo AME and progress towards achieving 100% compliance in phased manner

Completed

(d) Procurement of new lockers for improving quality of change rooms

Appendix ‘A’ (Refers to Para 2)

ORGANISATION CHART

SMSYSCdr G Venkateswarlu

JMSYSLt Cdr B Pande

Foreman (Gaz) R Jaiswar

Production in-charge C/Man-I RM Kunder

Store in-chargeAFM S Baretto

Line Supervisors

Appendix ‘B’ (Refers to Para 3)

II Floor

I Floor

I FloorPart Plan (PRS)

WORKERS CHANGE ROOM

TOILETS

SUPERVISOR CHANGE ROOM

STORE

F/MAN OFFICE

CONTROL CELL

MODEL ROOM

WATER COOLERS LIFT

LIFT

DM

SY

S

AM

SYS

F/MA

N

JOINT CUTTING BAY

TOILETS

W/C W/COFFICE

STORE CNO76

MACHINESHOP C.15

MSYS OFFICE LIFT

W/c

W/cLAYOUT OF C No.30

Appendix ‘C’(Refers to Para 4)

MACHINERY/EQUIPMENT IN SHOP

S.NO DESCRIPTION QTY HELD IN

NOs.

QTY OPS IN NOs.

QTY NON OPS IN NOs.

REMARKS

1. Electrical Overhead Crane

01 01 Nil Ops

2. Portable Crane (Capacity-2 ton)

01 01 Nil Ops

3. Lister Jumbo (Capacity-2 ton)

01 01 Nil Ops

4. Valve Handling Trolley (Capacity-2.5 ton)

03 03 Nil Ops

5. Portable Blower 02 02 Nil Ops

6. Portable Drilling Machine

01 01 Nil Ops

7. Hand OperatedPressure Test pump

02 02 Nil Ops

8. High Pressure Testing Pump

01 01 Nil Ops

9. Drilling Machine 01 01 Nil Ops10 Valve Lid Lapping

Machine02 02 Nil Ops

11. Portable Grinding &Lapping Machine

01 01 Nil Ops

12. Valve Grinding & Lapping machine

01 01 Nil Ops

Appendix ‘D’(Refers to Para 5)

TRANING STATUS CNO.30

S.NO YEAR TRAINING PLACEDURATION

(IN WEEKS)

NO. OF PERSONS

1 2007 Basic workshop on Science and Skills

ATI Sion & ND(MB)

09 Days 01

2 2007 Training in First Aid ND (MB) 01 Day 05

3 2007 Indian Standard Reading of Engineering Drawing

ATI Vidyanagar Hyderabad

02 Weeks 01

4 2007 Industrial Safety Course ND (MB) 02 Days 04

5 2007 Development Programme for Skilled Personnel

ND (MB) 03 Days 04

6 2007 Training in First Aid Fire Fighting

ND (MB) 03 Days 01

7 2008 Co-ordinate Measurements ATI Ludhiana 02 Weeks 068 2008 Personnel Survival

TechniquesNAMAC 03 Days 02

9 2009 Personnel Development Programme SSKL

MHRT 01 Week 02

10 2009 Development Programme SKL

MHRT 01 Week 02

11 2009 Orientation Programme SSKL

MHRT 01 Week 01

Appendix ‘E’(Refers to Para 11)

WORK LOAD OF REFIT FROM JAN 09 TO DEC 09

MONTH MANDAYS ALLOTTED

M/D CONSUMED

M/D NORMAL M/D OT

JANUARY 09 1990 1584 1371 213FEBRUARY 09 1950 1525 1275 250MARCH 09 1812 1410 1254 156APRIL 09 1721 1318 1183 135MAY 09 1735 1366 1222 144JUNE 09 1938 1558 1394 164JUL 09 2005 1533 1372 161AUGUST 09 1911 1485 1358 127SEPTEMBER 09 1842 1452 1359 93OCTOBER 09 1864 1434 1310 124NOVEMBER 09 2150 1627 1469 158DECEMBER09 2275 1711 1568 143

Appendix ‘F’(Refers to Para 13)

EDUCATION PROFILE

CLASS CATEGORYNON INDUSTRIAL INDUSTRIAL

BELOW VIII Nil 05NON SSC Nil 25SSC/HSC 07 41GRADUATE 01 04

TOTAL 08 75

Appendix ‘G’(Refers to Para 14)

MARITAL STATUS & FAMILY

S.NO STATUS NO. OF PERSONNEL PERCENTAGE1. UN MARRIED 08 6%2. MARRIED 75 61%

3. FAMILY PLANNING ADOPTED 41 33%

Appendix ‘H’(Refers to Para 15)

NUMBER OF CHILDREN

SNO NO.OF CHILDREN NO. OF PERSONNEL PERCENTAGE1. TWO OR LESS THAN

TWO47 67%

2. THREE 17 24%3. MORE THAN THREE 06 9%