FIAT Bogie Shop - Centre of Excellence

FIAT Bogie Shop - Centre of Excellence

• Cleaning of Bogies

• Movement of Bogies: stripping & assembly

• Improvements in flow of components/ other materials

• Palletization for segregating good, serviceable & condemned items and easy

handling of materials

• Availability of drawings and quick accessibility of maintenance information/

guidelines

• Computerised Traceability of items

• Total Quality Management

• Human Resource Development

FIAT Bogie Shop - Centre of Excellence

FIAT Bogie Shop - Centre of Excellence

Centre of Excellence –

Fiat Bogie Shop

Reduction in average POH cycle time – Reduction from 3 days to 2 days as a result of streamlined shop layout and use of standardized equipments

Reduction in Manpower requirement -

Use of specialized material handling equipments

• Specialized material handling equipments

• Less effort required for handling of heavy components due to hydraulic

operation

• Manpower reduction: 1 Helper for performing the same activity

Portable Crane Hydraulic pallet truck Hydraulic scissor Trolley

Centre of Excellence – Fiat Bogie Shop

Reduction in Manpower requirement –

High pressure water jet cleaning of fiat bogies Before After

• Effective cleaning of Fiat bogie using high pressure water jet machine (Working pressure : 250 bar)

• Manpower reduction: 1 Helper required for manual scrapping of bogie • Improved cleanliness

Centre of Excellence – Fiat Bogie Shop

Reduction in Manpower requirement –

Development of control arm pressing fixture

Before After

• Replacement of Dead weight of 5 Tons for pressing of control arm with

fixture

• Manpower reduction: 1 Helper for performing the same activity

• Requirement of overhead crane eliminated

• Safe in operation

Centre of Excellence – LPL (Fiat Bogie Shop)

Improvement in productivity

Year Out turn

(Coaches) Available staff

Out

Turn/Employee

2016-17 312 67 4.66

2017-18 433 74 5.85

• LHB Coaches Out turn increased by 38.78 % during 2017-18 compared

to 2016-17

• Out turn /employee improved by 25.53 %

Centre of Excellence – Fiat Bogie Shop

Centre of Excellence –

Shock Absorber Section

Work Instructions Proper Stacking

Computerised Load Testing Epoxy Flooring

Benefits achieved:

Streamlining of operations & clear demarcation of clean and dirty area

Reliability improvement with computerised load testing machine

Improvement in manpower productivity

Year Out turn

(SA+Damper) Available staff

Out

Turn/Employee

2017-18 17848 13 1373

2018-19(upto June) 3952 11 1437

Centre of Excellence –

Shock Absorber Section

KNOWLEDGE CENTRE/ Maintenance Hub

In reference to Railway Board letter Knowledge Centre is being created for

maintenance. of material handling equipments i.e Forklift, Battery Operated Platform

Truck, Battery Operated Stacker, Hand Pallet Truck, Road Mobile Crane & Traversor.

Technical Booklets Website:http://wr-knowledgecenter.com

“Knowledge Center” for Material Handling Equipments over Indian Railways.

A website, -the maintenance procedure, dos & don’ts Trouble shooting guide and

the list of spares.

Crack team.

Mobile application.

Conference room, library and cut models which are displayed prominently in the

center. On 24/03/2018 GM/WR inaugurated the knowledge center.

KNOWLEDGE CENTRE/ Maintenance Hub

Welding Training Centre As per the Railway Board instruction, Lower Parel Workshop developed

Welding Training centre and same was inaugurated on 24.05.2018 by Shri

Ravindra Gupta, MRS/Rly. Board. The first batch of 13 trainee welders started

on 9 July-18 are under going training at this facility.

BTC Model Room

Models of LHB and ICF parts displayed

Well illuminated hall

information displayed with posters.

A quiz also developed for trainees.