WAGON REPAIR SHOP, KOTA - West Central Railway zone › uploads › files...• KOTA workshop has...
Transcript of WAGON REPAIR SHOP, KOTA - West Central Railway zone › uploads › files...• KOTA workshop has...
-
WAGON REPAIR SHOP, KOTA
-
Item A
OUTTURN
-
Item-A
395
405
425440
450
424435 435
443.5
464.8
390
400
410
420
430
440
450
460
470
2011-12 2012-13 2013-14 2014-15 2015-16 upto Jan-16
Av
g W
ag
on
s/M
on
th
Years
Target Outturn
OUTUTRN (Monthly Average)
-
Item-A
MONTHLY OUTTURN (2015-16) Target – 450 Wagon
451 452
442
461465
503
455452
507
460
400
420
440
460
480
500
520
Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Jan-16
Wag
on
(Ve
hic
le U
nit
s)
Month
Outturn Target
Target 450
-
167 174204 191
235
160
124
69 85
97
0
50
100
150
200
250
2011-12 2012-13 2013-14 2014-15 2015-16 upto Jan-16
Avg.
Wag
ons
/ m
onth
Years
BOXN/BCN group v/s BTPN OutturnBOXN/BCN BTPN
Focus on increasing BOXN/BCN
POH
Item-A
Average Man hrs
BOXN-856 hrs BCN-1107 hrs BTPN- 351 hrs
-
41 57212
1228
0
200
400
600
800
1000
1200
1400
2012-13 2013-14 2014-15 2015-16 upto Jan-16
Wag
on
s
Years
Stainless steel Wagon
POH of Stainless Steel Wagons Item-A
-
OUTUTRN GROUP WISE (Monthly Average)
16
6
17
5 20
3
19
1 23
4
20
6
17
1
12
6
13
4 16
0
14
38
63 73
37
40
53 4
2 45 35
0
50
100
150
200
250
300
350
400
450
500
2011-12 2012-13 2013-14 2014-15 2015-16 upto Jan-16
Avg
. W
ag
on
s / m
on
th
Years
Others BLC /BLL TANK BOXN /BCN
Item-A
-
• Twin pipe conversion of BOXNHL, BCNHL and BVZI
wagons
• This year 164 BCNHL wagons fitted – departmentally-
with 2 Piece sliding door by Jan-16 end.
• First BOXNHAM rake made ready in Feb-16 with new
design Spring Loaded Side Bearer.
OUTTURN RELATED WORKS
Item-A
-
(21 in 2014-15, 758 in 2015-16)
Twin pipe conversion of BOXNHL wagons
Item-A
KOTA workshop is turning out 100% BOXNHL wagons
with twin pipe brake system since Sep-2015
-
KOTA workshop is turning out 100% BCNHL wagons
With twin pipe system since Nov-2014
Twin pipe conversion of BCNHL
wagons
Item-A
-
Retro fitment of two piece sliding door
in BCNHL wagon
– 172 Nos. (8 in 2014-15, 164 in 2015-16)
Item-A
KOTA workshop is turning out 100% BCNHL wagons with
modified doors from Aug-2013
-
• 172 nos. (8 in 2014-15, 164 in 2015-16)
Strengthening of BCNHL side walls to prevent bulging and jamming of sliding doors
Item-A
KOTA workshop is turning out 100% BCNHL wagons with
modified doors from Sep-2013
Modification is innovated
by KOTA workshop vide
letter no.
M 443/1/21 dated
22/07/2014 and
approved by RDSO vide
letter no. MW/BCNHL-
DOOR dated 09/04/2011
-
• KOTA workshop is turning out 100% BVZI wagons with
twin pipe system since MAY-2012
Twin pipe conversion of BVZI
wagons.
Item-A
-
Conversion of BOXN to BOXNHAM wagons
Item-A
BOXNHAM operational speed is 100/75 Kmph &
BOXN Ordinary operational speed is 75/60 Kmph
First BOXNHAM rake made ready in Feb-16 with new
design Spring Loaded Side Bearer.
-
Conversion of BOXN to BOXNHAM wagons – New design spring loaded side bearer
-
BMBS system being fitted in BOXNHAM
Item-A
-
Item B
Quality Parameters
-
POSITION of HOT axle cases (as per RDSO)
Year 2015-16 (upto Oct-15)
Item-B
WorkShop Outturn
Total
No of
Hot
Axle
Per
1000
wagon
outturn Rank
No of
Hot axle
(
-
90 Days Sick marking of KTTW as per IRCA
Year Quarter Outturn Sick Marking
% of Sick
% of Sick Avg
Rank in IR
2013-14 Total 4375 50 1.14 1.14 1st
2014-15
1st 1164 12 1.03
1.01 1st 2nd 1238 14 1.13
3rd 1211 11 0.91
4th 1153 11 0.95
Total 4766 48 1.01
2015-16 1st 1080 14 1.30
1.26
2nd 1292 16 1.24
Total 2372 30 1.26
Item-B
-
POSITION of Train Parting (as per RDSO)
Year 2015-16 (upto Nov-15)
Item-B
Work Shop
Outtu
rn
Total
No of
Train
Parting
Per
1000
wagon
outturn Rank
No of
Train
Parting
(
-
MAINTENANCE OF
INFRASTRUCTURE
-
Item-C
MAINTENANCE OF INFRASTRUCTURE
• DyCE post filled on 02 May 2014.
• Workshop has now started doing Engineering
tenders which were earlier done by Kota division.
• The 4 Engineering tenders are awarded by
DyCE/WRS/KTT
• Out of which 2 works has been completed and
2 works are running.
• The 3 Engineering works are under tendering
process.
-
MAINTENANCE OF INFRASTRUCTURE
• No of M&P value more than 10 Lakhs – 56 Nos.
• Total Break down hours of these M&Ps for period (Apr-15 to Jan-16) – 1034 hrs.
Item-C
-
Item D
CLEANLINESS
-
CLEANLINESS
1. IMS Certificate
2. Areas coved
under IMS
Mech.
Elec.
Store
Accounts
Establishment
Item-D
-
CLEANLINESS • KOTA workshop has been holding
ISO 9001 Certification since 29/12/1999 ,
ISO 14001 Certification since 08/03/2007 and OHSAS 18001 Certification since
05/01/2010.
• KOTA workshop has obtained IMS
Certification on 12/08/2013 which is valid
upto Aug-2016.
Item-D
-
CLEANLINESS • KOTA workshop is under process to obtain
ISO-5000 (Energy Management System)
• Certification audit conducted on
08 to 10 Feb 2016 by Mr Jayant Shridakar
Representative of
M/s LMS Certifications Pvt. Ltd. Lacknow.
• Recommended for ISO-5000 certification.
Item-D
-
CLENLINESS
Cleaned water Booth
Item-D
-
CLENLINESS
Cleaned toilet
Item-D
-
CLEANLINESS-ENVIRONMENT CONTROL SYSTEM
ETP & Incinerator
Item-D
ETP Incinerator
-
• Environment Lab Portable Carbon BOD High Value Mono Oxide Analyzer INCUBATOR Sampler Digital TDS Meter Sound Level Test Meter Spectro Photo Meter
Item-D
ENVIRONMENT CONTROL EQUIPMENT
-
CLEANLINESS Item-D
U-Racks: For Storage of Pipes and Rods.
Before After
Advantages:
• Use of Vertical space and less floor area requirement.
• Safety from rusting, dust etc.
• Portable - can be moved anywhere manually.
-
Buried scrap site Digging
Buried Scrap Disposal: Scrap buried under 2-3 feet since last 20-30 years disposed off on “As is where is basis”.
• Quantity Disposed: 1382 Mts.
• Value realised: Approx. 2.76 Crores
CLEANLINESS Item-D
-
Item E
HOUSEKEEPING
-
HOUSE KEEPING
1. No. Of Injuries in the current financial
year 2015-16 = 28
2. Availability of manual of safe practices - Yes
3. Availability of Auto racks – No.
4. Scrap disposal 2013-14 10424.7 MT
2014-15 10374.1 MT
2015-16 8855.43 MT(jan16)
5. % Green area in workshop - 40%
Item-E
-
GREENERY IN WORKSHOP
Green area in workshop – 40%
Item-E
-
GREENERY in WORKPLACE 100 plants planted in last two months
-
CWM office entrance gate
Item-E
Greenery
-
Heritage park
Item-E
GREENERY IN WORKSHOP
-
Greenery in Workshop
Item-E
GREENERY IN WORKSHOP
-
• Gardens
Item-E
GREENERY IN WORKSHOP
-
ITEM-F
AMENITIES FOR STAFF
-
AMENITIES FOR STAFF
• No of Employee = 2269
• No of lockers available = 2468
• No of meal served per day on canteen = 250
• % of payment through ECS/Bank = 100% employees
• No. of RO plants for drinking water = 10 Nos.
Item-F
-
• ATM in Workshop premises
AMENITIES FOR STAFF Item-F
-
AMENITIES FOR STAFF • Water coolers with RO plant
Item-F
-
• New Staff Canteen
AMENITIES for STAFF
-
AMENITIES FOR STAFF • Staff Canteen
Item-F
-
AMENITIES FOR STAFF • Staff Canteen (separate ladies cabin)
Item-F
-
AMENITIES FOR STAFF medical card
Item-F
-
MEDICAL CAMPS IN WORKSHOP
STAFF WELFARE Item-F
-
Innovations Initiatives
Good work done Other items
-
SOLAR POWER
“Solar power of 500
KW capacity planned at KOTA workshop”
• Tender floated - to open on 08/03/2016
• Kota is the first wagon workshop to float tender
for solar power.
-
INNOVATION
CNG Cutting trial and demo by GAIL
-
INNOVATION CNG Cutting in Workshop started as a Pilot
project
-
INNOVATION In house manufacture of Hydraulic operated work
bench for Overhauling of BMBS Brake Cylinder
This is
First in IR
-
Ladder for welding/painting on BCNHL wagon roof
INNOVATION
-
TRAINING CENTRE
Class Room Air brake System Working Model
Welding Lab Welding Lab
-
MOTIVATION and ENCOURAGEMENT
• Man of the Month Award Display Board
-
Competitive Environment
• Inter shop competition & Shield For
1. Safety
2. Cleanliness &
House keeping
3. Quality
4. Attendance
-
LPG Valve Model BTPN Valve Model
TRAINING CENTRE
-
Drum Pallets: For Storage and Transportation of Drums.
Before After
Advantages:
• More drums at a time, hence saving of Diesel in Transportation.
• Safe working.
• Utilisation of Vertical space in storage
HOUSE KEEPING
-
SPECIAL SAFETY MEASURES
Gate Pass system by web camera
Web Camera
Gate pass with Photo
-
• CCTV Surveillance system at workshop gate
SPECIAL SAFETY MEASURES
-
• Incoming & Outgoing Areas
SAFETY POSTERS
-
VIGILENCE SEMINAR IN WORKSHOP
-
STAFF WELFARE • Gold plated coin to retired employees
-
STAFF WELFARE • TOUCH SCREEN KIOSK
-
NEW INFRASTURURE ADDED Extension of Store depot
-
Roof re-sheeting of various shops Cost 1 Cr.
NEW INFRASTURURE ADDED
-
APM, LSD Test Bench
New (important) M&P Added
-
Excavator & loader Rs. 17.36 Lakhs
New (important) M&P Added
-
Static Weigh Bridge Rs. 21.36 Lakhs
Weigh Bridge Digital Control Unit
New (important) M&P Added
-
Wagon Model in CWM office entrance gate