PROJECT REPORT

ON

COMPARISON AND ANALYSIS OF PRODUCTIVITY OF STRUCTURAL SHOP OF ENGINEERING WORKSHOP MANMAD, SABARMATHI, LALAGUDA AND ARAKKONAM

by BALIJA ASHOK
K. Rajendran/ AWM/ EWS/ AJJ M. Govindaraju/ SSE/ EWS/ AJJ G. Ravichandran/ SE/ EWS/ AJJ
I

Assisted by

CE/ Workshop/ AJJ Southern Railway

Note
No.151/9206 08.05.09 Sub : Allotment of project : (course no. 9206)

The following topics are allotted for Project : SN 1 Names of Trainees (S/Sh) Balija Ashok, CE/W/SR Topic Comparison and Analysis of Productivity of struc tural shop of engineering workshop Manmad,Sabarmathi,Lalaguda and Arakkonam Motivation and related issues of the Civil Engineering Cadre (Group A,B and Supervisors)-Survey and Study Study of liner bite of rails under different conditions with field data collection analysis on SER,ECOR Efficiency of training o f Group C and D staff on Indian railways with special emphasis on NWR and suggestions for improvement Mechanisation of Track Maintenance on Indian Railways 2012 Case Study for improvements Working conditions of track machine field staff(A study on NCR and NR) and suggestions for improvements Site constraints in construction of limited height subway including comparing methods of construction Study and uses o f accidents on Unmanned level crossings in WCR and remedial measures Engineering and operational aspects involved in the work of remodeling of ADI yard and its impact A case study Study of liner bite of rails under different conditions with field data collection analysis on CR and SCR Guiding Faculty SPB2

2 3 4

Praveen Kumar Mishra, CE/Wks/BB D R Shyam Sundar, CTE/ECOR Subhodh Kumar Jindal, CE/Cont/Central Anil kumar pandey, CE/TMC/NWR Ravi Mohan Sharma, CTE/TMC/NWR Gopal Khairwar, CE/TM/Hubli/SWR Rajesh Arora, CPDE/WCR/JBP Anurag Kumar Sachan, CE/G/WR Vijay Kitke, CGE/SCR

SPB2 SPT2 SPW

5 6 7 8 9 10

DN PTM SPB1 SPT1 SPP SPT2

II

ARAKKONAM ENGINEERING WORKSHOP

Work shop location

Arakkonam (Rural) Southern Railway 1905 Riveted type girders Welded type girders, PPF Shelters and FOB Steel Channel Sleepers Dip lorry, Push Trolley, Motor Trolley, Glued Joint, LB Gate, Points & Crossings Assemblies, SEJ 1082 55 Years (avg) 4338.715 MT/Year 5028.527 / Year

Work shop Established on Main Products

: :

Number of Staffs Age Profile of the Staff Total Tonnage during the Year 08-09 Equated Unit

: : : :

STRUCTURAL SHOP No of Staff Outturn for the Year 08-09 Equated Unit Future proposal : : : : 104 634.25 MT/Year 634.25 /Year To be increased to 1200 MT/Year after augmentation of infrastructure

OUT TURN FOR THE YEAR 2008-09 Achieved During the Year 2008-09 (MT) 7.86 406.81 332.72 387.28

Sl No

Name of the Shop

1 2 3 4 5

M achine Shop Foundry Fitter Signal Fitter S tructural Girders Light S tructural

634.54 298.13 215.65 6.82 44.24 1356.51 656.30 TOTAL 4346.58

6 7 8 9 10

Glued Joint Tinker M illwright Pts & Xings Blacksmith

Metric Tonne 1000.00 1200.00 1400.00 1600.00 200.00 400.00 600.00 800.00 0.00 Machine Shop Foundry Fitter Signal Fitter Girders Light Structural Glued Joint Tinker Millwright Pts & Xings Blacksmith 656.30 6.82 44.24 1356.51 298.13 215.65 Production - Shop wise

OUT TURN FOR THE YEAR 2008-09 - ARAKKONAM

7.86 406.81 332.72 387.28 634.54

OUT TURN OF S TRUCTURAL S HOP FOR THE YEAR 2008-09 Sl No 1 S tructural shop a) Girders b) Light S tructural TOTAL 634.54 298.13 932.67 Name of the Shop Achieved During the Year 2008-09 (MT)

FLOW LINE PROCESS OF ARAKKONAM ENGINEERING WORKSHOP

Study Drawings Templating Marking Cutting & Drilling Tack Welding Final Welding - SAW ` Initial Assembly Riveting Final Assembly Inspection Despatch

PRODUCTIV ITY OF ENGINEERING WORKSHOPS / ARAKKONAM FOR THE YEAR 2008-09

Sl. No. (A) I 1 2 3 4 5 6 7 8 9 a II 1 2 3 4 5 b c d

Description (B) DIRECT STAFF : Foundry shop Fitter shop Signal Fitter shop Structural shop Glued Joint Section Tinker shop Millwright shop Points & Xings shop Blacksmithy shop Total :INDIRECT STAFF : Welding shop Paint shop P.C.O. Staff Night Shift Tool Room Total Indirect Staff :Staff diverted to FBW TOTAL STAFF ( a+b-c)

No.of staff Sup. ( C) Tech. (D) Total (E)

Out turn for year 2008-09 MT EQ.U (H) (I)

5 3 2 5 2 1 7 5 5 35

136 46 46 82 34 22 96 78 117 657

141 49 48 87 36 23 103 83 122 692

406.8 332.7 387.3 932.4 215.7 6.8 44.2

285.2 495.6 529.2 1054.9 208.3 68.7 141.8

1356.5 1202.8 656.3 1042.0

4338.7 5028.5

3 1 28 1 1 34 0 69

72 27 9 0 0 108 37 728

75 28 37 1 1 142 37 797

Staff for productivity calculation duly deducting absenteeism, m/c breakdown & power failure (in Hours)

7322

Total Eq.Units achieved during the Year 6

5028.5

g h

Total no. of days in the Year Actual no. of working days in the Year Description Productivity of EWS/AJJ in Equated Units/man/month

365 292 Average upto the Year 0.9

PRODUCTIVITY OF STRUCTURAL SHOP e f g h Staff for productivity calculation duly deducting absenteeism,m/c breakdown & power failure Total Eq.Units achieved during the Year Total no. of days in the Year Actual no. of working days in the Year Description Productivity of Struc tural shop in Equated Units/man/month 1180 1054.893 365 292 Average upto the Year 1.1

ACTIVITIES OF GIRDER FABRICATION IN ARAKKONAM

S AW ON OPEN WEB GIRD ER COMPONENT (VERTICAL)

DP TES T ON OPEN WEB GIRDER COMPONENT (VERTIC AL)

S URFAC E DEFECT ID ENDIFIED BY DP TES T

OPEN WEB GIRD ER ASS EMBLY

METALIZED DECK S TEEL GIRD ER

ASS EMBLY OF S HALLO W TYPE GIRD ER

10

LAYOUT OF STRUCTURAL SHOP

11

LALLAGUDA ENGINEERING WORKSHOP

Work shop location

Lallaguda(Urban) secunderabad South Central Railway 1964 Rivetted type girder Welded type girders up to 30m Span Fish belly type Rivetted Girder Glued joints 52Kg& 60 Kg (G3 L) FOB, Steel Channel Sleepers Rail dolleys, Diplorry, Motor Trolley. 220 40-45 Years 2436.18 MT/ Year 1403.6 /Year

Workshop Established Main Products

: :

Number of Staffs Age Profile of the Staff Total Tonnage During the Year 08-09 Equated Unit

: : : :

STRUCTURAL SHOP No of Staff Outturn for the Year 2008-09 Equated Unit Future Proposal : : : : 12 117 200.20 MT/Year 232.23/Year To be increased to 360 MT/Year after augmentation of infrastructures

OUT TURN FOR THE YEAR 2008-09 Sl No 1 S tructural a)Riveted Girder in MT b) Welded girder in MT 2 3 Others (P.Way items) in M T Glued Joint in MT (6291 Nos) Total Tonnage in MT 129.10 71.10 97.04 2138.94 2436.18 Name of the Shop Achieved During the Year 2008-09

OUT TURN 2008-09 - LALLAGUDA

2500.00 Achieved MT 2000.00 1500.00 1000.00 500.00 0.00 a)Riveted Girder in MT b) Welded Others (P.Way Glued Joint in girder in MT items) in MT MT (6291 Nos) Production - Shop wise

13

OUT TURN OF S TRUCTURAL S HOP FOR THE YEAR 2008-09 Sl No 1 S tructural a)Riveted Girder in MT b) Welded girder in MT Total (in MT) 129.1 77.1 200.2 Name of the Shop Achieved During the Year 2008-09

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FLOW LINE PRO CESS OF LALLAGUDA ENGINEERING WORK SHOP

Receipt of work orders Studying of drawings Placing of indents & procurement through stores Inspection of materials Templating Fabrication ` RDSO/CONSIGNEE inspection Despatch of finished products

15

PRODUCTIVITY OF ENGINEERING WORKSHOPS / LALLAGUDA FOR THE YEAR 2008-09

Sl. No.
1 2 3

Description Structural shop Glued Joint Section Mechanical Shop Total :5 2 1 8

No.of staff Sup. Tech. Total 111 87 11 209 116 89 12 217

Out turn for year 2008-09 MT EQ.U 200.2 2138.94 97.0 2436.18 232.23 1171.37 Nil 1403.6

Total Eq. Units achieved during the Year Total Tonnage achieved during the Year

1403.6 /Yr 2436.18/ Yr

16

ACTIVITIES OF GIRDER FABRICATION IN LALLAGUDA

JIG FOR S AW

COMPONENTS FOR S TEEL GIRDERS

17

I S ECTION FOR FIS HBELLY GIRD ER

JIG FOR I FORMING

18

DRILLING OF S TEEL PLATE GIRDERS

19

LAYOUT OF STRUCTURAL SHOP

20

MANMAD ENGINEERING WORKSHOP

Work shop location Work Established Products

: : :

Manmad(Urban), Central Railway. 1906 Open web Girder Welded type girder, Truss, Glued joints Joggled Fish plate 878 45-55 Years 7129.36 MT 12063.35/Year

Number of Staffs Age Profile of the Staff Total Tonnage During the Year 08-09 Equated Unit

: : : :

STRUCTURAL SHOP No of Staff Outturn for the Year 2008-09 Equated Unit Future Proposal 21 : : : : 494 2803.82 MT 3424.4 MT To be increased to 3600 MT/Year after augmentation of infrastructures

OUT TURN FOR THE YEAR 2008-09 Sl No 1 2 3 S tructural Girders Light S tructural Others* TOTAL Name of the Shop Achieved During the Year 2008-09 (MT) 2803.82 389.74 3935.80 7129.36

* Others inclusive of Glued joint, BS, BNR, M .Shop, M isc Works of EUR & Channel Sleeper

OUT TU RN 2008-09 - MAN MAD

4500.00 4000.00 3500.00

A chie ve d MT

3000.00 2500.00 2000.00 1500.00 1000.00 500.00 0.00 Struc tura l Gir de rs Light S tructur al Other s*

Productio n - Shop wise

22

OUT TURN OF STRUCTURAL SHOP FOR THE YEAR 2008-09 Sl No 1 2 Structural Girders Light Structural TOTAL Name of the Shop Achieved During the Year 2008-09 (MT) 2803.82 389.74 3193.56

23

FLOW LINE PROCESS OF MANMAD ENGINEERI NG WORK SHOP Templating Cutting Jig Tack assembly Initial assembly Riveting ` Initial assembly Final assembly

24

PRODUCTIVITY OF ENGINEERING WORKSHOPS / MANMAD FOR THE YEAR 2008-09 Out turn for year No.of staff Sl. Description 2008-09 No. Sup. Tech. Total MT EQ.U
1 2

Structural shop Others Total :-

37 41 78

457 343 800

494 384 878

3193.56 3935.80 7129.36

4051.55 8011.80 12063.35 12063.35 7129.36

Total Eq.Units achieved during the Year Total Tonnage achieved during the Year (in MT)

25

ACTIVITIES OF GIRDER FABRICATION IN MANMAD

PICTORIAL REPRES ENTATION OF PLATE S TRAIGHTEN ING MACHIN E

DYE PENETRANT TES T OF FILLET WELD

26

DRILLING OF COMPONENTS US ING FERRULES

HIGH S PEED DUAL NOZZLE PUG CUTTING MACHIN E

27

PICTORIAL VIEW OF S TOCK YARD

INS PECTION OF FERRULES

28

LAYOUT OF STRUCTURAL SHOP

29

SABARMATHI ENGINEERING WORKSHOP

Work shop location

Sabarmathi(Urban), Near Ahamedabad Western Railway. 1958 Open web Girder Welded type Girder Fish Belly Girder 656 35-50 Year 6011.39 MT/Year 4742.35 /Year

Work Established Products

: :

Number of Staffs Age Profile of the Staff Total Tonnage for the Year 2008-09 Equated Unit

: : : :

STRUCTURAL SHOP Number of Staffs Outturn for the Year 2008-09 Equated Unit Future Proposal : : : : 376 1645.89 MT/Year 2072.60 /Year To be increased to 2250 MT/Year after augmentation of infrastructures

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OUT TURN FOR THE YEAR 2008-09 Sl No 1 S tructural Open web girder Riveted Plate Girder Welded Plate Girder 2 3 4 Glued Joint Steel Channel Sleeper SEJ Set TOTAL 1343.39 198.70 103.80 3430.00 897.00 38.50 6011.39 Name of the Shop Achieved During the Year 2008-09 (MT)

OUT TURN FOR THE YEAR 2008-09 - SABARMATHI

4000.00

3500.00

3430.00

3000.00

2500.00 Achieved MT

2000.00

1500.00

1343.39 897.00 198.70

Open web girder Riveted Plate Girder

1000.00

500.00

103.80
Welded Plate Girder Glued Joint Steel Channel Sleeper Production - Shop wise

38.50
SEJ Set

0.00

31

OUT TURN OF S TRUCTURAL S HOP FOR THE YEAR 2008-09 Sl No 1 Structural a) open web girder b) Riveted Plate Girder c) Welded Plate Girder TOTAL 1343.39 198.70 103.80 1645.89 Name of the Shop Achieved During the Year 2008-09 (MT)

32

FLOW LINE PRO CESS OF SABARMATI ENGINEERING WO RK S HOP

Templating Cutting Initial assembly Drilling Fitting Riveting ` Final assembly

33

PRODUCTIVITY OF ENGINEERING WORKSHOPS / SABARMATI FOR THE YEAR 2008-09 Out turn for year Sl. No.of staff Description 2008-09 No. Sup. Tech. Total MT EQ.U 1 Structural shop 21 355 376 1645.89 2072.60
2

Others Total :-

25 46

255 610

280 656

4365.50 6011.39

2669.75 4742.35 4742.35 6011.39

Total Eq.Units achieved during the Year Total Tonnage achieved during the Year (in MT)

34

ACTIVITIES OF GIRDER FABRICATION IN SABARMATHI

PICTORIAL REPRES ENTATION OF I S ECTION FOR PLATE GIRDERS

PICTORIAL REPRES ENTATION OF OPEN WEB GIRD ER

35

S UBMERGED ARC WELD ING JIG FOR S TEEL PLATE GIRD ERS

S UBMERGED ARC WELD ING JIG FOR S TEEL PLATE GIRD ERS HAVING BOTH S IDES TRACK FOR DOING FILLET WELD

36

PICTORIAL REPRES ENTATION OF DRILLING OF COMPONENT ON BOTH TRACKS

PICTORIAL REPRES ENTATION OF FORMING I-S ECTION FOR FIS H BELLY GIRDER

37

LAYOUT OF STRUCTURAL SHOP

38

COMPARATIVE STATEMENT OF STRUCTURAL SHOP OF ALL WORKSHOPS 2008-09

Description Present Production of Structural shop in MT Proposed Production of Structural shop in MT

AJJ

LGD

MMR

SBI

634.25 200.20 2803.82 1645.89 1200.00 360.00 3600.00 2250.00

COMP ARITIVE CHART OF WORKSHOP S

4000.00 3600.00 3500.00 3000.00 2500.00 in MT 2000.00 1645.89 1500.00 1000.00 634.25 500.00 0.00 AJJ LGD MMR SBI WORKSHOP UN IT 360.00 200.20 1200.00 2803.82

2250.00

Present Production

Proposed Production

Sl No

TOTAL OUT TURN OF ALL WORKSHOPS FOR THE YEAR 2008-09

Name of the Shop Achieved During the Year 2008-09 (M T) ARAKKONAM LALLAGUDA MANMAD 4346.58 2470.35 7129.36 SABARMATHI 1645.89

TOTAL

39

CONCLUSION
Arakkonam : Flow line has to be improved, since one more covered shed is required. Welders and gas cutters have to be augmented. Augmentation of Speed Gas Cutting Equipment, Compressors, Plate Bend Removal Machine, Drilling Machines are essential for increasing production. Since Arakkonam workshop is having all type of other shops such as Mill Wright, Fitter shop, Crossing shop, Motor Trolley shop, glued shop, foundry, black smith shop along with structural shop. With available shed and machineries along with re-employment of other shop staff, present production of 50 T / month will be increased to 100 T/ month during Aug 2009 ( 1200 T / Year ). Lallaguda : Land constraint is affecting for further development of this shop. Flow line cannot be further improved due to non availability of land. How ever with available man power and machines, the present structural shop capacity of 220.2 MT/ Year can be increased to 360 MT/ Year. Manmad : The flow line is excellent, since it has got three parallel long shed of 260 m length. Feeding of material is very good. It has got Speed Pug Gas Cutting Machine, Shear Cutting Machines, Plate Straightening Machines, Ferrules System of Drilling, and more numbers of Drilling Machines along with 17 numbers of EOT Cranes . Their structural shop capacity can be increased from 2803.82 MT to 3600 MT/Year per year by suitable deployment of additional staff. Sabarmathi : The flow line is moderate since two bays are narrow. It has got more number of Drilling Machines, Good Fixtures & Jigs, Cutting Machines, and Plate Straightening Machines . One more additional shed may be erected along with second bay to increase the production. However final assembly yard requires improvement. It is proposed to increase the production of girders from 1645.89 MT/Year to 2250 MT/ Year with in 3 years.
40

RECOMMENDATIONS 1. Works Manager and Asst. Works Managers should be trained in Basic Principles of Design of Steel Structures in IRICEN/PUNE. 2. Annual SEMINAR CUM WORKSHOP to be conducted in rotation on ALL-INDIA basis for AWM/ WM/ Dy CES for dissemination of knowledge and what is going in different shops of Indian Railways. 3. Supervisors and other critical staff such as welders, gas cutters should be given periodical training in reputed institutions other than railways also for absorbing latest technology in respective fields. $$$

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