1

G.275/WSSR-071718/2017-18

WORK STUDY TO REVIEW

THE STAFF STRENGTH

AT

BOILER SHOP-GOC

2

SOUTHERN RAILWAY

PLANNING BRANCH

G.275/WSSR-071718/2017-18

STUDIED BY

WORK STUDY TEAM

OF

PLANNING BRANCH

AUGUST - 2017

.

WORK STUDY TO REVIEW

THE STAFF STRENGTH

AT

BOILER SHOP-GOC

G.275/WSSR-121617/2016-17

3

I N D E X

SERIAL

NUMBER

CONTENTS PAGE

NUMBER

(i) ACKNOWLEDGEMENT

1 (ii) TERMS OF REFERENCE

(iii) METHODOLOGY

(iv) SUMMARY OF RECOMMENDATIONS 2

CHAPTERS

I INTRODUCTION 3-8

II PRESENT SCENARIO 9-17

III CRITICAL ANALYSIS 18-22

IV PLANNING BRANCH REMARKS ON CO-ORDINATING OFFICER’S VIEWS

23

V FINANCIAL SAVINGS 24

ANNEXURES

I BOILER SHOP DETAILS 25-34

II TRAINING DETAILS 35

III IR CODE FOR MECH WORKSHOPS 36-37

IV CO-ORDINATING OFFICER’S VIEWS 38

.

1

(i)

ACKNOWLEDGEMENT

The work study team acknowledges the valuable guidance given by

Dy.CME/GOC,PE/GOC,APE/GOC, SSE/Planning, SSE/Boiler Shop and the staff of

Shop which was very helpful in completing the study in time.

(ii)

AUTHORITY

Annual programme of work studies for the year 2017-18

(iii)

TERMS OF REFERENCE

Work study to review the staff strength at Boiler Shop/GOC

(iv)

METHODOLOGY

The work study team has applied the following techniques in conducting the work study.

(1) Collection and compilation of Data.

(2) Observation of present system of working.

(3) Interaction with Dy.CME/GOC,PE/GOC,APE/GOC, SSE/Planning, SSE/Boiler Shop and the staff of Shop

(4) Discussion with Officers and Supervisors

(5) Provision as per AT/TT/yardstick/requirement as deemed fit.

(6) Evaluation of the manpower requirement for the current workload as Well as to meet the Production Schedule for the Financial Year 2017-18.

.

2

(v) SUMMARY OF RECOMMENDATIONS

Category Sanction Actual Required Surplus

SSE 8 6 6 2

JE 4 1 1 3

Recommendations

Two posts of SSE in Grade pay Rs.4600/- and Three posts of JE in Grade pay

Rs.4200/- are found excess to the requirement, may be surrendered and credited to the

Bank of Surplus Posts.

( 5 Posts)

.

3

CHAPTER-1

1.0 Introduction:

1.1 Golden Rock Railway Workshop

The Golden Rock Railway Workshop (officially Central Workshop, Golden Rock) is

situated in Ponmalai (Golden Rock), Tiruchchirappalli in the Indian state of Tamil

Nadu, is one of the three mechanical railway workshops serving the southern

zone of the Indian Railways.

This repair workshop is basically a "Mechanical Workshop" which comes under

the control of the Mechanical Department of the Indian Railways. The other two

mechanical workshops of Southern Railway are located in Perambur, Chennai.

They are "Carriage Works, Perambur" and "Loco Works, Perambur".

1.2 This central workshop was set up in 1897 by South Indian Railways at

Nagapattinam mainly to cater to the requirement of steam locomotive

maintenance. South Indian Railways decided to shift the workshop to

Trichinopoly, presently known as Tiruchchirappalli, owing to its locational

advantage. Consequently, foundation stone was laid by Mrs. R.P. MUNRO on

20.10.1926. It was shifted to Tiruchchirappalli in 1928 because of its strategic

location. The Central Workshop, Golden Rock is functioning at Tiruchchirappalli

since then.

The total area of this workshop is around 200 acres (0.81 km2), out of which 26

acres (110,000 m2) is covered under roof. At present 6,091 employees are

working in this workshop. This workshop is primarily engaged in the activities of

DSL Loco POH, heritage steam locomotive POH, coaching stock maintenance and

wagon manufacturing and other sundry activities.

This workshop does have a long traverser way around 600 metres long and 80

feet (24 m) wide. This workshop was involved in repairing of Royal Air Force's air

planes during World War II.

This workshop when built had state-of-the-art facilities rarely seen in those days.

It had its own powerhouse which generated electricity for the workshop and the

colony. In fact, Railway colony, Golden Rock was one of the first places to be lit

by electrical lights in Tiruchchirappalli city those days.

4

1.3 The organizational set up of Boiler Shop/Central Workshop /GOC is as below :

1.4 BOILER SHOP

1.4.1 This Shop is responsible for POH / conversion of X class locomotives. In view of

the UNESCO's world heritage site status given to the Nilgiri Mountain Railways,

maintaining and augmenting the rolling stock for this Railway has gained

significance. The Golden rock workshops has been entrusted with the

responsibility of carrying out the POH of X-class locomotives (special locomotives

which have a toothed cog which engages with the racks available in the railway

track in very steep gradients)and manufacturing of new locomotives.

1.4.2 At the time of POH, the original coal-fired boiler of the loco is converted into oil

fired loco without altering the external looks to preserve the heritage value. The

conversion has become necessary in view of the logistics, economy and

availability of coal for the loco. At present the workshop has also secured the

order for manufacturing 4 X class locomotives.

1.4.3 Apart from the regular Reclamation / Manufacture of DSL components viz.,

Equalising beams, Side buffers, Cattle guards, Main Reservoirs, Lube oil filters,

Dust guard, ECG Guard, Sand box, etc.,

1.4.4 Reclamation / Manufacture of Coaching components viz., Brake beams,

Equalising stays, Buffer plungers, Battery fuse box, Body part pillars, etc.,

CWM

Dy.CME

AWM

SEs

JEs

APE

WM PE

WPO

5

1.4.5 Reclamation/ Manufacture of Components pertaining to other divisions under A,

C orders.

1.4.6 This present work study is to review the staff strength at Boiler Shop of this

Workshop.

1.4.7 This work shop is an incentive based shop working under the Chittaranjan

Pattern Scheme of Incentive.

1.5 CHITTARANJAN PATTERN SCHEME:

1.5.1 Introduction

Piece work bonus systems were in existence in certain workshops like Jamalpur,

Kancharapara and Perambur prior to Independence. The Railway board decided

in 1949 to introduce some form of incentive scheme in Railway workshops to

afford direct financial incentive to workers who exceed a minimum level of

performance.

The first formal incentive scheme was introduced in Chittaranjan Locomotive

Works in December 1954. Time was the basis of this scheme and the time

standards used were pre-determined after systematic work measurement.

The scheme was considerable success and it was extended to Integral Coach

Factory in 1960.

1.5.2 Salient Features of Chittaranjan Pattern of Incentive Scheme:

Under the incentive bonus scheme, the basic wages are guaranteed to all the

works.

Time is yardstick for measuring work. The various operations in the workshops

are subjected to time study measurement. The allowed time are so fixed that

the workman of normal ability may earn 33-1/3% bonus over and above his

basic wages in respect of period spent on piece-work jobs. This allowed time

includes all allowances such as fatigue, general handling, and gauging and

production bonus allowance.

The scheme is based on the concept that an average worker while working

under non-incentive conditions is assumed to be working at a rating of 60 units.

6

The same worker while working under incentive conditions would be expected to

improve his ratings to 80 units i.e., 33-1/3%more. It is expected that an average

worker would complete an operation in ¾ of the allowed time. The time

saved/lost on the time allowed in each operation is calculated separately for

each worker and the gain or loss cannot be carried over to the next month.

1.5.3 The various terms in use and their meaning is given below.

The incentive workers are classified as Direct, Essentially Indirect and Indirect

Workers. Supervisors are directly responsible for idle time arising out of lack of

work and lack of tools. Apprentices are not eligible for participating in the

incentive bonus scheme.

DW - Direct workers:

They are so called because they play a direct role in producing output. ‘Direct

role’ means that their role is confined to those mandatory operations that need

to be performed as per ‘CAMTECH’ on the arising to produce the out turn. It

does not include ancillary activities such as procurement of materials, tools etc

that need to be done to perform the operations. They earn bonus ranging from

1% to 49% based on the time saved on doing a particular operation.

EIW - Essentially Indirect Workers:

They supplement the efforts of the DWs in producing out turn by procuring

materials, picking up tools, erecting implements etc. Since their role is not

directly linked to the out turn and is only supplementary in nature, they are

entitled to only 80% of the bonus earned by the DWs they assist.

IW –Indirect worker: Their role is confined to such of those activities that are

in no way linked to the out turn, such as keeping the shop floor clean etc. They

do not get any incentive.

Outturn: The results of incentive working will be determined on basis of the

total quantity ‘Passed’ in respect of each operation, as recorded on the job card.

AT –Allowed Time:

As and when an arising rolls in to a work shop for POH, operations that need to

be performed as mandated are determined and the time taken to complete such

7

operations are computed based on the computation sheet that lists the time

required to perform various operations. This is called as Allowed Time. As such,

AT denotes the workload of an incentive shop. AT is fixed based on time study

and takes in to consideration various factors, such as infrastructure, skill set etc,

that determine the capacity of a worker to produce an output.

Time Study:

AT for each operation is fixed through time study. It is a technique for

determining, as accurately as possible, from limited number observations, the

time necessary to carry out a given activity at a defined standard of

performance. While carrying time study the actual time of each element is

normalised depending upon the rating performed by the worker.

Rating:

Rating is the assessment of the skill and effort involved in each element. Every

element should be rated individually. The principle of rating is that, an average

worker, working at non incentive conditions, at such an effort just enough to

earn the basic pay, is said to be working at a 60 rating. This can be interpreted

as saying that he is producing 60 units per hour. The same average worker

when working under incentive conditions, is capable of working at an 80 rating

and is said to be producing 80 units of work per hour so as to earn 33-1/3 %

more ((80-60/60)%).

TT – Time taken: This is the time actually taken by a DW to finish an operation

as mandated.

TS – Time saved: AT – TT = TS.

Bonus %:

This is the percentage of bonus paid to the DWs based on the Chittaranjan

pattern Scheme. This is equal to TS x 100 / TT. While the scheme mandates that

every DW should earn a bonus of 33.33%, it may vary anywhere between 0 to

50%. Bonus less than 33.33% indicates that AT of an operation is too less to

save time and bonus more than 50% means that AT is too high that a worker

8

could do the operation in much lesser time with consummate ease. In both the

cases AT has to be reviewed.

.

9

CHAPTER – II

2.0 PRESENT SCENARIO:

2.1 BOILER SHOP

The boiler of a locomotive is made of a steel alloy and holds thousands of

gallons of water. The boiler must be treated with care at all times, as it must

withstand tremendous amounts of heat, pressure and vibration. The fireman

should take care to minimize the thermal stresses placed on the boiler when

safety permits.

2.2 Oil Burning Locomotives

Oil burning locomotives in the steam era mainly used "Bunker C" fuel oil.

(Bunker C is also known as Type 6 or Number 6.)While some preserved steam

locomotives of today (circa 2005) still use Bunker C, most have switched to

various alternative fuels as Bunker C can be difficult to locate, transport, and

store. Alternatives include Number 4 fuel oil, kerosene or diesel oil (and

sometimes a mixture of diesel/kerosene), others employ used motor oil.

Regardless of the kind of oil used, most locomotives store the fuel in a tank on

the tender. The oil tank is equipped with steam heat coils to heat the fuel before

combustion. This is done to keep the oil viscosity such that the oil can flow freely

to the combustion chamber. Bunker C fuel oil is very thick and difficult to use

without pre-heating.

The fire in an oil burning locomotive is controlled with two valves: The fuel

valve, which controls the flow of oil to the atomizer, and the atomizer valve,

which controls the steam to force the oil into small droplets for burning.

The fireman must control the amount of steam, oil, and air in the combustion

chamber to produce the most efficient fire to boil the water. The fireman

observes the colour of the smoke emitted from the smoke stack to determine

what the fire needs. Thick, foul smelling black smoke indicates that the fire is not

burning correctly due to too much fuel oil. The fireman can increase the draft of

air using dampers and the blower or reduce the amount of oil to the burner.

Blue smoke indicates too much steam is being admitted to the atomizer, and he

10

must reduce the steam pressure. A light grey smoke indicates proper

adjustment, while no smoke at all means the fire is too light and should be

increased.

It is worthy to note that under some circumstances, the fireman can cause a

series of hollow booms or small explosions though maladjustments of the fire. If

one were to be watching with the fire doors open at such a time, one would see

that the flame is being ripped away from the burner and into the flues. This also

can cause heavy amounts of soot to be deposited in the flue, reducing the

efficiency of the boiler. The soot can be cleaned by throwing sand into the

combustion chamber, but this causes undesirable wear to the flues and any

super heaters.

2.3 The staff strength in the Boiler Shop is 66 as on 18/08/2017 :-

The staff distribution is as follows:

Staff deployed for each activity:

a. For coaching activity - 29 Staffs (45% of total staff)

b. For DSL activity - 20 Staffs (31% of total staff)

c. For X class activity - 10 Staffs (16% of total staff)

d. For Divisional activity - 05 Staffs(08% of total staff)

e. EIW - 02 Staffs

TOTAL - 66 Staff.

Note:

(1) The above brake up particulars have been obtained based on the last 27

months actual booking data’s ie., from April-2015 to June-2017.

(2) Out of 10 staff (as mentioned in above.c) involved for ‘X’ class activities

only one staff at Boiler shop and remaining 9 staff are working at Erecting

Shop.

2.4 No. of OT hours allowed for last 2 years:

1021 OT hours have been allowed for maintenance works during May week

holidays works in the year 2015.

1630 OT hours have been allowed for maintenance works during May week

holidays works in the year 2016.

11

2.5 No. of CR/ DR issued:

CR - 34 Man-days

DR - NIL

No. Training details of employees - Enclosed in Annexure-II

2.6 Failure statistics of shop

Status of M/c idle hours pertain to Ele.& Mech. available with EMW and MMW.

2.7 No. of staff deployed for online attention, material collection, training

etc., for the last 2 years.

a. For On line attention – 649 Man days

b. For Material collection- 64 Man days

c. For training- 55 Man days

2.8 Activities already outsourced / proposed for outsourcing:

PU painting of Steam locos is outsourced.

Contract /AMC - NIL

Details of sub-units – NIL

2.9 Machineries Details :-

Sl.

No

GOC MC ID M/C DESCRIPTION Shift Machine

Commnd.

OLD M/C

NO.

1 314017124 RADIAL DRILL & TAPPING 1 02/01/1950 BS D 12

2 314017290 RADIAL DRILLING M/C 1 19/08/1957 BS RD 29

3 314026046 DOUBLE ENDEDGRINDING 2 21/09/1964 BS G 4

4 314040020 RAPID HACK SAW 1 01-01-1934 BS HS 2

5 314101020 PUNCHING & SHEARINGM/C 2 30/04/1990 CRS S 2

6 314103030 PLATE BENDING ROLLER 1 01-01-1946 BS RL 3

7 314103041 PLATE BENDINGM/ 1 22/09/1951 BS RL 4

8 314105025 LATESPLITTING HEARS 1 01-01-2010 BS S 2

9 314105049 SPITTING SHEAR 1 19/03/1958 BS S 4

10 314105050 GUILLTINE SHEARINGM/C 2 11-01-1974 BS S 05

11 314129017 PLATE STRAIGHTENROLLS 1 01-01-1928 BS RL 1

12 314151060 EOT CRANE 7.54 TONSAC 2 22/07/2008 BS CR 706A

13 314151760 EOT CRANE (1 TON)(AC) 2 05-12-1992 BS CR 776

14 314151930 EOT CRANE (25 TON)(AC) 2 28/08/1996 BS CR 793

12

15 314157037 JIB CRANE (1 TON) 1 15/02/1994 FY EH 03

16 314158613 HAND OPRTD. OVERHD. CRANE 1 01-02-2008 BS CR 761

17 314259030 HYDRAULIC TEST PUMP 1 01-01-1989 BS HTP 15

18 314301197 AIR COMPRESSOR (500/14.15 CFM CUM 2 07-01-1988 DCS AC 19

19 314301215 SCREW AIR COMPRESSOR (530/14.99

CFM/CUM)

2 02-10-1989 BS AC21

20 WELDING PLANT(DC/MMA) 600 AMPS BS AC 9

21 WELDING PLANT (DC/MMA)600 AMPS BS SC 11

22 WELDING PLANT (DC/MMA) 600 AMPS B SAC 116

23 WELDING PLANT (DC/MMA) 600 AMPS BS SAC 117

24 WELDING PLANT(DC/MMA) 600 AMPS BS SAC 168

25 314403152 WELDING PLANT (AC/MMA) 350 AMPS 2 01-01-1967 BS WP 115

26 314403437 WELDING PLANT (AC/MMA) 300 AMPS 2 01-01-1962 BS WP 43

27 314403589 WELDING PLANT (AC/MMA) 450 AMPS 2 09-12-1974 BS WP 158

28 314404193 WELDING PLANT (DC/MMA) 600 AMPS 2 02-01-1989 BS WP 219

29 314405630 WELDING PLANT (AC/MMA) 600 AMPS 1 02-05-2002 BS WP 363

30 314405641 WELDING PLANT (DC/MMA) 600 AMPS 1 05-05-2002 BS WP 364

31 WELDING PLANT (DC/MMA) 300 AMPS BS SL 72

32 WELDING PLANT (DC/MMA) 300 AMPS BS WP 193

33 WELDING PLANT (DC/MMA) 300 AMPS BS WP 239

34 314457021 OIL FURNACE 1 01-01-1936 BS OF2

35 314457070 RIVET HEATING FURNACES 1 01-01-1928 BS OF 7

36 314508170 HYD. TUB. SWELLING & REDUCIN 1 01-01-1928 BS TSW 1

37 314508181 RIVETTIG HAMMER 1 01-01-1926 BS H 1

38 314508193 TUBE DSCALING MACHIE 1 01-02-1928 BS TSC 01

39 314508200 GANTARIES FOR DRILLING 1 01-02-1938 BS DG 01

40 314612130 HYDRAULIC RIVETING MACHINE 1 03-01-2016 BSHRM 13

41 WELDING PLANT (DC/MMA) 300 AMPS BS WP 53

42 WELDING PLANT (DC/MMA) 400 AMPS NEWBSWP 0

43 WELDING PLANT (DC/MMA) 300 AMPS BSWP 28

13

2.10 Allowed Time for each activities / Jobs:-

314 - BOILER SHOP

SL. No.

OPERATION DESCRIPTION UNIT AT

COMPUTATION No.326 - DSL Reservoir

1 DSL air reservoir(Large) dish end remove by gas cut clean, assy. weld and Hyd. test(BG)

NO 25.08

2 Lub. oil filter mark, gas cut, Mod. Wing nut provision, weld, repair &Hyd. test

NO 33.44

COMPUTATION No.327 - DSL EQUALISING BEAM

1 Eq. Beam welding NO 2.09

2 Eq. Beam grinding. NO 4.18

3 Eq. Beam Corroded portion and damaged portion (if

necessary) weld & grind. NO 0.905

4 Clean and Paint NO 0.316

COMPUTATION No.328 - ICF/BG COACHES COMPONENTS

1 Equalising stay for ICF/BG (16 +33 ) Mark, Cut, Level, Assemble ,Tack weld ,Weld.

NO 7.106

2 Manuf. of ECC guard marking, cut, level bend, assemble, expand metal mark, cut, assemble, weld

NO 32.604

3 manufacture of outer frame for ECC guard marking cutting levelling welding bending

NO 10.032

4 Repair of side load pad Dust guard level the bottom plate, side plate, side rib plate mark cut bend assemble, weld

NO 5.852

5 Manuf., of half round guard mark, cut, bend, drill, grinding, clamp provide

NO 4.598

6 Manufacturing of dust guard base plate mark, cut, clean burr, bend, assemble, and weld

NO 17.556

7 Manufacturing of indication board mark cut, corner mark, cut bend ,weld and grind

NO 5.016

8 Addition cylinder Rack cylinder side lagging PER

BOILER 146.3

9 Pivot lagging Manufacture & assembly PER

BOILER 146.68

10 Steam pipe lagging Both side & manufacturing PER

BOILER 125.4

11 New X-class doom NO 141.284

12 REPAIR & RE-CONDITION OF AUXILARY RESERVIOUR FOR BG COACHES 200 LIT. CAPACITY

NO 28.792

13 Mounting seating, stud clearing PER

BOILER 6.622

14

14 Fitting of regulator valve PER

BOILER 60.326

15 Fitting of gauge column cock, pressure gauge cock, washout plug, blow off cock clack box, dome joint

PER BOILER

191.277

16 Fitting of safety valve, steam stand NO 20.9

17 Repair and Reconditioning of old brake beam NO 14.564

18 Remove the bushes from equalizing stay NO 1.067

19 Manufacture and painting of Belly Panel Board (Item 1 = Large Board, Item 2 = Inner Fold Board)

NO 7.624

COMPUTATION No.329 - DSL CATTLE GUARD & MISCELLANEOUS

1 Buffer plunger rivet & grind NO 5.016

2 Loco side buffer repair & recondition NO 10.952

3 Repair and modified cattle guard for diesel loco (BG) NO 69.033

COMPUTATION No.332 - BOILER MOUNTING

1 Fit up laggings. NO 91.96

COMPUTATION No.333 - REPAIR & RECONDITION OF DLS GEAR CASE

1 Repair and recondition of gear case BG & MG cleaning, scrapping of cardium compound and by burning

HALF 0.836

2 Boss, remove cut by gas out including gasket ribs HALF 0.334

3 Pinion support block remove by gas cut including gusset ribs

HALF 0.276

4 Wiper felt ring wheel side remove by gas cut HALF 1.564

5 Wiper felt ring motor side remove by gas cut HALF 1.564

6 Wiper felt ring pinion side remove by gas cut HALF 0.777

7 Preparation and assemble of new felt ring, worn out portion on side plate mark, gas cut, clean burr and grind the gas cut portion of Boss & pinion supports.

HALF 1.672

8 Side periphery plate mark cut file, side bend by bend to suit and remove the old damaged portion assembly T/weld and weld.

HALF 1.571

9 Wiper ring with side plate wheel side assemble and tack weld

HALF 1.254

10 Weld complete (8mm fillet) HALF 1.17

11 Wiper ring with side plate motor side assemble & T/weld

HALF 1.254

12 Weld complete (8MM fillet) NO 1.17

13 Wiper felt ring portion side assemble - T/weld HALF 1.254

14 Weld complete (8 mm fillet) HALF 1.17

15 Check the alignment motor side HALF 1.254

16 Check the alignment - wheel side HALF 1.254

15

17 Preparation of gusset ribs (3 Nos.) - Mark ,shear , flatten, clean burr & grind

NO 0.836

18 Preparation of end plate blocking piece both side - 4 Nos.- Assemble weld & grind

HALF 0.836

19 Assemble, tack & weld boss & gusset - 3 Nos. NO 1.588

20 Manufacture of lids complete (small) for BG HALF 2.508

21 Manufacture of lids complete (large) - MG NO 3.344

22 Preparation of bottom baffle strips of sizes, worn out, cracked portions & weld

HALF 2.09

23 Preparation of bottom baffle - remove bend, resistance & distortion , check up to gauge & suit

PER BOX 3.344

24 Matching top & bottom final check up & rectification after assembly with end recess fitting of clamps & Sq. head bolts

NO 10.032

25 M/F and supply of bulb cotters (RM size 3.15X10X200mm

NO 0.695

COMPUTATION No.334 - MISC.

1 Buffle collector support plate, mark shear cut, bend, weld grind

NO 3.177

2 Buffle collector frame (round type and square type) NO 7.148

3 Packing pieces large and small NO 0.836

4 Destination board , mark shear cut bend clean burr NO 2.508

5 Sizes of clamps 5mm manuf.1/4,,1/2,3/4, NO 1.881

6 Manuf.of clip BG & MG mark, shear, bend, drill set to shape

NO 2.508

7 Manuf.of bottom square cover mark, shear, bend NO 1.672

8 RTTM belt guard for (BG&MG) mark, shear, drill assemble 1 to 7 weld and provide side clamp 2 Nos., weld 2 to 4 for BG

NO 24.244

9 Door for governor room mark, cut, drill provide handle, assemble, and weld

NO 11.4

10 Manufacture of shim NO 0.95

11 Partition plate for ALCO & WDS 6 Loco mark ,cut by gas , bend ,assemble, and weld

NO 11.4

12 Battery box cover clamp mark, shear drill, bend and grind

NO 0.557

13 Manuf. of axle box grease keep complete NO 6.688

14 X class boiler tubes NO 447.842

15 Manuf. of flange for steam pipe mark cut by gas and de-burr

NO 1.846

16 Body part pillar mark shear 2 x 310 x 528 mm long NO 0.125

17 Sand box for all locos new manufacture NO 20.064

18 Spring Seat piece DSL/Loco 6 x 35 x 240mm NO 0.334

19 Repair and recondition of Cabin top for 'X' class Loco

POH NO 421.79

16

20 EXPRESSOR FAN GUARD NO 28.5

21 Wall Plate for DSL Loco NO 3.105

22 Strip NO 0.696

23 Super Heater element pipe assembly NO 9.707

24 Bracket for brake beam 13 Tonnes for ICF/BG NO 1.131

25 M.S. Plate NO 1.185

26 M/F and supply of air dryer guard (AB-DSL) NO 2.493

27 M/F and supply of safety bracket for commode chute NO 0.719

28 M/F and supply of engine hood centrifugal cleaners side door plate

NO 0.719

29 M/F and supply of rain guard plate (1 set=5 piece) set 8.36

30 M/F and supply of flat NO 0.676

31 M/F and supply of shim for CBC couplers (Up to 4mm) NO 1.673

32 M/F and supply of shim for CBC couplers (5mm to 10mm)

NO 3.736

33 Exhaust funnel modification Chimney NO 13.333

34 M/F and supply of Battery Fuse box NO 7.283

35 Manufacture of Body part pillar for ICF BG Coaches NO 3.62

36

Manufacturing of Bracket for Vestibule Garbage bag Mfg. of 1. Outer Bracket-1 No. 2. Inner Holding Bracket-1 No. 3. Half Bracket-2 Nos. 4. Bracket-4 Nos. 5. Vertical Clamp-1 No. 6. Hinge pipe-2 Nos. Set and assemble and purchase, weld and grind

NO 4.02

COMPUTATION No.335 - X class BOILER construction

1 Manufacture of vacuum reservoir for oil firing system NO 35.783

2 Internal main steam pipe with elbow joint for header lapping and assembling

NO 263.464

3 Brazing of rack & adhesion piston head NO 71.998

COMPUTATION No.328 - X-CLASS LOCO

1 PIECE WORK FOR BOILER SHOP NO 1.000

2.11 Man hours for each activity pertaining to Boiler/X-class locomotives

314 - BOILER SHOP

SL.

No. OPERATION DESCRIPTION UNIT AT

1 Addition cylinder Rack cylinder side lagging PER BOILER 146.3

2 Pivot lagging Manufacture & assembly PER BOILER 146.68

3 Steam pipe lagging Both side & manufacturing PER BOILER 125.4

4 New X class doom NO 141.284

5 Mounting seating, stud clearing PER BOILER 6.622

6 Fitting of regulator valve PER BOILER 60.326

7 Fitting of gauge column cock, pressure gauge cock, washout plug, blow off cock clack box, dome joint

PER BOILER 191.277

17

8 Fitting of safety valve, steam stand NO 20.9

9 X class boiler tubes NO 447.842

10 Repair and recondition of Cabin top for 'X' class Loco POH

NO 421.79

COMPUTATION No.332 - BOILER MOUNTING

1 Fit up laggings. NO 91.96

COMPUTATION No.335 - X class BOILER construction

1 Manufacture of vacuum reservoir for oil firing system

NO 35.783

2 Internal main steam pipe with elbow joint for header lapping and assembling

NO 263.464

Brazing of rack & adhesion piston head NO 71.998

COMPUTATION No.328 - X-CLASS LOCO

1 PIECE WORK FOR BOILER SHOP NO 1.000

2.12 In this Workshop the maintenance and the earth moving equipment

maintenance is carried out by the Millwright Shop.

2.13 Activities carried out

a. POH of X class Steam Loco and Boiler;

b. Reclamation / Manufacture of DSL components viz.,

• Equalising beams

• Side buffers

• Cattle guards

• Main Reservoirs

• Lub oil filters

• Dust guard

• ECG Guard

• Sand box, etc.,

c. Reclamation / Manufacture of Coaching components viz.

▪ Brake beams

▪ Equalising stays

▪ Buffer plungers

▪ Battery fuse box

▪ Body part pillars, etc.,

d. Reclamation/ Manufacture of Components pertaining to other divisions under

A, C orders.

18

CHAPTER – III

3.0 CRITICAL ANALYSIS

3.1 Average TT/DW/Month:

As per Mechanical Code, for a Workshop governed by the Chittaranjan Pattern of

Incentive Scheme, the average available Man hours per employee per month is

200 + 67 = 267 Man hours. The Railway Board is fixing Target for workshops

based on the norms of 267 Man hours per employee per month. This has only

been taken into consideration in the work study. The detailed working for the

above is given below.

Total number of days in a year .. 365 days

No. of Sundays in a Year (approximately) .. 52 days

Available working days in a Year .. 313 days

Less no. of Holidays ` .. 20 days

Nett working days available in a Year .. 293 days

Total Man hours available in a Year .. 293 x 8 = 2344 Hrs.

Average Man hours per employee per month .. 2344/12 = 195.33 or

.. say 200 hrs

Add 33-1/3% under incentive scheme .. 67 hrs

Total .. 267 hrs.

The details of incentive scheme, basis, working hours etc are given in paras201,

208, 401 & 402 of Chapter II & IV of Mechanical Code. (copy enclosed as

Annexure-III).

This figure indicates the work actually performed by a DW in terms of man

hours. For the sake of calculation as per the CPS, this should be 200 man hours.

(365 x 8 man hours per day – 52 (Sun) x 8 – 20 (Declared Holidays) x 8) = 195

= 200 (Approx) Hrs per month per DW. Any figure less than this indicates that

the worker has remained idle for such number of hours exceeding the figure up

to 200 hrs.

Add 33-1/3% for incentive shops - 67 hrs. Total - 267 hrs. As per the Mechanical Code (for workshops) 267 hrs are available per employee per month.

19

3.2 Man power Requirement

Boiler Shop

The manpower requirement in respect of Incentive shops are

calculated based on the Allowed time. Normally the average allowed

time will be taken for the last three financial years and the manpower

requirement would be decided accordingly.

3.3 Methodology adopted to arrive the requirement of Man Power

for Incentive shops.

The month wise total Allowed time for work discharged for each shop /

activity were collected from financial year 2015, 2016 and up to June

2017. This prime factor is divided by the average monthly man hours

of 267 (which is the denominator) as prescribed in the Mechanical

code for workshops to arrive at the Direct workers (DWs) required. As

per Mechanical code for workshops the Leave reserves for the DWs are

worked out at the rate of 12.5% and for Essentially Indirect Workers /

Indirect Workers (EIWs / IWs), it varies from 10% to 15%.

3.3 IW/EIW staff calculation per month

In Mechanical code Chapter IV of para 431, the details regarding % of unskilled

workers to be engaged as IW & EIW are given for various Sub-shops.

It is observed that in CW/GOC, EIWs / IWs were allowed to the extent

of 15%. Instructions were issued on several occasions from

Headquarters to see that the percentage of EIW is reduced to the

barest minimum and guidelines were given in Chapter-4 of the

mechanical code for considering EIW % of each shop. Considering the

practice followed at present while assessing the requirement of

manpower, EIW is allowed at the rate of 10%. As per mechanical

code.

The Allowed Time for various activities at Boiler Shop is collected from Planning

Section, for the period from Mar’2015 to June 2017 (27 months). This prime

factor is divided by the average monthly man hours of 267 (which is the

denominator) as prescribed in the Mechanical code for workshops to arrive at

20

the Direct workers (DWs) required. As per Mechanical code for workshops the

Leave reserves for the DWs are worked out at the rate of 12.5%

Let Load discharged (Allowed Time) = AT

Let Idle time booked = IDL

Average monthly Man-hours = 267

DWs required to complete the above AT = AT + IDL = X

267

LR for DWs (12.5%) = X x 12.5 = Y

100

Therefore total DW required = X + Y

100

EIW & IW @ 12.5% = ( X +Y ) x .125 = Z

Total Artizan staff required = X + Y + Z

3.4 BOILER SHOP PERFORMANCE FROM APRIL2015 TO JUNE2017

BOILER SHOP 2015-16

AT TT TS %

Apr-15 19850.220 13342.500 6507.720 48.77

May-15 14687.172 9862.000 4825.172 48.93

Jun-15 19142.496 12829.500 6312.996 49.21

Jul-15 19208.818 12885.500 6323.318 49.07

Aug-15 19112.325 12811.000 6301.325 49.19

Sep-15 19098.000 12798.000 6300.000 49.23

Oct-15 16479.934 11046.000 5433.934 49.19

Nov-15 17649.528 11828.450 5821.078 49.21

Dec-15 19992.605 13387.780 6604.825 49.33

Jan-16 16982.832 11382.290 5600.542 49.20

Feb-16 18271.274 12243.000 6028.274 49.24

Mar-16 18017.802 12059.150 5958.652 49.41

218493.006 146475.17

21

BOILER SHOP 2016-17

AT TT TS %

Apr-16 17947.488 12035.120 5912.368 49.13

May-16 12767.480 8549.800 4217.680 49.33

Jun-16 18537.922 12402.120 6135.802 49.47

Jul-16 18173.728 12166.110 6007.618 49.38

Aug-16 16539.521 11073.240 5466.281 49.36

Sep-16 18070.576 12101.990 5968.586 49.32

Oct-16 17878.181 11959.920 5918.261 49.48

Nov-16 17142.567 11470.200 5672.367 49.45

Dec-16 17687.415 11840.370 5847.045 49.38

Jan-17 16334.467 10936.190 5398.277 49.36

Feb-17 17319.751 11590.820 5728.931 49.43

Mar-17 16939.013 11343.820 5595.193 49.32

205338.109 137469.7

BOILER SHOP 2017-18

AT TT TS %

Apr-17 18434.647 12331.740 6102.907 49.49

May-17 12492.999 8381.410 4111.589 49.06

Jun-17 18254.245 12224.820 6029.425 49.32

49181.891 32937.97

3.5 Calculation of Men required for Boiler Shop :-

Total Allowed Time For 27 Months (APRIL2015 TO JUNE2017)

218493.006+205338.109+49181.891=473013.006

AVERAGE/MONTH= 473013/27 =17519

Since the average incentive earnings in the shop is more 49 % the man days is

calculated as 200 + (49% of 200) = 298. Hence 298 man days is taken for arriving

the required manpower.

Average Direct Workers Required = 17519/298 = 58.78 Say 59 MEN

LR for DW @ 12.5 % = 7.34 Say 7 MEN

Total DWs staff = 66 STAFF

EIW & IW @ 10% = 6.6 say 7 men

Total staff required for Boiler Shop(59+7+7) = 73 men

22

The time taken for completing the target was less than the AT since the incentive

earnings is 50% in every month. Even then, on the higher side and in consideration of

Target, the AT is considered for man power calculation.

Requirement of Supervisors

The requirements of Supervisors are found excess to the requirement since the

requirement of staff is 73 and the actual is only 65. Hence the existing Supervisors is

allowed to continue and the vacant posts may be surrendered and credited to the

vacancy bank.

3.6 SANCTION Vs REQUIREMENT

Category Sanction Actual Required Surplus

SSE 8 6 6 2

JE 4 1 1 3

Recommendations

Two posts of SSE in Grade pay Rs.4600/- and Three posts of JE in Grade pay

Rs.4200/- may be surrendered.

(5 Posts)

23

CHAPTER - IV

4.0 PLANNING BRANCH’S REMARKS ON CO-ORDINATING OFFICER’S VIEWS

4.1 Co-ordinating Officer’s Remarks:

The surrender proposal of 5 posts in supervisory cadre of Boiler shop is not agreed to and may be reviewed to 3 posts (SSE-2 & JE-1) based on the reasons furnished below:

1. The activities of Boiler shop is not only confined to Boiler alone but dealt with other related activities such as coach POH, DSL Loco POH, Divisional work orders etc., and induction of new activities which require specific attention at various stages.

2. As per Railway Board guidelines, every shop has to obtain the IMS related certification activities of QMS, EMS, OHSAS & 5S and time to time new certification processes have to be initiated for which the role of SSE/JEs are very crucial and needs to be considered.

3. On considering with the above facts, the supervisory requirement of Boiler Shop have been arrived and furnished below:

Section Requirement

SSE JE Total

Administration 1 1

Coach POH Components 1 1 2

DSL POH components 1 1

Steam Loco POH attention 1 1 2

Divisional components attention & Misc.activities 1 1 2

Total 5 3 8

LR @ 12.5% 1 - 1

Grand total 6 3 9

Planning Branch’s Remarks :

The activity of Divisional Components attention & Misc. activities can be managed with the existing supervisors of Boiler Shop. Hence, 1 post of JE may be surrendered in addition with the surrender of 2 SSE & 1 JE.

Revised Recommendation:

Category Sanction Actual Required Surplus SSE 8 6 6 2

JE 4 1 2 2

Two posts of SSE in Grade pay Rs.4600/- and Two posts of JE in Grade pay Rs.4200/- are found excess to the requirement, may be surrendered and credited to the Bank of Surplus Posts.

( 4 Posts)

.

24

CHAPTER - V

5.0 FINANCIAL SAVINGS:

5.1 If the recommendations of the study report are implemented, the Annual

Financial Recurring Savings will be as follows.

Sl.

No

Designation Grade

Pay (Rs.)

No. of

posts

Money

value

(Rs.)

Annual

Financial

Savings

(Rs.)

1. SSE 4600 02 97396 2337504

2. JE 4200 02 76856 1844544

Total 04 4182048

.

25

26

ANNEXURE-III

INDIAN RAILWAYS MECHANICAL CODE (for workshops):

431. Introduction of Incentive Scheme.�The proposal to bring the direct workers,

essentially indirect workers and staff of service shops under the coverage of Incentive

Scheme shall be dealt with on the basis indicated in the broad guidelines laid down by the

Railway Board from time to time and shall be sanctioned by the General Managers under

their own powers.

Following points should be kept in view while introducing incentive scheme in

shops/sections of a workshop:�

(i) Whether a list of items to be manufactured or repaired in the section/shop in which

incentive scheme is proposed to be introduced has been prepared.

(ii) Whether adequate load to meet the increased capacity generated as a result of

introduction of Incentive scheme has been ensured.

(iii) Whether the computation and the time studies have been carried out on Chittaranjan

pattern.

(iv) Whether the allowed times have been approved by the Production Engineer/Works

Manager.

(v) Whether quota cards have been introduced and the allowed time established before any

system of payment by results can be introduced, the allowed times computed from basic

data should be checked to see that they compare favourably with those actually required to

carry out the job.

(vi) Whether the strength and categories of indirect workers and essential indirect workers

have been approved by Chief Mechanical Engineer.

(vii) Whether the strength and the categories of staff of indirect workers including those

declared essentially indirect have been fixed as a result of proper analysis.

The following targets should be worked to the extent possible in respect of unskilled staff

engaged as indirect workers including essential indirect workers.

Name of the sub-shop Strength of unskilled workers engaged as indirect workers

including essential indirect worker

Erecting 15% of the total strength of the erecting/shop.

Boiler 10% of the total strength of the Boiler shop.

Tender 15% of the total strength of the Tender shop.

Fitting 15% of the total strength of the Fitting shop.

Copper & Tin 15% of the total strength of the Copper & Tin shop.

Welding 12�% of the total strength of the Welding shop.

Motion 10% of the total strength of the Motion shop.

Saw Mill 30% of the total strength of the Saw Mill shop.

27

Carriage Building 10% of the total strength of the Carriage Building shop.

Carriage Repair 10% of the total strength of the Carriage Repair/Shop.

Paint 10% of the total strength of the Paint shop.

Trimming 10% of the total strength of the Trimming shop.

Wagon building 12% of the total strength of the Wagon Repair shop.

Wagon repair 15% of the total strength of the Wagon repair shop.

General Iron Foundry 20% of the total strength of the General Iron Foundry.

Brass Foundry 25% of the total strength of the Brass Foundry.

Smith & Forge 10% of the total strength of the Smith & Forge shop.

Machine 10% of the total strength of the Machine shop.

Wheel 10% of the total strength of the Wheel shop.

Tool Room 10% of the total strength of the Tool Room.

Mill Wright 25% of the total strength of the Mill Wright.

(viii) Whether the strength and categories of staff of direct workers have been determined

with reference to the work load on the different load centres and sections. The No. of

effective hours available per shift per month will be taken as 200 and with the addition of

33 1/3% representing the average efficiency under incentive scheme, 267 man hours per

man per month shall be the basis for working out the number of direct workers.

(ix) Whether the number of supervisors has been determined according to actual need

keeping in view the supervisory ratio authorised by the Railway Board from time to time.

(x) Whether regular supply of raw-materials has been ensured. Also whether arrangements

have been made with the stores departments for their reservation before the release of

work orders.

(xi) Whether a system of periodical oiling of machines, tools and plants and other

preventive maintenance measures have been introduced.

(xii) Whether a proper system of inspection has been introduced.

(xiii) Whether the punching clocks have been installed and booths erected.

(xiv) Whether production forms on the Chittranjan Locomotives Works pattern have been

introduced.

(xv) Whether Adrema machines or computers have been brought into use.

.

28

INDIAN RAILWAY CODE FOR THE MECHANICAL DEPARTMENT (WORKSHOPS)

CHAPTER II

ATTENDANCE IN WORKSHOPS

201. Hours of Work.� The hours of work in Railway Workshop which come within the

definition of "Factories" given in the Factories Act, 1948 or have been declared to be

"Factories" under that Act, are regulated by the provisions of Sections 51-56 of the Act. For

convenience of reference some of more important limitations provided in the said Sections

of the Act, are stated in paragraphs 202 to 208.

209. Working Hours.�The normal working hours of labour in Railway Workshops are

eight and a half hours of week days and five and a half hours on Saturday making a total

working week of 48 hours equivalent to an 8-hour day. Any departure from an 8-hour day

involving payment of a day's wages for less than 8 hours work requires the specific sanction

of the Railway Board, but the actual working hours and their distribution between the days

of the week may be altered in accordance with local requirements subject to the limitations

stated in paragraph 201.