Wagon Rehabilitation Shop – Bottlenecks & Suggestions For

overcoming them

By:

Shadab Jamal 2K301

Abhishek kumar singh 2K302

Ashutosh prasad 2K303

Ritwik Sharma 2K304

Objectives

• To study the reasons for under performance of WRS – 1.

• Suggestions and recommendations for increasing its productivity.

ORGANISATIONWRS-1 WRS-2 WRS-3

SSE 6 2 2

SE 7 5 8

JE 16 13 17

WELDING MACHINES

46 31 60

D A POINTS 26 18 15

OXY POINTS 30 34 28

WORKERS 475 450 520

Steps involved in POH

1. Initial inspection of sick wagons for POH2. Cleaning and marking the shortcomings3. Body separation and body fitting4. Placing the body over the pit5. Stripping of CBC , air brake arrangement

etc.6. Repairing of under frame member like

center seal , sole bar

7. Repairing of end wall , side wall and floor

8. Assembling the wagon body

9. NTXR examination

10. Fixing the anomalies

11. Wagon ready for loading

Bottlenecks in the shop

1. High absentee rate in the shop (on an avg. 30% are always away from work )

2. Only four hours of effective work (time consumed in assembling the equipment)

3. Lack of co ordination between welding and fitting section

4. Lack of accountability

5. High downtime of EOT cranes

6. Lack of skill and leadership in the supervisory staff.

7.No proper arrangement of removal of scrap from the shop.

8.Unauthorized encroachments along the shop wall leading to space congestion

9.Lack of proper lighting arrangements.

10.Improper pits with low heights and congested bays.

11.Inefficient material movement and over dependency on EOT cranes.

12.Inefficient material movement between the wagon shop and B.S.T.

13.Substandard main switches used for welding and EOT cranes

14.Water logging during rainy season.

15. The under frame obtained after stripping operation is not fit for carrying out rebuilding and has to be reworked

16.Damaging of welding cables

17. Lack of motivation in workers

18. Improper utilization of available space

19. Procrastination in heavy repair wagons

Suggestions

Problem: High absentee rate in the shop-on an avg. 20-25% are always away from work .

Solution:

• Strict control over grant of leave to workers.

• The concerned SSE should send the daily report to the Dy. CME

Problem: Only four hours of effective work:-

1. Late arrival of workers

2. High equipments setting times in both halves

3. Workers found sleeping during working hours

Date : 30-05-08Time : 12:27

Solution :• Most of the workers come by workers train

hence shift timings/train timings should be adjusted accordingly.

• Dedicated welding machines for each pit along with the shelf where worker can safely put his equipments.

• High penalty for workers found sleeping during duty hours.

• Surprise visits by officials.

Solution :• Most of the workers come by workers train

hence shift timings/train timings should be adjusted accordingly.

• Dedicated welding machines for each pit along with the shelf where worker can safely put his equipments.

• High penalty for workers found sleeping during duty hours.

• Surprise visits by officials.

Problem :

Lack of co ordination between welding and fitting section:-

1. Welding staff not under control of SSE

Solution :

Both the welding and fitting staff should be placed under the control of single person on the shop floor.

Problem : Lack of accountability

Solution : both the sections should be equally responsible for the dispatch of wagons.

At present only the fitting section is responsible.

Problem : High downtime of EOT cranes

Solution :

• Recruiting/deputing dedicated electrical staff for the maintenance of EOT cranes.

• System should be setup to phase out old EOT cranes and procurements of new cranes.

Problem : Lack of skill and leadership in the supervisory staff.

• Supervisory staff not qualified enough.

• Lack of supervisory staff during day shifts.

Solution :

• Most of the supervisory staff should be booked during the day shift.

Problem : No proper arrangement of removal of scrap from the shop.

Solution :

• regular removal of scrap should be ensured.

• person concerned for removal of scrap should report to SSE

Problem : Unauthorized encroachments along the shop wall leading to space congestion

Solution :

These encroachments should be demolished . This will result in recovery of lot of space and also make the shop spacious and well ventilated.

Problem : Lack of proper lighting arrangements

Solution :

• Workers should be provided with miner’s helmet for working on under carriage.

• Sufficient lighting bulbs should be placed at proper locations.

Problem : Improper pits with low heights pedestals and congested bays

Solution : Construction of fixed pits with pedestals of proper height so that workers can work conveniently under the wagons.

Problem : Inefficient material movement between the wagon shop and B.S.T.

Solution : Better availability of trucks for transportation should be ensured.

Problems : Substandard main switches used for welding and EOT cranes:-

• The main switches supplied are blown off during use.

Solution : standard switches of rated wattage should be used.

Problem : Water logging during rainy season:-

• Arc welding not possible due to improper earthing logging during rainy season

Solution :

• Proper arrangement for drainage should be made

• Proper flooring and roofing should be done

Problem :

Damaging of welding cables

Solution :

• Dedicated equipment for each pits so that there is no need for long cables.

• Workers should be motivated to act more responsibly and take better care of equipments.

Problem : Lack of motivation in workers

Solution :

• Incentive scheme should be better monitored.

• More amenities for workers such as drinking water, gloves, ear plugs, helmets etc. should be provided.

Problem : Improper utilization of available space

Solution : the number of pits can be increased by making use of space available between WRS 3 and WRS 1

Problem : Procrastination in heavy repair wagons:-

• Tendency among the shop staff of delaying heavy repair work.

Solution :

The outturn position should be made pit specific so that any wagon occupying a pit for unusually long periods can be detected.

Problem : The under frame obtained after stripping operation is not fit for carrying out rebuilding and has to be reworked.

This increases time required by fitting people to rebuild the wagon again.

Solution : The supervisor should ensure that the stripping operation is of superior quality and doesn’t require rewoking.

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WRS 1WRS 2WRS 3

• Increasing number of pits-

The space available between WRS 1 and WRS 3should be utilized for increasing capacity.

• Relocation of pits-

• Increasing number of pits-

The space available between WRS 1 and WRS 3should be utilized for increasing capacity.

• Relocation of pits-