coating inspection reports

7/28/2019 Coating Inspection Reports

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I

PROJECT REPORT

ON

COMPARISON AND ANALYSIS OF

PRODUCTIVITY OF STRUCTURAL

SHOP OF ENGINEERING WORKSHOP

MANMAD, SABARMATHI, LALAGUDA

AND ARAKKONAM

by

BALIJA ASHOKCE/ Workshop/ AJJ

Southern RailwayAssisted by

K. Rajendran/ AWM/ EWS/ AJJM. Govindaraju/ SSE/ EWS/ AJJ

G. Ravichandran/ SE/ EWS/ AJJ


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II

Note

No.151/920608.05.09

Sub : Allotment of project : (course no. 9206)

The following topics are allotted for Project :

SN Names of Trainees(S/Sh)

Topic GuidingFaculty

1 Balija Ashok,

CE/W/SR

Comparison and Analysis of

Productivity of structural shop of

engineering workshop

Manmad,Sabarmathi,Lalaguda andArakkonam

SPB2

2 Praveen Kumar

Mishra,

CE/Wks/BB

Motivation and related issues of the

Civil Engineering Cadre (Group A,B

and Supervisors)-Survey and Study

SPB2

3 D R Shyam Sundar,

CTE/ECOR

Study of liner bite of rails under

different conditions with field datacollection analysis on SER,ECOR

SPT2

4 Subhodh KumarJindal,

CE/Cont/Central

Efficiency of training of Group C and Dstaff on Indian railways with special

emphasis on NWR and suggestions forimprovement

SPW

5 Anil kumar pandey,

CE/TMC/NWR

Mechanisation of Track Maintenance

on Indian Railways 2012 CaseStudy for improvements

DN

6 Ravi Mohan Sharma,CTE/TMC/NWR

Working conditions of track machinefield staff(A study on NCR and NR) and

suggestions for improvements

PTM

7 Gopal Khairwar,

CE/TM/Hubli/SWR

Site constraints in construction of

limited height subway including

comparing methods of construction

SPB1

8 Rajesh Arora,

CPDE/WCR/JBP

Study and uses of accidents on

Unmanned level crossings in WCR andremedial measures

SPT1

9 Anurag Kumar

Sachan,

CE/G/WR

Engineering and operational aspects

involved in the work of remodeling of

ADI yard and its impact A case study

SPP

10 Vijay Kitke,

CGE/SCR

Study of liner bite of rails under

different conditions with field data

collection analysis on CR and SCR

SPT2


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1

ARAKKONAM ENGINEERING WORKSHOP

Work shop location : Arakkonam (Rural)Southern Railway

Work shop Established on : 1905 Main Products : Riveted type girders

Welded type girders,

PPF Shelters and FOBSteel Channel Sleepers

Dip lorry, Push Trolley, Motor Trolley, Glued

Joint, LB Gate,

Points & Crossings Assemblies, SEJ

Number of Staffs : 1082 Age Profile of the Staff : 55 Years (avg) Total Tonnage during the

Year 08-09 : 4338.715 MT/Year

Equated Unit : 5028.527 / YearSTRUCTURAL SHOP

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

after augmentation of infrastructure


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2

OUT TURN FOR THE YEAR 2008-09

Sl No Name of the ShopAchieved During the Year

2008-09 (MT)

1 Machine Shop 7.86

2 Foundry 406.81

3 Fitter 332.72

4 Signal Fitter 387.28

5 Structural

Girders 634.54

Light Structural 298.13

6 Glued Joint 215.65

7 Tinker 6.82

8 Millwright 44.24

9 Pts & Xings 1356.51

10 Blacksmith 656.30

TOTAL 4346.58


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3

7.86

4

332

38

298.

215.65

6.82

44.24

0.00

200.00

400.00

Machine Shop

Foundry

Fitter

Signal Fitter

Girders

Light Structural

Glued Joint

Tinker

Millwright

Pts & Xings

Blacksmith

Production-Shopwise


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4

OUT TURN OF STRUCTURAL SHOP FOR THE YEAR 2008-09

Sl No Name of the Shop

Achieved During

the Year 2008-09(MT)

1 Structural shop

a) Girders 634.54

b) Light Structural 298.13

TOTAL 932.67


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5

FLOW LINE PROCESS OF ARAKKONAM ENGINEERING WORKSHOP

`

Stud Drawin s

Tem latin

Tack Weldin

Cuttin & Drillin

Initial Assembl

Final Weldin - SAW

Markin

Riveting

Final Assembly

Inspection

Des atch


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6

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

No.of staffOut turn for

year 2008-09Sl.

No.Description

Sup. Tech. Total MT EQ.U

(A) (B) ( C ) (D) (E) (H) (I)

I DIRECT STAFF :

1 Foundry shop 5 136 141 406.8 285.2

2 Fitter shop 3 46 49 332.7 495.6

3 Signal Fitter shop 2 46 48 387.3 529.2

4 Structural shop 5 82 87 932.4 1054.9

5 Glued Joint Section 2 34 36 215.7 208.3

6 Tinker shop 1 22 23 6.8 68.7

7 Millwright shop 7 96 103 44.2 141.8

8 Points & Xings shop 5 78 83 1356.5 1202.8

9 Blacksmithy shop 5 117 122 656.3 1042.0

a Total :- 35 657 692 4338.7 5028.5

II INDIRECT STAFF :

1 Welding shop 3 72 75

2 Paint shop 1 27 28

3 P.C.O. Staff 28 9 37

4 Night Shift 1 0 1

5 Tool Room 1 0 1

b Total Indirect Staff :- 34 108 142

c Staff diverted to FBW 0 37 37

d TOTAL STAFF ( a+b-c) 69 728 797

e

Staff for productivity calculation duly

deducting absenteeism, m/c breakdown &

power failure (in Hours)

7322

f Total Eq.Units achieved during the Year 5028.5


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7

g Total no. of days in the Year 365

h Actual no. of working days in the Year 292

DescriptionAverage upto

the Year

Productivity of EWS/AJJ in Equated

Units/man/month0.9

PRODUCTIVITY OF STRUCTURAL SHOP

e

Staff for productivity calculation duly

deducting absenteeism,m/c breakdown &

power failure

1180

f Total Eq.Units achieved during the Year 1054.893

g Total no. of days in the Year 365

h Actual no. of working days in the Year 292

Description Average upto the Year

Productivity of Structural shop in Equated

Units/man/month1.1


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8

ACTIVITIES OF GIRDER FABRICATION IN ARAKKONAM

SAW ON OPEN WEB GIRDER COMPONENT (VERTICAL)

DP TEST ON OPEN WEB GIRDER COMPONENT (VERTICAL)


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9

SURFACE DEFECT IDENDIFIED BY DP TEST

OPEN WEB GIRDER ASSEMBLY


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10

METALIZED DECK STEEL GIRDER

ASSEMBLY OF S HALLO W TYPE GIRDER


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11

LAYOUT OF STRUCTURAL SHOP


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12

LALLAGUDA ENGINEERING WORKSHOP

Work shop location : Lallaguda(Urban)secunderabad

South Central Railway

Workshop Established : 1964 Main Products : Rivetted type girder

Welded type girders up to 30m Span

Fish belly type Rivetted GirderGlued joints 52Kg& 60 Kg (G3 L)FOB, Steel Channel Sleepers

Rail dolleys, Diplorry, Motor Trolley.

Number of Staffs : 220 Age Profile of the Staff : 40-45 Years Total Tonnage During the

Year 08-09 : 2436.18 MT/ Year

Equated Unit : 1403.6 /YearSTRUCTURAL SHOP

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

augmentation of infrastructures


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13


Sl No Name of the ShopAchieved

During the Year

2008-09

1 Structural

a)Riveted Girder in MT 129.10

b) Welded girder in MT 71.10

2 Others (P.Way items) in MT 97.04

3 Glued Joint in MT (6291 Nos) 2138.94

Total Tonnage in MT 2436.18

OUT TURN 2008-09 - LALLAGUDA

0.00

500.00

1000.00

1500.00

2000.00

2500.00

a)Riveted

Girder in MT

b) Welded

girder in MT

Others (P.Way

items) in MT

Glued Joint in

MT (6291Nos)

Production - Shop wise

AchievedMT


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14



During the Year2008-09

1 Structural

a)Riveted Girder in MT 129.1

b) Welded girder in MT 77.1

Total (in MT) 200.2


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15

FLOW LINE PROCESS OF LALLAGUDA ENGINEERING WORK SHOP

`

Receipt of work orders

Studying of drawings

Placing of indents & procurement through stores

Templating

Inspection of materials

RDSO/CONSIGNEE inspection

Fabrication

Despatch of finished products


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16

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

No.of staffOut turn for year

2008-09Sl.

No.Description


1 Structural shop 5 111 116 200.2 232.23

2 Glued Joint Section 2 87 89 2138.94 1171.37

3 Mechanical Shop 1 11 12 97.0 Nil

Total :- 8 209 217 2436.18 1403.6

Total Eq. Units achieved during the Year 1403.6 /Yr

Total Tonnage achieved during the Year 2436.18/ Yr


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17

ACTIVITIES OF GIRDER FABRICATION IN LALLAGUDA

JIG FOR SAW

COMPONENTS FOR STEEL GIRDERS


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18

I SECTION FOR FISHBELLY GIRDER

JIG FOR I FORMING


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19

DRILLING OF S TEEL PLATE GIRDERS


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21

MANMAD ENGINEERING WORKSHOP

Work shop location : Manmad(Urban),Central Railway.

Work Established : 1906 Products : Open web Girder

Welded type girder,Truss, Glued jointsJoggled Fish plate

Number of Staffs : 878 Age Profile of the Staff : 45-55 Years Total Tonnage During the

Year 08-09 : 7129.36 MT

Equated Unit : 12063.35/YearSTRUCTURAL SHOP

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

after augmentation of infrastructures


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22


Sl No Name of the Shop

AchievedDuring the

Year 2008-09(MT)

1 Structural Girders 2803.82

2 Light Structural 389.74

3 Others* 3935.80

TOTAL 7129.36

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

OUT TURN 2008-09 - MANMAD

0.00

500.00

1000.00

1500.00

2000.00

2500.00

3000.00

3500.00

4000.00

4500.00

Structural Girders Light Structural Others*

Production - Shop wise

AchievedMT


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23


Sl No Name of the ShopAchieved Duringthe Year 2008-09

(MT)

1 Structural Girders 2803.82

2 Light Structural 389.74

TOTAL 3193.56


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24

FLOW LINE PROCESS OF MANMAD ENGINEERING WORK SHOP

`

Templating

Cutting

Initial assembly

Tack assembly

Initial assembl

Riveting

Jig

Final assembly


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25

PRODUCTIVITY OF ENGINEERING WORKSHOPS / MANMAD FOR THE YEAR2008-09


2008-09Sl.

No.Description


1 Structural shop 37 457 494 3193.56 4051.55

2 Others 41 343 384 3935.80 8011.80

Total :- 78 800 878 7129.36 12063.35

Total Eq.Units achieved during the Year 12063.35

Total Tonnage achieved during the Year (in MT) 7129.36


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26

ACTIVITIES OF GIRDER FABRICATION IN MANMAD

PICTORIAL REPRESENTATION OF PLATE STRAIGHTENING MACHINE

DYE PENETRANT TEST OF FILLET WELD


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27

DRILLING OF COMPONENTS USING FERRULES

HIGH S PEED DUAL NOZZLE PUG CUTTING MACHINE


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PICTORIAL VIEW OF STOCK YARD

INSPECTION OF FERRULES


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30

SABARMATHI ENGINEERING WORKSHOP

Work shop location : Sabarmathi(Urban),Near Ahamedabad

Western Railway.

Work Established : 1958 Products : Open web Girder

Welded type Girder

Fish Belly Girder

Number of Staffs : 656 Age Profile of the Staff : 35-50 Year Total Tonnage for the

Year 2008-09 : 6011.39 MT/Year

Equated Unit : 4742.35 /YearSTRUCTURAL SHOP

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

MT/Year after augmentation

of infrastructures


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31


Sl No Name of the ShopAchieved Duringthe Year 2008-09

(MT)

1 Structural

Open web girder 1343.39

Riveted Plate Girder 198.70

Welded Plate Girder 103.80

2 Glued Joint 3430.00

3 Steel Channel Sleeper 897.00

4 SEJ Set 38.50

TOTAL 6011.39

OUT TURN FOR THE YEAR 2008-09 - SABARMATHI

1343.39

198.70 103.80

3430.00

897.00

38.500.00

500.00

1000.00

1500.00

2000.00

2500.00

3000.00

3500.00

4000.00

Open web girder Riveted Plate Girder Welded Plate Girder Glued Joint Steel Channel Sleeper SEJ SetProduction - Shop wise

Achieved MT


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During the Year2008-09 (MT)

1 Structural

a) open web girder 1343.39

b) Riveted Plate Girder 198.70

c) Welded Plate Girder 103.80

TOTAL 1645.89


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FLOW LINE PROCESS OF SABARMATI ENGINEERING WORK S HOP

`

Templating

Cutting

Initial assembly

Fitting

Drilling

Final assembly

Riveting


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34

PRODUCTIVITY OF ENGINEERING WORKSHOPS / SABARMATI FOR THEYEAR 2008-09


2008-09Sl.

No.Description

Sup. Tech. Total MT EQ.U1 Structural shop 21 355 376 1645.89 2072.60

2 Others 25 255 280 4365.50 2669.75

Total :- 46 610 656 6011.39 4742.35

Total Eq.Units achieved during the Year 4742.35

Total Tonnage achieved during the Year(in MT)

6011.39


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ACTIVITIES OF GIRDER FABRICATION IN SABARMATHI

PICTORIAL REPRESENTATION OF I SECTION FOR PLATE GIRDERS

PICTORIAL REPRESENTATION OF OPEN WEB GIRDER


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36

SUBMERGED ARC WELDING JIG FOR STEEL PLATE GIRDERS

SUBMERGED ARC WELDING JIG FOR STEEL PLATE GIRDERS HAVINGBOTH SIDES TRACK FOR DOING FILLET WELD


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37

PICTORIAL REPRESENTATION OF DRILLING OF COMPONENT ON BOTH

TRACKS

PICTORIAL REPRESENTATION OF FORMING I-SECTION FOR FISH BELLY

GIRDER


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COMPARATIVE STATEMENT OF STRUCTURAL SHOP OF ALL

WORKSHOPS 2008-09

Description AJJ LGD MMR SBI

Present Production of Structural

shop in MT

634.25 200.20 2803.82 1645.89

Proposed Production of Structural

shop in MT1200.00 360.00 3600.00 2250.00

COMPARITIVE CHART OF WORKSHOPS

634.25

200.20

2803.82

1645.89

1200.00

360.00

3600.00

2250.00

0.00

500.00

1000.00

1500.00

2000.00

2500.00

3000.00

3500.00

4000.00

AJJ LGD MMR SBI

WORKSHOP UNIT

inMT

Present Production Proposed Production

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

Name ofthe Shop

Achieved During the Year 2008-09 (MT)

ARAKKONAM LALLAGUDA MANMAD SABARMATHI

TOTAL 4346.58 2470.35 7129.36 1645.89


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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 essentialfor 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 ofother shop staff, present production of 50 T / month will beincreased 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 ofDrilling, and more numbers of Drilling Machines along with 17

numbers ofEOT 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. Onemore additional shed may be erected along with second bay to

increase the production. However final assembly yard requiresimprovement.

It is proposed to increase the production of girders from 1645.89MT/Year to 2250 MT/ Year with in 3 years.


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RECOMMENDATIONS

1.Works Manager and Asst. Works Managers should be trainedin Basic Principles of Design of Steel Structures inIRICEN/PUNE.

2.Annual SEMINAR CUM WORKSHOP to be conducted inrotation on ALL-INDIA basis for AWM/ WM/ Dy CES for

dissemination of knowledge and what is going in different shopsof Indian Railways.

3.Supervisors and other critical staff such as welders, gas cuttersshould be given periodical training in reputed institutions other

than railways also for absorbing latest technology in respective

fields.

$ $ $

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