SOUTH EAST CENTRAL

RAILWAY

Hand out

WAGON REPAIR SHOP

Raipur

Shri D. Govind Kumar

Principal Chief Mechanical Engineer

SEC Railway

On: 19/12/2019

2019

Wagon Repair Shop Raipur

Wagon Repair Shop Raipur was established in 1968 as combined Carriage

& Wagon Repair Workshop at Raipur, now the capital city of Chhattisgarh

state. It was initially built to cater to Bengal Nagpur Railways which became

SE Railway and subsequently, after trifurcation, SEC Railway of today.

With time, coaching feed was gradually shifted to KGPW & MCSW and

Raipur workshop became exclusively a Wagon Repair Shop with an annual

target outturn of 6000 Wagons for 2019-20.

Raipur workshop is located in the heartland of the coal and other mineral

rich belt of Chhattisgarh and adjoining areas of Orissa. This location gives it

tremendous opportunity to contribute to freight operations of SECR. In fact,

Wagon Repair Shop Raipur also play vital role in making SECR the highest

loading zones in Indian Railways.

Wagon Repair Shop Raipur attends to almost all types of good stock

except tank wagons for POH and NPOH apart from undertaking RSP and

other specialized works such as midlife rehabilitation of wagon, retro

fitment of twin pipe air brake system and retro fitment of BOXN into

BOXNHS. Wagon Repair Shop Raipur has been consistently surpassing

the outturn target set by Railway Board for many years in spite of working

with low manpower ratio. Working on CLW pattern of incentive scheme, the

productivity of workshop is 42-44% in terms of incentive earning. Wagon

Repair Shop Raipur has completed 50 years in 2018. To meet the need for

modernization of infrastructure and M&Ps to adjust technology & increase

productivity a project for augmenting capacity to 6000 Wagons has been

sanctioned, work of which is now in progress.

Milestones

Wagon Repair Shop, Raipur scaled many milestones, attaining special distinction on

IR through its unstinting efforts, innovative culture and immense caliber. Few such

milestones are:

First Modern Workshop on Indian Railways dedicated to wagon Repair.

First workshop to have wagon over wagon movement and traverses since its inception

with less operation.

First Workshop in Indian Railways in turning out one Formation of BOXNR

(Stainless Steel) Wagons.

Pioneer workshop in Indian Railways to convert BOXN wagons to BOXNEL

extreme axle load wagons i.e. 20.3T to 25T.

First Workshop to develop repair facilities for High Capacity Draft Gears (RF-361

& Mark-50).

Acquired prestigious ISO–9001 version Certification for Quality Management

System since April 2005.

First workshop to convert BOXN to BOXN-UG wagon. 10 Rakes of BOXN-UG

turned out.

First workshop to start overhauling of CTRB in Indian Railways.

IOH of ICF wheel sets was started in May’09 to meet the challenge of IOH

requirements of ICF coaches on SECR.

First workshop to retrofit twin pipe arrangement on BVZI wagons.

First workshop to implement WISE and to have the coveted status of being the

pilot of pilots in WISE implementation.

First workshop to implement restructuring orders and promote 351 staff and

implement a productivity improvement of 6 %.

Introduction of single batch salary payment through NEFT.

Pilot of the pilot workshop for implementation of WISE-II.

Salient features of WRS/Raipur

Established in : Feb 1968

Bounded area : 550 Acres

Covered area : 10 Acres.

Track length : 27.35 Kms.

Max. Demand of power : 850 KVA

Outturn Target : 500 Wagons per month(w.e.f. April’19)

Avg. Salary bill : 8.84 crore/Month

Consumption of steel per month : 316.95 MT/ Month

Average consumption of Electrical power: 106895 KWH/Month

Factory License No.- 842/842/G-0/RPR/2M(I)

Consent to operate (Water)- Consent to operate has been obtained from CECB,

Raipur vide letter no. 205/TS/CECB/2019 dt. 06.04.2019 which is valid upto

31.07.2021.

Consent to operate (Air)- Consent to operate has been obtained from CECB, Raipur

vide letter no. 205/TS/CECB/2019 dt. 06.04.2019 which is valid upto 31.07.2021.

Registration No.- Udyam Aakanksha/Unit No. 11100405993440

Present activity of the workshop

Periodic overhauling (POH) of wagons & its components.

Rehabilitation of BOXN wagons.

Overhauling of BVZI wagons.

POH of diesel & electric locomotive wheels.

Retrofitment/Conversion of Single pipe brake system to twin pipe brake system.

Deposit Works of different PU & Privet units such as NTPC, NALCO, SAIL,

BALCO etc.

Organization Chart Of Wagon Repair Shop, Raipur

Chief Workshop Manager

(SAG)

Pradeep Kamle

Dy. CME (Admin)

(SG)

Dayanand Sahu

AEE

(JS)

P.V. Subbaiya

Dy. CME (POH)

(SG)

A. Banerjee

AWPO

(JS)

Smt. A. Patel

Dy. CMM/RWSS

(SG)

P. Sethi

Sr. AFA(W)

(S S )

S. G. Rao

AWM-I

(JS)

A. Meena

AFA

(JS)

(Vacant)

ac

AWM-II

(JS)

D. Majumdar

Factory Med. Officer

(JS)

S. Gajbhiye

Dy. CME - III

(JAG)

S.K.Verma

Performance parameters

(i) Outturn

S.N. Activity 2018-19 2018-19 (Upto Nov)

2019-20 (Upto Nov)

1 POH of wagons 4801 3411 3641

2 BOXN wheel set Overhauling 27039 17830 18805

3 Overhauling of CTRB 48739 31958 28731

(ii). Scrap disposal

S.N. Items Unit 2018-19 2018-19 (Upto Nov)

2019-20 (Upto Nov)

1 Ferrous MT 12313.83 6017.2 6622.51

2 STB MT 405 0.85 1.74

3 Non-Ferrous MT 1.6 180 138

4 Disposal of Cond. Wagons

Wagons 527 263 482

(iii) Incentive performance in last 3 years

Year % earned Load Lifted Per DW

Amount paid (in Rs.)

OT (in Hrs.)

OT paid (In Rs.)

2016-17 42.94 % 276.64 42871214/- Nil Nil

2017-18 43.55 % 254.21 45357930/- Nil Nil

2018-19 41.22 % 281.65 41156009/- Nil Nil

(iv) NTXR Rejections

Year Total cases Cases per month

2016-17 Nil Nil

2017-18 Nil Nil

2018-19 62* 5.16

2019-20 (till Nov) Nil Nil

*Due to non-availability of BMBC breather valve mesh filter. (v) 90 days sick marking

Year Total cases Cases per month

2016-17 39 3.25

2017-18 21 1.75

2018-19 36 3.00

(vi) Average POH cycle time

Year Average Cycle time

2016-17 09.11 days

2017-18 08.51 days

2018-19 09.31 days

2019-20 (till Nov) 07.44 days

(vii) Average wagon holding

Year Wagon Holding in VU

2016-17 376

2017-18 419

2018-19 419

2019-20 (till Nov) 454

Certifications-

ISO Standard Valid upto

Quality ISO 9001:2015 08.03.2022

Environment ISO 14001:2015 08.03.2022

Occupational Health and Safety ISO 45001:2018 08.03.2022

Energy ISO 50001:2011 09.08.2020

Welding ISO:3834-2 13.04.2021

GreenCo Bronze March 2021

Housekeeping 5S April 2021

Staff deployment broadly based on major activities performed

Activity Staff sanctioned Staff Deployed as on 01.12.2019

Body Repair 660 597

Wheel & Bearing Repair 151 128

Bogie Repair 190 188

Brake Gear Repair 125 123

CBC Repair 80 80

Painting of wagons 34 32

Machine & Smithy 35 25

Others 42 42

Total 1317 1215

Shop staff strength as on 01.12.19

Category Sanction Actual Vacancy

Gazetted 09 09 000

Mechanical 1515+02(W/C Post) 1403 114

Ministerial Staff 82 67 15

IT/Drawing/CMS 15 12 03

Electrical 31 25 06

RWSS Store 70 53 17

Accounts 26 13 13

RPF 27 21 07

TOTAL 1777 1603 175

Retirement profile of shop staff for 2019-20

Ap

r

Ma

y

Ju

n

Ju

l

Au

g

Se

p

Oct

No

v

De

c

Ja

n

Feb

Ma

r

Tota

l

5 2 8 5 2 2 4 1 2 5 - 3 39

Indents Placed For Recruitment Of Staff

S.N. Designation P.B. G.P. No. of Post

Quota Date of Indent Placed- Online

1. Junior Eng.(W/s) 9300-34800 4200 09 DR 15.02.2018

2. Junior Eng. (IT) 9300-34800 4200 01 DR 15.02.2018

3. Junior Eng. (Drawing)

9300-34800 4200 01 DR 22.12.2018

4. Canteen Manager

9300-34800 2000 01 DR 13.02.2019

5. Jr. Clerk 5200-20200 1900 02 DR 13.02.2019

6. Tech-III 5200-20200 1900 09 DR 12.01.2019

7. Helper 5200-20200 1800 100 DR 13.02.2019

Creation of post- Revenue- proposal of 379 posts has been sent to HQ.

SSE JE Sr. Tech Tech-I Tech-II Tech-III Total

16 08 92 181 29 53 379

Budget Grant 2019-20-(WMS)

S.No. DEBIT CREDIT

Description Amount in , 000 of Rs.

Description Amount in , 000 of Rs.

1 Payment to shop labour 902000 Issue to works nil

2 Drawal of materials from stores

1302520 Issues to Store Suspense

250000

3 Procurement of materials by direct purchase

110422

Revenue Works

2085709

4 Materials by adjustment 45000 RSP -Railways nil

5 Outlay for Pink Book charged to WMS

nil RSP-non Railways

45000

6 Miscellaneous 139552 Special repair 00

7 Gross Debit 2499494 Gross Credit 2380709

8 Deduct Issue 250000 Deduct Issue 250000

9 Net Debit 2201552 Net Credit 2130709

Budget Grant 2019-20-Revenue

S.No. Demand No.

Description Spending Limit in,000 of Rs.

1 A General Superintendence and Services. 217267

2 D Repairs and Maintenance of Carriages and Wagons.

2173215

3 E Repairs and Maintenance of Plant and Equipment.

36634

4 J Staff Welfare and Amenities. 30539

5 K Miscellaneous Working Expenses. 7023

6 L Provident Fund, Pension and other retirement benefits.

338429

TOTAL 2803107

Safety training of staff at BTC:

S. N. Course 2018-19 2017-18 2016-17

1 Three days safety module training for regular staff got promotion

249 354 137

2 Three days safety module training for newly appointed staff

126 00 14

3 Safety training for contractor staff 201 82 47

Total 576 436 198

Training of ACT apprentice

Year Trade

Total Welder Fitter Machinist & Turner

Electrician Motor Mechanic

2015 48 64 7 9 2 130

2016 36 67 6 9 3 121

2017 15 15 03 01 03 37

2018 66 52 3 5 0 126

Achievements:

1. 11.14% increase in outturn compared to Last year. 2. Industry 4.0 implemented on 8 out of 10 machines. 3. Biometric Gate Attendance System implemented. 4. Lowest IOD cases over a period of last 9 years resulting in loss of 413 man days.

Also in 2018, lowest number of work days lost due to injury per 100 workmen since 2010.

5. Reduction in wagons detaining for more than 30 days from 120 last year to 39. 6. Plantation of 19000 trees done inside WRS. 7. Three seminars have been organized for all the workshops of IR in Knowledge centre

on Industrial safety. Other activity/Innovation done-

(A) Installation of roof mounted 1MW Solar PV system.

(B) Online Requisition of Materials: Requisition of stock as well as non stock item is

being initiated in online mode of iMMIS and being submitted to store for further

course of action w.e.f. 13.07.2019

(C) UMID Registration: Registration, Approval and Card generation process of 1525

staffs of WRS/R has been done.

(D) Medical Camp in the workshop premises: Health Check up Camp was organized

by WRS Raipur from 18/02/2019 to 23/02/2019 and total 1474 staffs were covered.

(E) Disaster Management Mock Drill: Demonstration on Disaster Management Mock

Drill conducted on 12.04.2019.

Innovations done in 2019-20:

a)Wagon condemnation software was developed for online processing of condemnation of wagons in the month of April’19.

b) Integrated BMBC test bench was innovated for testing of APM and brake cylinder of BMBS in the month of June’19.

c) Surface flushed type Repairing stand for assembly & disassembly of BMBC

d) Elevated type Repairing stand for

assembly & disassembly of BMBC e) Heavy repair stand for BMBC

Face lifting &System improvement

(a) Garden in front of Admin Building

(b) Epoxy flooring inside workshop

(c) Construction of false ceiling in Admin. Building

(d) Provision of Modular furniture to staff

(e) New Ambulance service (f) Face-lifting of canteen

(g) Make in India Logo (h) Glow sign board on Admin Building

(i) Flooring in Admin Building

(j) Automated Baker Gauge for checking CTRB’s cup and

Cone

(k) Floor mounted JIB Crane of 1 Ton capacity

(l) CNC Vertical Turning Lathe Machine

Action plan for Increase in outturn of POH target for the year 2019-20

There is shortfall of approximate 51000 Man hours for achieving target of 500 wagons/month. Efforts are being made to generate equivalent Man hours by outsourcing under revenue as well as Rolling Stock programme. Similarly, additional facilities required to handle wagons, M&P, material, budget etc. needed for additional outturn have also been planned as given below- (A) Planning for infrastructure facility- Present infrastructure is inadequate for POH of 500 wagons/month. Augmentation work under PH-42 sanctioned in 2016-17 for which contract awarded with completion period of 24 months. However, works which firm is impressed upon to prioritize following would help to create additional space for attending wagons-

Construction of Cantilever Shed Flooring requirements Renovation of Smithy Shop and laying of track inside. Construction of CTRB section Replacement of Roof sheets of existing shops

Proposals for developing following infrastructural facilities have also been initiated which is awaiting sanction. It would be helpful till facilities planned under augmentation project are in place.

PWP proposal for inclusion in umbrella work of 16.34 Cr.

Automation proposal for inclusion in umbrella work of 10 Cr. (B) M&P Planning 1-Covered under project- Following M&P have been planned for procurement on priority.

EOT Cranes 10T Platform Truck Road Mobile Crane Truck FLT

2-Covered under project-Supply of following M&P is planned to be synchronized with construction of shed.

CNC portal wheel lathe CNC VTL-commissioned on 31.05.2019, PTC on 25.07.2019. EOT Cranes 20 T, 5T, 3 T. Motorized capstan Winch. Rotary Screw Compressor.

3-CTRB cleaning plant is being proposed under umbrella work for automation.

(C) Resources through outsourcing-

Outsourcing of following non-core activities has been done in the workshop to release

technical staff -

1. Canteen outsourcing. 2. Material Transportation.

3. Pushing of bogie and wheels sets and cleaning of bogies by jet cleaning machine at

WRS/R.

4. Stripping of panel and floor for 300 wagons has been started. 5. Stripping Fitting and Welding of 400 BOXN wagons.

6. Heavy repair of 750 Bogies. 7. Store purchase of items earlier manufactured regularly in fitting, Machine and Smithy

Shop. 8. Heavy repair work of other wagons. 9. Flap door repairs.

10. Outsourcing of assistant to CMS, 11. Bearing refurbishment. 12. Draft gear reconditioning 13. BMBC overhauling. 14. Handling of AR, Brake cylinder, DV, SAB, AC, DC etc 15. Hiring of FLT.

(D) Material planning

EAC has been sanctioned as per target of 500 wagons/month.

(E) Budget

WMS is enhanced as per proposed target of 500 wagons per month. (F) Manpower planning

Indents have been submitted to CPO office.

Proposal for Creation of 355 posts of artisan and 24 Supervisors has been initiated and sent to HQ.

(G) Long term contracts in place and planned

Rehabilitation of 1300 BOXN wagons and 334 BOXNR wagons in BMY would help workshop in meeting outturn by rehabilitation of wagons due for POH.

Heavy repair of BOXN wagon has been planned to be done through outsourcing at WRC/BMY or oil siding area in WRS for 1000 wagons.

Assistance required:

1. Early completion of augmentation project for 500 wagons and nominations of Engineering officials to monitor the work.

2. Repair procedure of centre sill crack of BRN 22.9 wagons needs to be issued by RDSO.

3. Additional fund for Medical Health Check up of workshop staff as per provision of

C.G. Factory Rules.

4. Sanction of manpower proposed for additional outturn.

5. Stock plus dues less than 5 months is 109. No improvement since last identified in

July’19 by PCMM (110).

6. Extreme slow pace of Augmentation Project.

7. Month wise IP not generated

April’19 23

May’19 15

June’19 21

July’19 6

August’19 4

September’19 9

October’19 9

November’19 9

8. Early supply of critical items-

S.N. Item EMC 2019-20

1 Adapter Narrow-jaw 3584

2 coupler body 407

3 Knuckle HT 1000

4 Yoke 370

5 Bogie center pivot bottom 245

6 POH kit for PU pad, Design-A 1137

7 Bearing piece assembly 1000

8 Cable assembly for hand brake-BMBS 57

9 Angle Cock 458

10 kit for DV 407