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eqaxsj ¼fcgkj½ 811214eqaxsj ¼fcgkj½ 811214eqaxsj ¼fcgkj½ 811214eqaxsj ¼fcgkj½ 811214 Locomotive Works, Eastern Railway

Jamalpur – 811214

Railway ¼jsyos½ 24000 BSNL ¼ch-,l-,u-,y½ 06344-243105 Fax ¼QSDl½ 06344-243205

D.O.No.F/CWM/37/MCDO Dated: 9.4.2012 Dear Shri Kumar

Sub: MCDO for the month of March 2012.

Review of Annual Performance

The year 2011-12 was a glorious year and apart from celebrating a series of functions to mark the 150 years of Jamalpur workshop marked by visit of many high officials notable being MM, many performance mile stones were set. A few important ones being,

a) Manufacturing of a diesel loco for the first time, which also happened to be first loco manufactured after 1923.

b) BEST EVER WAGON POH outturn (10% better than previous Best of

2007-08) and crossing the 400 p.m. barrier for the 1st time. c) BEST EVER WAGON manufacturing outturn. d) Emerging as the largest wagon manufacturing workshop of Railways.

Besides, an air show was carried out by Indian Army to mark the 150 years of Jamalpur workshop, creating a history of its own.

Out of 14 key performance indices, in 10, targets were either achieved or bettered (Sheet attached). Balance 4 areas consisted 2 from wagon manufacturing where supply failure crippled the progress and were beyond our control despite this, not only highest nos. of wagons were manufactured, but also, amongst all railway workshops, Jamalpur emerged as the largest one. Remaining 1 related to 20T crane manufacturing which is held up for materials. The last, wagon POH, annual feed (4921) was less than annual target (4980), not reckoning the wagons condemned out of total feed. Thus, overall, all performance parameters were in essence met.

,- ds- flUgk eq[; dkj[kkuk izcU/kd A. K. Sinha Chief Works Manager

- 2 -

ANNUAL PERFORMANCE SHEET OF 2011-12

Sl. No.

Items Target

2010-11 Achievement

of 2010-11 Target

2011-12 Achievement

of 2011-12 Remarks

1 Diesel Loco POH 72 80 66 81 Better than target. 1 loco (WDS6) manufactured for first time.

2 Wagon POH

(Including BOXN-R) 4440 4442 4980 4884

Less Feed. (Total feed 4921 only including wagon condemned).

3 140T Crane POH+MLR 5 7 6 6 Target Achieved.

4 20T Crane POH 3 3 3 3 Target Achieved.

5 Tower Car POH 12 12 12 12 Target Achieved.

6(a) BOXNR Mfg 240 350 420 232 Due to no supply of Side walls & End walls from trade @ 50% of Qty.

6(b) Rebuilding of Wagon 360 358 250 357 Better than target.

6 Total RSP Wagons 420 589

Better than target. (As per Bd’s letter no. 2011/M(W)/814/1 dt. 18.02.11, the combined target for Re-building & BOXNR is 420 Wagons only).

7 BLC Mfg 240 273 420 341

Due to late receipt of Draw bar components by 9 months (June’11 to Feb’12), No Underframe could be manufactured from April to June.

8 BVZI Mfg 120 102 15 15 Target Achieved.

9 BOXN HL Mfg 240 152 300 200

Production stopped due to non availability of Draft gears & Couplers (Railway Board supply items).

10 140T Crane Mfg 5 1 5 5 Target Achieved.

11 20T Crane Mfg 2 2 2 1 Manufacturing of 1 crane deferred to 2012-13 by HQ.

12 JMP Jack Mfg 120 124 120 120 Target Achieved.

13 ICF Bogie 120 156 200 239 Better than target.

14 ER Clips 240000 144175 74114 74114 Full qty. order complied.

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1. CELEBRATION OF 150 YEARS:

The series of functions for 150 years celebrations had started with “Shramdan” on 7th January’12 and concluded on 14th February’12 with a series of events (Given under) interspersed in between. Celebration of sesquicentennial day on 8th February’12 was graced by AM(ME), Shri R Vijaya Mohan. A special cover was released on this day by Department of Post, to commemorate the 150 years of workshop. Hon’ble MM, GM and AM(PU) were present during the closing ceremony on 14.02.12.

a) Sports Meet of Railway School/Inter College on 18.01.12. b) Blood Donation Camp on 21.01.12. c) 150 Years Run on 22.01.12. d) Kavi Sammelan on 24.01.12. e) Drama Competition from 27.01.12 to 30.01.12. f) Welding Competition from 30.01.12 to 03.02.12. g) Diesel Maintenance Quiz Competition on 31.01.12. h) Painting Competition for school children i) District Inter school debating competition j) Prabhat Pherry on 01.02.12. k) No Vehicle Day on 02.02.12 l) Marshal Arts Competition on 31.01.12 to 02.02.12. m) Cross Country on 05.02.12. n) Flagging off of 1st 140 T crane of last lot . o) Mashal Juloos on 08.02.12. p) Welding Seminar on 09.02.12 to 10.02.12. q) Cultural Programme on 09.02.12 to 12.02.12. r) Closing Ceremony on 14.02.12 – Chief Guest MM/Rly.Bd.

All the functions were grand success with blood donation camp attracting a record 74 donors, the highest in Munger Commissionery in recent times.

Event wise photographs of a few events are as under –

Shramdan Sports Meet

Blood Donation 150 Years’ Run

- 4 -

• Indian Army in a goodwill gesture organized an Air Show at Safiabad airstrip to commemorate 150 years of Jamalpur Workshop where its Faizabad unit displayed parasailing and Gaya unit displayed micro light flying which enthralled the spectators having MM and GM and other senior officers.

Parasailing by Indian Army Micro light aircraft fly past

by Indian Army

Kavi Sammelan Drama Competition

Welding Competition Quiz Competition

Visit of Hon’ble MM, GM, AM(PU) and CAO(Mech) on 14.02.2012

- 5 -

2. ANNUAL INSPECTION OF GM:

• On 21st February’12 GM along with other PHODs visited this workshop for Annual Inspection.

• 2300th Diesel Loco (No.13020 WDG3A/UDL) has been flagged off by GM/ER after POH on the day.

3. NOTABLE ACHIEVEMENTS/GOOD WORK DONE/SYSTEM IMPROVEM ENTS

DURING 2011-12:

• IREE-2011 – Jamalpur workshop represented Eastern Railway in the Exhibition held on 28th – 30th Sept’ 2011 at Pragati Maidan, New Delhi. Hon’ble Minister of Railways visited Eastern Railway’s stall and spent a considerable time.

Diesel Organization

• Jamalpur workshop has bagged order from RITES for m anufacturing and assembly of 3 WDS6 locos at the cost of �� 2,32,59,423.45 each. First of these locos has been despatched on 14.02.12. Furth er payment of ��2,32,59,423.45 has been received for manufacturing of the 2 nd loco i.e. Loco No.123.

• 81 Locomotives have been turned out against target of 66. There has been an improvement of 22.72%. This includes manufacturing of one WDS6 loco manufactured for RITES at a cost of Rs. 2.32 Crore.

Loco being flagged off by Hon’ble GM

Hon’ble MR, MM, EDs, foreign Visitors are at ER stall

- 6 -

• Cycle Time for POH & IOH has improved as compared to last year. In current financial year Cycle Time achieved is 34.84 & 25.98 as compared to 35.84 & 26.92 in 2010-11 in terms of Calendar Days and Working Days respectively. Cycle time for all types of repair has also improved and achieved as 33.64 & 24.91 as compared to 34.28 & 25.73 in last year in terms of Calendar Days and Working Days respectively.

• In 2011-12 total no of reported incidences were 41 only as compared to 43 in 2010-11.

• Significant increase in revenue earning from PSU i.e. 9.5 Crore as compared to 5.77 Crore in last year.

• Retro fitment of MBCS has been done on 10 Locomotives and cumulative figure of such modification is 24.

• Retro fitment of Panel mounted AB system has been done on 05 locomotives.

• Retro fitment of Up-Graded Compressor has been done on 04 locomotives.

• Separate Inspector’s Seat have been fitted in 27 locomotives for the foot plating official.

• Safety Guard for BP & FP Angle Cock have been fitted on 35 locomotives to avoid loco failure due to breakage of cock in case of cattle run-over or any other reason.

• Manufacturing of WDM3D type gear case started and 07 nos. have already been dispatched.

• Manufacturing of plate type cattle guard for WDM3A/WDG loco started and till now 35 nos. have been manufactured.

• 03 Locomotives have been converted from plain Bearing to Roller Bearing wheel.

• 04 Locomotives have been converted from Twin Discharge to Single Discharge TSC.

• 03 locomotives have been upgraded from Conventional to High Speed Truck.

• Spray painting of truck frame has been implemented. • Face lapping machine for cylinder head has been introduced. • Air Main Reservoir cleaning has been started by introducing separate

cleaning tank. • Tr. Motor Bearing cleaning plant has been introduced. • Shot Blasting Machine for cleaning of Cyl. Hd. Valves, springs etc. has

been introduced. • New Electrical Brazing Machine has been introduced to overcome

burning of cable insulation during Oxy-Brazing. • Honing Machine has been introduced to ensure concentricity of Main

Bearing bore. • Hot–Water Hydraulic plant has been introduced for hydraulic testing of

Engine block, Power pack etc. • Pneumatic operated Torque Wrench has been introduced for easy

fitment and removal of cylinder head stud. • Shock Pulse Analyser has been introduced to check the undue

vibration/shock of assembled Tr.Motor. • Computerised SFC recorder has been introduced to obtain exact SFC

value.

- 7 -

• 14th February’12 also marked the restarting of loco manufacturing after 1923 when MM flagged off the WDS6 loco (No.RITES-122), manufactured after a gap of 89 years.

Wagon Manufacturing

• Wagon manufacture by this workshop has increased considerably over years. The performance status is as under:

Year Wagon Manufactured 2007-08 128 2008-09 198 2009-10 350 2010-11 527

2011-12 556

• Best ever BLC Wagon manufacture achieved: 46 Nos. in March’12.

• ICF Bogie manufacture is one of the activity being tackled successfully by Jamalpur. Year wise performance is as under:

Year Wagon Manufactured 2008-09 16 2009-10 143 2010-11 156 2011-12 239

• Best ever ICF Bogie ( 23 Nos. ) manufactured in the month of April’11 & May’11.

• Training for welders – Training of welders had been organized at DLW for quality improvement. Further arrangement is being made to get training by Jadavpur University at Jamalpur itself.

RITES loco flagged off by Hon’ble MM on 14.02.2012

- 8 -

• Development of ICF bogie manipulator for enhanced w elding quality and safety at Shop (HMRS)

This is a complete in-house development. The benefits are as under:

1. Reduced dependencies on EOT cranes. 2. Reduction in man power requirement. 3. Down hand welding became easier means improvement in

quality. 4. Improved cost effectiveness as less man power needed.

Re-commissioning of nearly dead profile cutting mac hine at BLC

• One profile cutting machine lying unused in BST has been re-commissioned in GIF Part-II (BLC) using in-house resources. This has reduced manual cutting of plates for manufacturing small components leading to the following benefits:

1. Saving in man power as simultaneously it can cut with three torches improving productivity.

2. Superior quality.

Stores Depot

• Jamalpur Stores Depot was awarded the Best Depot Shield for three consecutive years i.e. 2008-09, 2009-10 and 2010-11.

• Web based MMIS has been implemented fully in this depot.

- 9 -

Savings in Electricity

• 5% savings earned over consumption (in unit) during April’11 to February’12 in comparison with the same period of 10-11.

Crane Organization

• All India Crane Seminar in September’11 held with live webcast and website launching for on line logging, and as a repository of Technical literature, manuals, guides etc.

• An open conference on maintenance of Gottwald design 140 T crane was organised on 29.04.11 & 30.04.11 at Jamalpur. RDSO’s officers, divisional officers from twelve along with their supervisors participated. Users of Cowans crane from Kota, Itarasi and New Katni also attended.

• This was followed by All India Crane seminar organised at Jamalpur

on 2nd & 3rd Sept’2011 in which 38 officers and 21 supervisors participated. Many Landmark decisions were taken. The Proceedings simultaneously posted in website (www.140t.weekly.com) . This has facilitated real time actions.

• Comments those have been received through website were promptly

addressed to and now it is serving as online forum for complaints/assistance logging and remedial action by shops.

Conference on 140 T Crane (Gottwald Design)

for Spares requirement and Repair requirement on 2 nd & 3rd September 2011

• Customer Care - 140T Crane : As per programme SEG visit for 140 T cranes

are being conducted regularly. This excludes the on call services that requires from our valued customers spread over Indian Railways.

View of the Crane Conference at Jamalpur on 2/3.09.2011

- 10 -

Wagon POH

• Best ever wagon POH outturn of 451 VUs in December’11 and for the first time workshop has sustained a monthly outturn of 400+ (Actuals: 407 for 2011-12, previous Best 370 for 2007-08).

• Wagon POH cycle time achieved to 3.6 days during 2011-12.

• 100% CBC are being dropped in POH wagons .

• 100% conversion in PU side bearer in high speed casnub bogies

• Improvement in Sick Marking within 90 days after POH : A Reducing trend

Year Sick Marking 2010-11 4.84% 2011-12 3.4%

• Improvement in CTRB Failure – During 2011-12 reported cases are of 13Nos. only which was 18 cases during 2010-11.

• QAP of wagon POH, wagon NPOH and Rebuilding has been prepared and followed.

• 12 Pairs new diesel wheel set (extra pool) has been generated by wheel shop for WDM3A.

• 6 Pairs diesel wheel set has been generated and supplied to newly

manufactured WDS6 Loco for RITES. • Dust free room for mounting of CTRB has been completed. • Digital weighing machine has been provided for checking the right quantity of

grease in CTRB • One cone cleaning machine has been modified in which K.oil is used instead

of water in wheel shop. • One gadget has been developed by WCS-II for operating the BOBR/BOBRN

bottom door with reducing valve arrangement and successfully used. • One SWTR has developed by WCS-II converting from A9 diesel loco valve

and successfully used.

- 11 -

Casnub bogie overhauling

• Work station module of working activated with 40 such stations.

• Break beam dropping 100%.

• Bush & bulb cotters are replaced 100%.

• All bogies are converted to 22.9T.

• PU pad fitted in all bogies.

• Gauges are available.

Grievance Redressal

• Staff grievance camps were organized regularly throughout the year. During the financial year a total of 184 grievances registered. Out of these 101 cases were redressed. Out of balance 83 cases 6 cases are related to HQ and 77 cases related to Engineering Deptt. are on various stage of compliance. Paucity of fund was a major bottleneck, which, partly has been overcome by in-house fabrication of doors and windows. This has strengthened the industrial peace.

Observation of cleanliness

• Special emphasis was given to cleanliness. All roun d cleaning drives,

maintenance drives of Greenery right from Workshop premises to colonies, Hospital, etc. were launched. The achievements are as under:

a) Generation of scraps through picking up from the shop floors and

disposal of old unused/unserviceable/obsolete materials.

b) Debris heaps demolished and cleared.

c) Dry leaves, bushes and shrubs were cut and disposed off.

d) Proper stacking of materials.

e) Unwanted local made tool boxes, goomties, almirahs scraped.

- 12 -

4. ASSISTANCE REQUIRED:

MATERIALS OF IMMEDIATE CONCERN:

Materials which have become constraints are indicated at Annexure 1 to 5 .

Further the extreme urgent materials are appended below for convenient appraisal–

Sl. No.

Requirement Area Description Status Remarks

1.

500 BOXN HL

Imported Couplers Requirement : 1000 Received : 18

These are Board free supply items. Received quantity exhausted. Outturn of BOXN HL has come to stand still since March’12. Urgent supply is required from Board.

2. Imported Draft Gears Requirement : 1000 Received : 18

3.

Diesel POH

Cylinder Liner PL No. 10124603

(1) Supplementary SPS,05-12-01-1025 dt.07.01.2012, Qty.280 DP 01.04.12 to 31.03.13. (2) Indent 19-10-5605-9-00729 dt:13.01.11, Qty. 800 on DMW/PTA

No Supply

4. Gasket at section, flexitallic, exh. manifold, large PL No.10171393

PO 09-10-1401-1-03611 dt:06.07.11, Qty. 435 on M/s. Starflex Sealing India (P) Ltd./MUMBAI

Material received on 25.01.12 & rejected.

5. Lever fulcrum pin with plain washer & flat split cotter PL No.11990806

(1) CST 05-10-10-1198 dt:08.10.10, Qty. 354, PD 01.08.11 to 31.07.12 (2) PC 19-11-1475 dt:10.08.11 TC 19-11-1475, Qty. 480, PD 01.08.12 to 31.07.13

No Supply

6. Set of Outgoing cables A, AA, F, FF (one each) PL No. 12992707

(1) Indent 19-09-5601-9-00684 dt:10.03.10, Qty.307 on DMW/PTA (2) CST 05-12-03-1317 dt:01.03.12, Qty. 377

(1) DP expired on 31.03.12 (2) PD 01.04.12 to 31.03.13

7.

Wagon POH

Coupler Body PL No.38135840

(1) 860 Nos. (out of 1023 Nos.) on P.O No. 21.08.1296.1.01044 dt:27.1.10 on M/S Jupiter Alloys Steel Ltd./Kol. DP- extended upto 31.3.12 Six way bill issued on 01.02.12 (2) 462 in out of 480 Nos. PO-21.11. 4001.1.04123 dt.23.08.11 on COS/CLW. DP up to 23.09.11 (3) PO-21.10.1274.1.04063 dt.17.08.11 for 355 out of 555 Nos. JMP Qty. M/s. Siena Engg. Pvt. Ltd. DP-2 to 12 months. (4) 222 Nos. P.O 21.11.4007.1. 01826 dt:16.2.12 M/S. Atul Engg. Udyog Agra, DP upto 28.3.13 (5) 148 Nos. P.O. 21.11.4007.1. 01825 dt:16.02.12 M/S. Siena Engg. Indore, DP up to 31.8.12

(1) 163 Nos. received. (2) 18 Nos. received. (3) 200 Nos. received. (4) & (5) Nil received.

8. ‘L’ type Composite Brake Block,

PL No.38145900

(1) 4229 nos 21.11.4114.1. 01654 dt 08.02.2012 M/s. Rane Brake DP-25.4.12 (2) 4229 nos. 21.11.4114.1.01655 dt.08.02.2112. on M/s. Industrial Laminates (3) 4229 21.11.4114.1.01660 dt.08.02.2012 M/s Hindustan Composite. Dp 25.04.2012. (4)1287 21.11.4114.1.01659 dt 08.02.2012 M/s Cemcon Dp 25.04.12. (5) 4229 21.11.4114.1.01658 dt. 08.02.2012 M/s Escorts Dp 25.04.2012.

(1) & (2) materials are under transit (3) 2000 Nos. received. Rest under transit. (4) Road permit issued. (5) Materials received fully.

- 13 -

9. BOXNR Side wall and End wall etc.

PO No.21.10.6036.1.141571 dtd.22.12.11, Qty. 175 Sets on M/s. Trident Auto Components Pvt. Ltd./Kanpur, DP-1st lot of 35 sets within 2 months & balance @ 35 sets per month.

Delivery expected in the last week of April’12.

10. HCC Bogie Mfg.

Components of Air spring Bogie (31 items)

(1) PO No.11/10/6031/1/41153 dated 30.03.12 on M/s. M. C. Mira/Kol (2) PO No.11/10/6060/1/41040 dated 30.01.12 on M/s. M. C. Mira/Kol

Supply awaited.

Diesel Organization Non-availability of Truck Frames, TSCs and other spares as indicated in Annexure – 1 has affected the POH Cycle time. Assistance is required in this regard.

Crane Organization

Structural Audit scheme of 09 Nos. (Over Aged Crane ) A draft structural audit scheme prepared by RDSO was received by JMPW for comments. Comments have already been sent to director/MP/RDSO. Finalized audit scheme from RDSO is still awaited. Special MLR of 09 Nos. Over Aged Crane As per CWE/HQ’s L/No- MR-466/MLR/140T Crane Kolkata dt. 17/21.02.2012 and instruction of HQ, estimate of special MLR of 09 Nos. over aged Crane has been prepared and shall be processed after RSP sanctioned by Railway Board as per demand of HQ/KKK vide L. No. MR-466/MLR/140T Crane Kolkata, dt.5/10th Jan’2012.

RSP Sanction 11 Nos. MLR Vide Dy. CME/HQ/ER/KKK’s L/No- MR-466/MLR 140T Crane dt. 11.01.2012. Railway Board has been requested to give RSP sanction of 11 Nos. of Gotwald design Crane which will likely to fall due for its MLR during the year 2012-13, 2013-14 & 2014-15.

RSP Proposal of 11 Items for POH/MLR

New acquisition 2012-13, RSP Proposal of 9 (for 140T) +2 (for 20T) =11 items to be used as unit exchange spares during POH/ MLR of 140T Crane, 20T Crane. Keeping in view reducing the cycle time of POH/MLR, the proposal has been vetted by local account on 23.12.2011 and the same was sent to HQ/KOAA on 10.01.12 for further process by Railway Board. Recently 07 items out of 11 items returned to JMP with observation. Clarification was sent to DY. CME (HQ) on 16.03.2012.

8mm Plate for HCC Bogie Mfg. received on 19.03.12. Supply of components of Air Spring Bogie (31 Items) is still awaited.

- 14 -

Special Issues of Attention

Tie up with Patna based hospital

For better treatment along with tackling of emergent needs, tie up with Patna based reputed hospital is a must. Concerned case file (No.H/ST/29/RS/Pvt Hos/2009) needs to be cleared at the earliest. Requirement of inspection of Patna based hospitals done by Jamalpur on 04.01.12 as per directives and Inspection report sent to CMD on 30.03.12.

Posting of Supervisors against RRB indents

Posting against RRB indents needs to be cleared urgently. Filling of DR quota vacancies of technical supervisors (JE & SSE) – Mech (Workshop) as given underneath will be of great help.

Position of RRB indents is as under -

Sl. No.

Panel Date Category Total Nos. in Panel

Total Reported

Shortfall

1. 17.02.11 SSE 12 5 7 2. 17.02.11 JE 1 1 - 3. 28.11.11 SSE 6 4 2 4. 28.11.11 JE 10 5 5

Total 29 15 14 (48%)

Nos. indented on RRBs to be increased considering the non compliance to the tune of almost 50%.

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- 15 -

6. MODERNIZATION OF JAMALPUR WORKSHOP:

THE STATUS

• Sanctioned vide P.B. item no-418 of 2008-09 on 03.04.2008. Detail estimate has been sanctioned on 10.5.10 by GM/ER vide estimate No 24/CAO/CON of 2010-11 under P.B no-527 of 2010-11. Total Estimated cost for modernization is � 117.46 Cr. The project cost break up is as under:

Civil : � 55.53 Cr. Mechanical : � 48.89 Cr. Electrical : � 13.04 Cr.

Scope of Work

Ext

ensi

on

of

She

d (m

2 )

Hea

vy

Dut

y F

loor

ing

(m 2 )

New

flo

orin

g (m

2 )

Nor

th

Ligh

t gl

ass

(m 2 )

Per

plex

S

heet

(m

2 )

Alu

min

um

She

et

(m 2 )

Pai

ntin

g (m

2 )

SS

E

Cha

mbe

r /B

uild

ing

(m

2)

Dra

in

repa

iring

(m

)

1 Wagon POH & Rebuilding 2000 6000 1000 670 1030 2000 6000 100 500 2 BST HMRS 2000 4000

300 100

3 Diesel POH Shop

5000

400 500 1200

250 400

4 Component manufacture & Repair shop

2000 3000 1000

4000 100

5 Crane POH & manufacturing* 3000 3000 1200 4000 250

6 Bogie fabrication shop (ICF & EMU) 400 300 600 2000 200

7 Trainee, Security communi-cation & Staff welfare

3830 2000 100 200 600 3000 1500 400

8 CMT/LAB

50 100 300

200 100 9 Store

4000 400 225 225 300 1000 200

Total Estt Qty 9000 28830 4400 1845 2355 6200 20000 2850 1750

* Heavy Duty road 2375 m2

CIVIL ENGG WORKS Item Ecological park

(m2) Conc Road

(m2) Cycle stand

(m2) Toilets (m2)

Drainage (m2)

Roof rep (m2)

Bitumin Road (m2)

Canteen (m2)

Modern of Bld (m2)

DI pipe (m)

Qty 1000 4000 500 833 2728 20000 20000 200 5000 1200m

• The Civil Engineering work is planned to be executed through two contracts.

i) Structural work at the estimate cost of � 40.96 Cr.

ii) Other civil work at the cost of � 9.84 Cr.

• Tender for structural work has been awarded on 18.11.10 & tender for other civil work on 25.11.10 to M/s. KEC- DELCO- DUTSON (JV) of Gurgaon, Haryana.

Status

• Construction work of road is on, already 900 meter is completed.

• Heavy duty flooring - 4800 m2 completed, progressing at Forge shop (200 m2 done).

• Renewal of roof sheets by aluminium sheet completed for 6000 m2.

• Renovation work of CMT lab has completed and of BTC is in progress.

• Concrete flooring is done over the level crossing near main entry inside the shop.

• Painting of shops - BBF completed, progressing at WCS, FS & BBF.

Financial Progress

Outlay 2011-12 Expenditure till March’12 Progress 5.6 Crores (RG) 4.0 Crores 71.43%

- 16 -

STATUS OF INDENTS FOR MODERNISATION

(Indents for items sanctioned under Mechanical estimate have been placed and are under different stages of procurement)

Sl. No. B.O's Total Nos.

of Items

Pen

ding

for

spec

ifica

tion

Under Process

Dro

p

Item

s

Finalised

Remarks

A/C

s

vetti

ng

pend

for

de

cisi

on

In

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d

WC

WC

HQ

Dy.

CM

M

/JM

P

P.O

R

elea

sed

1 Dy CME (Prod)

22 COFMOW 15 Dispensation 01 MTS 38 = Total

0 0 0 0 0 9 0 19 0 10

01 No. EOT Crane of capacity 40 ton is received on 27.01.12.

2 Dy CME (Wagon)

03 WRS 01 WS 04 = Total

0 0 0 0 0 0 0 4 0 0

3 Dy CME (Mfg)

06 TPT(Rd) 02 (TTS) 07 (New item) 04 D&G A/Cs 02 DSL Equip 01 DSL Infra 01 M&C Lab 23= Total

0 0 2 1 4 2 2 5 0 7

i) Universal tool and Drg office mod. have been clubbed in Estimate. ii) Reqn. for A.C. awaiting approval of CEE. iii) 03 Nos. mat. pickup van sanctioned in estimate, but Rly. Board approved only 02.

4 Dy CME (Crane)

10 (CRS) 02 (New Item) 12 = Total

0 0 0 0 0 6 0 5 1

5 Dy CME (Diesel)

20 DSL Equip 06 DSL Infra 26 = Total

0 0 0 0 6 2 0 6 10 2

6 Dy CCMT 26 0 0 0 0 1 0 0 11 7 7

7 Production Engineer 1 0 0 0 0 0 0 0 1 0

8 WPO 1 0 0 0 0 0 0 0 1 0

Total 131 0 0 2 1 11 19 2 52 18 26

Total Balance Items after dropped out items : 131-19 = 112

- 17 -

7. PERFORMANCE:

i) Diesel POH:

• The outturn of Diesel POH has been 07 locos against target of 5.5 locos for the month.

• The average cycle time for March’12 is 34.00 Calendar days and 24.78 Working days for all type of repairs.

Break-up of Diesel Outturn is as under:

POH - 05 POH/SR - 01 IOH - 01 ------ Total - 07

Achievement

Comparison of outturn with the previous year

Period 2010-11 2011-12 Target 72 66 Achievement 80 81 % Improvement in outturn over target

11.11 22.73

ii) POH of Wagons:

• Outturn of Wagon POH has been 426 VUs against the target of 443 in March’12.

Achievement


Period 2010-11 2011-12 Target 4440 4980 Achievement 4442 4884 Improvement in 9.95%

72 6680 81

0

50

100

2010-11 2011-12

Target

Achievement

4440

4980

4442

4884

4000

4200

4400

4600

4800

5000

5200

2010-11 2011-12

Target

Achievement

- 18 -

outturn over last year iii) BOXN-R Conversion:

• Outturn of BOXN-R has been Nil in March’12 because of the non availability of Side walls and End walls from trade (PO No.20/10/6036/1/41571 dated 22.12.11 on M/s. Trident Auto Components Pvt. Ltd., Kanpur, DP – 35 sets within 2 months, balance @ 35 sets per month. DP up to 30.06.12).

Dropping and Fitment of Draft Gears for POH wagons (2011-12)

Month APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR

Dropping & Fitment (Nos.)

426 415 462 430 484 518 399 500 512 508 502 682

Percentage 69.8 75.3 76.1 75.5 76.7 76.5 76.3 76 78 78 84 85

Cycle Time & Holding – Wagon POH

Outturn vs. Cycle time of BOXN-R

Period Outturn Av/Cycle Time (Working Days) April’11 20 8.0 May’11 3 14.6 June’11 8 13.9 July’11 12 10.0

August’11 15 15.6 September’11 35 9.1

October’11 30 9.1 November’11 30 9.1 December’11 28 9.4 January’12 30 9.3 February’12 21 9.6

March’12 Nil -

iv) Rebuilding of wagons:

Month 2010 -11 2011-12

Shop Holding Cycle Time

Shop Holding Cycle Time

Target Actual Target Actual APR

150

159.8 5.5

170

173.5 4.6 MAY 163.0 4.4 209.3 2.9 JUN 133.5 4.3 230.0 3.4 JUL 183.7 3.4 212.6 3.5 AUG 212.7 3.4 192.1 3.0 SEP 224.1 4.4 189.1 2.9 OCT 184.4 5.7 149.6 3.3 NOV 192.9 3.5 179.0 3.9 DEC 224.6 4.0 189.8 3.5 JAN 229.0 3.3 193.8 4.1 FEB 207.0 4.4 131.6 4.1 MAR 158.5 5.2 124.2 4.1

Average 189.43 181.2

- 19 -

• Rebuilding outturn has been 37 against target of 20.83 during March’12. The outturn achieved was 357 during 2011-12 surpassing the target by 42.8%.

Total Rebuilding:

• During 2011-12, Total Rebuilding (SS+MS) achieved is 589 against the target of 420. The outturn achieved is 40.23% higher than the target.

v) Fitment of Bogie mounted Brake System in wagons (BMBS)

• Quantity - 200 Nos. (Retrofitment of BMBS in Air Brake Wagons)

• Outturn achieved in March’12 is 24 wagons. The cumulative outturn

achieved is 97 during 2011-12. Prototype approval of RDSO was communicated in November’2011 (25.11.11) only.

vi) Manufacture of Jamalpur Jack:

• 15 Nos. of Jamalpur Jacks has been manufactured against the target

of 10. The cumulative outturn achieved is 120 and target of 2011-12 met.

vii) Manufacture of ER Clips:

• Outturn is Nil in March’12 as in hand order has been already complied

(In September’11) and no further order exists. For capacity utilization immediate orders are required. The outturn achieved during 2011-12 is 74114.

viii) Manufacture of 140 Ton Crane (5 Nos. Lot):

• 02 cranes (4th and 5th of 5 Nos. lot) i.e. Crane No.144027/Manmad/CR and 144028/Gangapur City/WCR have been manufactured in March’12, thus the manufacturing target of 5 achieved during 2011-12.

ix) Manufacture of 20 Ton Crane (Target is 2 for 20 11-12):

•••• No crane could be manufactured in March’12. However against the

target of 02, one crane (No.2001013) has already manufactured and despatched. Manufacturing of the 2nd crane has been re-scheduled in 2012-13 vide HQ’s letter No.MR-466/MLR/140T Crane dated 17/21.02.2012.

x) Manufacture of HCC Bogies:

Manufacturing of HCC Bogies is yet to be started for want of undernoted materials:

Item PO details Status Components of Air Spring – 31 items

i) PO No.11/10/6031/1/41153 dt.30.03.12 on M/s. M.C. Mira &

- 20 -

Co., Kolkata ii) PO No.11/10/6060/1/41040 dt.30.01.12 on M/s. M.C. Mira & Co., Kolkata with DP 4 to 6 months.

Supply awaited.

xi) Manufacture of DHTC: Ordered Qty. – 02 Nos.

• Work has been started for one after receiving of 2 sets of Power pack assembly, 2 sets of Underframe and 1 set of Superstructure against the order of 2 of each.

xii) Manufacture of BLC wagons:

• 46 Nos. of BLC wagons have been manufactured against the target of

35.


Period 2010-11 2011-12 Target 240 420 Achievement 273 341 Improvement in outturn over last year 24.91%

xiii) Manufacture of BOXN HL wagons:

•••• No BOXN HL wagons have been manufactured during the month due

to non availability of imported Couplers and Draft Gears.



xiv) Manufacture of BVZI wagons:

•••• Outturn is Nil as in hand order of 15 has been already complied (In

September’11) and no further order exists. Total Wagon Manufactured:

•••• During 2011-12 a total of 556 wagons (BLC-341 Nos, BOXNHL-200 Nos & BVZI-15 Nos) were manufactured while this figure was of 527 during 2010-11. This is the highest wagon manufactured figure against all odds. Had there been no constraint of free supply items and other items, full targeted quantity would had been achieved during 2011-12.

xv) Retrofitment of Twin pipe Brake system in BOXNH L/BCNHL/BVZI:

- 21 -

• Earlier material planning did not cover the same for 300 BOXN HL as was not included in the specification then. However for the next order of 500 Nos. lots, this has been included and will be complied.

xvi) Manufacture of ICF Bogie Frame:

• 17 Nos. of 13T ICF Bogie Frames have been manufactured against

target of 16.67 during the month. Achievement



Zonal Distribution of ICF Bogies being manufactured against RSP

Manufacture of 16-T ICF Bogies

Sl.

No. Indentor

Req. No. &

L.No. Dt.

Demand

Qty.

Dispatch

Qty.

Rest

Qty.

Comp.

Qty. Remarks

1

SME/HQ-II/ KKK

MR-5

/ 2007-0

8 R

SP V

ol-

I 03.6

.08

100 Set

ER 20 Set 20 Set Nil

08 Set Desp. to LLH on 20.06.11.



E.Cost Rly. 20 Set 20 Set Nil

06 Set

Complied in 2010-11 06 Set

08 Set

N.E.Rly 20 Set 08 Set 12 08 Set Desp. to CWM/NE

Rly./Gorakhpur,dt. 23.04.11

S.E.Rly 20 Set 20 Set Nil

08 Set


04 Set

N.F.Rly 20 Set 20 Set Nil

07 Set


06 Set

2

SME/HQ-II for

CWE/KKK

MR-5

/ 2009-1

0 R

SP V

ol-

I

14.1

0.0

9

70 Set

ER 20 Set

04 Set 16 04 Set Complied (4 Sets on

10.12.11, 8 Sets on

30.01.12 and 8 Sets on

25.02.12)

08 Set 08 08 Set

08 Set Nil 08 Set

ECR 10 Set 10 Set Nil

08 Set Complied (8 Sets on

25.03.11 and 2 Sets on

08.08.11) 02 Set

E. Coast Rly. 10 Set 10 Set Nil 04 Set


N.E.Rly 10 Set

S.E.Rly 10 Set 10 Set Nil 02 Set Complied in 2010-11

120

200

156

239

0

100

200

300

2010-11 2011-12

Target

Achievement

- 22 -

08 Set

N.F.Rly 10 Set 02 Set

Nil 02 Set

Complied in 2010-11 08 Set 08 Set

NB: Total despatched 1 48 Sets out of 170 Sets (Ordered Qty.) * SER - 13T Bogie Assly were despatched instead of 16T as demanded by SER.

Manufacture of 13-T ICF Bogies

Qty. On

order

RSP Detail Railways Demand

Qty. Dispatch

Qty. Rest Qty.

Comp. Qty. Remarks

180

Rly

.Bd.

L.N

o.20

10/M

(c)/

142/

2/N

.DLI

da

ted

14.0

7.10

ER 30 Set

07 23 07 Despatched to LLH on 30.01.12

08 15 15 Despatched to LLH on 22.03.12

08 07 23 Despatched to LLH on 03.04.12 ECR 20 Set ECoR 15 Set 08 07 08 Despatched to CRWS/Mancheswar on 17.10.11.

NCR 25 Set NER 5 Set 05 Nil 05 Despatched to Kashganj on 16.01.12.

NFR 50 Set 08 42 08 Despatched to CWM/Mechl. Workshop, Dibrugarh

on 22.11.11.

08 34 16 Despatched to CWM/Mechl. Workshop, Dibrugarh on 08.02.12

SER 35 Set

NB: Total despatched 52 Sets out of 180 Sets (Order ed Qty.)

xvii) POH/SR/MLR of 140 T Cranes:

• SR of Crane No.143003/SEE/ECR has been done in March’12. The target fulfilled achieving outturn of 6 during 2011-12.

xviii) POH/Retrofitment of 20 T Cranes:

• POH of Crane No.2001009/Dy.CMM/Jamalpur has been done in

March’12. The target fulfilled achieving outturn of 3 during 2011-12.

xix) POH of Tower Car:

• POH of Tower car No.003 M-IV/MGS and SR of Tower car No.779 M-III/SDAH have been done in March’12. The target fulfilled achieving outturn of 12 during 2011-12.

xx) Divisional Compliances:

Supply of Diesel Wheels

• 01 pair of WDM2C Diesel wheel set (For HWH) had been made ready as the Turning Machine (No.10626) is still (since 26.12.11) under break down (LTC) and no any Wheel Disc was available during March’12. However till date compliance (226 sets ) is ahead of the yearly target (180 sets ) i.e 25% better.

Outstanding Diesel Wheel Sets as on 01.04.12

Eastern Railway - 105 pairs (Including 62 pairs of Wide horn Wheel sets). E. C. Railway - 29 pairs (Including 24 pairs of Wide horn).

- 23 -

DV C3W2 (Freight)

• These are the repair and return items. Till date nothing has been received from the divisions hence compliance is void.

8. STATUS OF INCENTIVE PERFORMANCE:

Shop-Wise Incentive Earning (2011-12)

Shop APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MA R

BBF 35.18 34.50 45.50 46.22 46.40 45.91 38.92 40.54 30.56 19.51 40.80 35.09

BFS 32.38 41.09 6.47 -25.79 38.47 41.32 36.75 41.82 26.08 38.04 39.21 -21.61

BKS -42.64 -26.28 -55.29 -59.68 21.31 23.83 24.35 24.94 20.10 22.14 13.92 15.71

BSS & SS 38.55 40.19 37.83 39.77 40.70 39.33 40.18 24.94 43.15 39.03 39.86 44.21

BWF 26.27 14.59 23.16 -6.46 37.06 46.18 35.49 33.34 26.93 39.90 22.91 26.19

CRS 36.08 41.03 15.56 22.44 39.53 41.16 45.90 44.52 43.76 42.41 46.28 47.11

DCS 30.58 38.69 37.83 36.52 42.54 25.20 41.75 42.45 34.11 29.84 24.55 38.06

DSS 35.80 0.01 -52.01 1.44 26.60 36.44 39.71 44.58 43.98 48.39 45.05 45.25

FS 40.02 39.68 39.24 43.47 45.28 46.81 45.57 44.47 45.46 44.75 39.23 45.55

FTS/WCS (2) 15.54 39.29 39.21 38.34 30.53 38.29 41.39 37.03 43.74 22.41 19.73 15.89

GIF -51.39 36.44 24.36 27.69 -2.88 32.66 37.84 28.07 24.61 28.01 22.40 22.30

HTS 34.68 31.50 33.70 7.66 29.06 35.12 28.89 37.14 34.98 28.97 36.24 32.60

BST/HMRS 39.11 34.73 37.49 37.96 40.07 28.21 29.88 -17.98 35.01 33.51 34.28 32.41

MCTR 23.24 -1.59 -17.51 -0.02 10.42 16.36 18.57 22.69 20.19 7.86 15.30 15.23

MS & PMS 27.66 27.16 14.01 10.06 42.81 36.27 19.98 18.25 23.89 -13.49 -19.37 -26.62

MTS 30.67 32.13 35.85 34.52 36.02 34.58 35.02 38.39 36.48 46.13 37.71 40.73

RM/WCS (1) 38.52 42.30 42.36 41.82 42.62 42.65 39.54 45.15 43.70 42.98 42.04 38.57

SF 27.48 24.96 24.83 31.99 27.35 23.92 29.87 24.62 28.45 26.62 15.21 25.71

SMS 21.49 38.32 32.52 45.94 37.38 32.56 43.30 39.48 36.18 38.40 47.43 43.50

TTS 31.74 34.89 33.63 34.37 35.36 33.23 18.09 35.86 37.52 35.82 35.84 32.75

WLD 23.11 20.77 37.12 32.88 37.17 34.14 34.21 29.48 35.95 28.55 28.04 28.38

WS 23.55 40.07 33.17 29.33 35.82 29.97 28.94 41.66 32.16 26.23 20.99 28.74

ES & PAINT/ WRS-I 24.58 49.68 30.15 23.89 28.97 28.23 18.49 26.19 35.00 18.53 19.22 23.58

BRS/WRS-II 29.93 39.95 31.37 26.71 34.30 32.37 32.93 40.65 39.15 37.46 23.14 32.34

HSS/WRS-III 20.92 42.48 25.49 19.07 32.51 22.70 15.54 23.61 34.90 23.52 16.10 24.75

Total (Mech) 22.49 34.39 31.11 28.47 33.66 32.12 31 .26 29.40 35.76 28.98 25.75 27.86

Electrical 46.61 47.45 46.66 47.76 46.56 47.29 46.75 47.07 47.06 44.98 47.88 46.96

Grand Total 22.61 34.47 31.20 28.57 33.73 32.20 31. 36 29.49 35.81 29.05 25.84 27.94

Overall incentive performance of the workshop during March’12 is 27.94%

- 24 -

- 25 -

9. CUSTOMER CARE:-140T Crane

Apart from SEG team visits the undernoted attentions were also paid to the customers on their report:

CUSTOMER CARE BY CRANE CELL March’12 Sl. No.

CRANE No.

MFG./POH/ MLR/SR with date

Consignee Reporting date

Failure as Reported

Staff moved

on

Problem rectified on

1. 144025 Samastipur

Feb’2012 Sr. DME (C&W) Samastipur/ECR

02.03.12 For commissioning

02.03.12 Commissioned on 12.03.2012

2. 144021 Gondia

Dec’2010 Sr. DME Gondia/SECR

20.03.12 Oil level increasing in slewing gear box

20.03.12 31.03.12

10. TRAINING AND DEVELOPMENT:

For Crane Users

• As per the directives of Railway Board time to time training on Maintenance and Operation for 140 Ton new design cranes are being done at this end which excludes the consignees of the cranes those are turning out (During despatch) from the workshop either manufactured or duly POHed. A training on “Maintenance and Operation of 140 T Crane” organised in Feb’12 where 44 trainees participated from different divisions of Indian Railways.

Internal

•••• In-house trainings are imparted through BTC, PTS and Simulator to our work force for their upkeepment and to improve efficiency. Details are in Annexure – 21 .

11. ENERGY MANAGEMENT:

Following action has been taken in Jamalpur worksho p and colonies for energy conservation :-

Justified power regulation has been introduced to earn more benefit through energy conservation. Regular raids are being conducted to debar energy theft. In addition undernoted planning in force to conserve energy. i) Replacement of 40 W T/Lights and Incandescent lamps by T-5 (28W)

and CFL

Description Till March’11 2011-12 March Cumulative

CFL 8016 21 205 T-5 (28 W) 4440 10 204

- 26 -

ii) Replacement of 90 W Ceiling fans & Conventional Regulators by 60 W Ceiling fans and Electronic Regulators respectively

Description Till March’11

2011-12 March Cumulative

60 W Ceiling fan 200 09 96 Electronic Regulator 10 08 140

iii) Adequate capacitor banks have been provided in each sub-stations

both inside and outside of workshop to improve power factor towards energy saving and earning rebate thereby. Month wise achievement is as under.

Month

33 KV 11 KV

PF

Power factor PF

Power factor

Rebate (�) Surcharge Rebate (�) Surcharge

(�)

APR’11 0.95 245250 - - Meter out of order since Oct’10 -

MAY’11 0.97 406402 - - - do - - JUN’11 0.96 370446 - - - do - - JUL’11 0.96 407227 - - - do - - AUG’11 0.96 392899 - - - do - - SEP’11 0.97 504754 - 0.95 15159 - OCT’11 0.98 586734 - 0.96 24121 - NOV’11 0.98 544746 - 0.92 7547 - DEC’11 0.98 632201 - 0.89 - 8344 JAN’12 0.99 766808 - 0.90 - - FEB’12 0.99 679698 - 0.95 22581 -

12. BUDGET AND FINANCIAL MANAGEMENT:

i) Disposal of special letters of Accounts: Brief particulars of audit references of Jamalpur unit are as follows:

Issue No. of cases Para No. Amount Involved AIR Part-I 01 – CMS/JMP 01 0.2043 Crores Audit Note Part-I 01 – DTE/JMP 01 0.0879 Crore Special Letter CWM (JMP)/DRM (MLDT) 01 3.77 Crores

Status

AIR Part-I Recently issued (on 28.02.12). Audit Note Part-I Initial reply is awited. Special letter

- 27 -

Final reply sent to audit, closure advice is awaited.

- 28 -

ii) Position of Stock Sheet as on 31.03.12: Deptt. OB as on

01.03.12 Accn during

the month

Clearance during

the month

CB Amount involved in � Amount Recovered till

Feb’12 in �

Engg. 3 0 0 3 2 – Awaiting compliance 1 – Awaiting initial reply

-

Mech 3 1 2 2 356260 - Stores 7 1 2 6 - - Elect. 0 0 0 0 - - Total 13 2 4 11 356260 -

Status

Engineering (3 cases are pending) - 1 case is awaiting compliance, 1 case is under pricing and the third case i.e. the case of Sri J.C.Sahu (since 92-93), EX-IOW/JMP is awaiting compliance of proceedings.

Mechanical : – The case of Sri R.P.Yadav, EX-SSE/JMP is awaiting on account of administrative reasons and 1 No. recently issued.

Stores: - Total 6 cases. 5 Nos.- sub Judiced, 1 No. – Awaiting posting in TR.

iii) Status of WMS Balance (Comparative):

Figure in Crores Month Balance during 2010 -11 Balance during 2011 -12 April 19.14 22.99 May 25.95 31.34 June 31.26 17.65 July 25.24 28.22

August 24.35 27.96 September 26.30 39.84

October 33.81 33.82 November 29.85 31.34 December 27.44 46.70 January 22.16 34.00 February 24.94 18.84

iv) Financial Status (Figures in crores):

a) Revenue Exp. to end of February’12 under D-3 to 13 181.40

B.G. of Rev. Grant for 2011-12 195.54

b) Plan Head Exp. to end of February’12 109.14

B.G. of Plan Head Exp. for 2011-12 93.34

v) Turnover:

The turnover of the workshop to the end of February’12 is � 532.58 crores registering growth of � 105.88 crores i.e. 24.81% over the corresponding period of previous year (� 426.70 crores).

- 29 -

13. SCRAP MANAGEMENT:

Scrap Target

2011-12 (MT)

March ’12 Cummulative (Upto March’12) Target (MT)

Achievement (MT)

Target (MT)

Achievement (MT)

Ferrous 15600 1300 1161.680 15600 15202.03 Non-

Ferrous 400 33.33 56.492 400 428.025

14. ISO 9001 OF 2008:

• Jamalpur workshop obtained its ISO certification (9001-2000) on 28th May 2003 which got subsequently upgraded to ISO 9001-2008 during 2010-11. Thus, now this workshop has become at par with any other heavy engineering industry.

• Functioning of ETP plant – The discharge of the workshop is being treated through this plant and thus only safe discharge is being allowed to flow out confirming to the standard as laid down by Govt. of Bihar. The plant is functional since 01.09.2006, capacity - 1.5 MLD.

Yours sincerely, (A K Sinha) Shri Hemant Kumar Chief Mechanical Engineer Eastern Railway Kolkata Copy forwarded to: 1. Secretary/E.Rly./KKK for kind information of G.M. 2. AGM/E.Rly./KKK for his kind information please. 3. COS/E.Rly./KKK for his kind information please. 4. COS/JMP at KKK for his kind information. 5. CEE/E.Rly./KKK for his kind information please. 6. CMM(M)/E.Rly./KKK for information and necessary action please. 7. FA&CAO/E.Rly./KKK for his information please. 8. CPO/E.Rly./KKK for information please. 9. CWE/E.Rly./KKK for his information please.

- 30 -

10. Dy.CME(W)/HQ/ER/KKK for information.

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