workshop management pcoirimee.indianrailways.gov.in/instt//uploads/files/1434540953044... · north...

Workshop Management &

PCO

2

AIO APE

PE

Dy.CME(Prod.)

AWM(Crane)

WM(Crane)

Dy.CME(Crane)

AWM(M&P)

WM(M&P)

Dy.CME(M&P)

AWM(Dsl.)

WM(Dsl.)

Dy.CME(Diesel)

ACOS

DCOS

Dy.COS(W)

AWAO

WAO

DY.CAO(W)

ACMT

CMT

Dy.CCMT

APO

WPO

DY.CPO ASC

Chief Works Manager

(CWM)

Chief Workshop Engineer

(CWE)

Chief Mechanical Engineer

(CME)

General Manager

WORKSHOP

ORGANISATION CHART

THE GENERAL MANAGER (GM )

• The General Manager of Zonal Railway is the head of the

administration and the organization.

• In discharge of his duties he is assisted by a number of Principal

Officers who are departmental heads of their respective departments

Chief Mechanical Engineer (CME)

• One of the Principal Officers of each Railway Administration is the Chief

Mechanical Engineer who is head of the Mechanical Department.

• He is responsible for maintenance of the rolling stock and other mechanical

equipment of the Railway.

• Every Railway has one or more Workshops under the control of its

Mechanical Department in which Locomotives, Carriages & Wagons are

periodically examined, repaired and overhauled before being placed back

on the line.

Chief Workshop Engineer (CWE)

• The direct control on the affairs of the workshop is exercised by the "Chief

Workshop Engineer" who is the administrative head of the department for

workshops.

• The Chief Mechanical Engineer acts as the overall coordinating officer for

ensuring effective working of the department.

• In all matters relating to policy formulation which concerns the Mechanical

Department the Chief Workshop Engineer issues instructions in

consultation with the Chief Mechanical Engineer who is the Principal Head

of the Department.

• Responsibility for budgetary controls in the workshop rests with Chief

Workshop Engineer.

Chief Workshop Manager (CWM)

• The Head of the Workshop is called Chief Workshop Manager (CWM)

• He is directly responsible to Chief Mechanical Engineer (CME) or

Chief Workshop Engineer (CWE) for efficient conduct of his Workshops.

Note :

• Where main Workshops are sufficiently large and important, Chief

Workshop Manager or a Dy.CME is placed direct incharge of such shops.

• Smaller Workshops are placed under Works Manager (WM) or an Assistant

Works Manager (AWM).

Dy. Chief Electrical Engineer (DY.CEE)

DY.CEE in the Mechanical Workshops works under administrative control of

CWM.

DY.CEE is also under the technical control of the Chief Electrical

Engineer(CEE) for technical aspects of electrical engineering and

observance of Electricity Act Rules and Regulations.

The duties of Electrical Engineers attached to Mechanical Workshops

include:

• running of power house

• the supply and distribution of electrical energy

• the maintenance of all the electrical plants and machinery in the workshop

• and electrical repairs of rolling stock.

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PERSONNEL DEPARTMENT

- Dy CPO or WPO is head of this department.

- May take Policy directives from Chief Personnel Officer (CPO) of the Railway.

- Responsible for all Establishment matters:

• Recruitment

• Payment of Wages and Overtime

• Grant of Leave and Passes

• Complaints

• Payment of Provident Fund

• Gratuity and Compensation

• Maintenance of Service Register etc.

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CHEMICAL AND METALLURGICAL TESTING (CMT)

Dy.CCMT is the head of this department.

• It has a technical laboratory equipped to carry out necessary chemical

and metallurgical tests :-

i. Radiographic & Ultrasonic tests of Axles & Wheels.

ii. Testing of Springs, MS plates, other components of rolling stock

during overhauling.

• He is responsible for quality control of manufacturing and repair activities in

Workshops involving special knowledge of modern chemical and metallurgical

techniques.

ACCOUNTS DEPARTMENT

Dy.CAO or WAO (Workshop Accounts Officer) in the Workshop is incharge

of all the costing and accounting of the workshop.

He is the Financial Adviser to the Head of the Workshop and is responsible

for rendering him all the assistance and cooperation that may be required

by the latter.

He is administratively under the control of the Financial Advisor and Chief

Accounts Officer (FA&CAO) of the Railway.

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STORES ORGANIZATION

Dy.CMM is the incharge of the Stores Organization in a Workshop

The Stores Organization is to assist the workshop for the custody,

replenishment and distribution of workshop stores.

Dy.CMM is directly responsible to the Controller of Stores(COS) at

HQ.

He is to run stores service required by the workshop in most

efficient manner possible and to maintain all records for the correct

and prompt procurement/accountal of all stores/stores transactions.

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Departmentalization of Workshops

• The Workshops are sub-divided into ‘Shops’ which are further sub-divided into ‘sections’ for the

purpose of technical control, as well as financial and cost control.

• The Shops are under the supervision of ‘Shop Superintendents (SSEs) who have under them are

Junior Engineers (JEs) to assist them in the work of supervision.

• The Shops are either Process Shops, (i.e. Manufacturing Shops ) or Job Shops (i.e. Repair shops).

• The Process Shops consists of foundries, rolling mills, forge shops, welding shops, and bolt and

nut shops etc. All the other shops are Job Shops.

• Each shop should be allotted a shop number by which it can be distinguished.

Classification of staff in Workshops

The staff employed in Railway workshops, other than Ministerial staff may be classified under the following broad categories:

(i) Unskilled Artisans Grade

(ii) Skilled Gr. III

(iii) Skilled Gr. II

(iv) Skilled Gr. I

(v) Master Craftsman

(Vi) Supervisory Staff

Classification of staff under CLW Incentive Scheme in Workshops

The classification of staff under CLW incentive scheme in Workshops are as under:

Direct Worker(DW): Sr Technician, Technician I, Technician II, Technician III

Essential Indirect Worker(EIW) : Crane Driver, Gunner, Rigger, JEs

Indirect Worker(IW): Helper I & Helper II

Mechanical Workshops

. The main locomotive workshops of the railway may be either situated at the same

station as the main carriage and wagon workshops or at different stations.

• The Works carried out in a Mechanical Workshop involves the following :

(i) Repair and reconditioning of rolling stock and of Plants & Machinery

(ii) Assembly and overhauling of :

a) Locomotives

b) Coaching Vehicles

c) Goods Vehicles

d) Cranes of different capacities

(iii) Manufacture of articles required by the Stores Department as stock and non- stock

items.

(iv) Manufacture of articles of various kinds for

( a) Other Government Department.

(b) Foreign Railways

(c) Others.

LIST OF RAILWAY WORKSHOPS (MECHANICAL DEPARTMENT)

Railway Name of the Workshop

1. Eastern Railway

(i) Locomotive Workshop, Jamalpur

(ii) Railway Workshop,Kanchrapara

(iii) Carriage Workshop, Lilluah

2. East Central Railway (i) Mechanical Workshop, Samastipur

(ii) Rail Wheel Plant, Bela

3. East Coast Railway (ii) Carriage Workshop, Mancheswar

4. Northern Railway

(i) Carriage & Wagon workshop,Alambagh

(ii) Mechanical Workshop,Amritsar

(iii) Locomotive Workshop,Charbagh

(iv) Carriage & Wagon Workshop,Jagadri

(v) C&W Workshop,Kalka

5. North Central Railway (i) Wagon POH Workshop,Jansi

6. North Eastern Railway (i) Rly. Mechanical Workshop,Gorakhpur

(ii) Railwar Workshop, Izzatnagar

List of Railway Workshop (Mechanical Department)

Railway Name of the Workshop

7. Northeast Frontier Railway

8. North Western Railway

9. Sourthern Railway

(i) Railway Workshop,Dibrugarh

(ii) Rly. Workshop ,New Bongaigoan

(iii) Rly. Workshop, Tindharia

(i) Carriage Workshop, Ajmer

(ii) Locomotive Workshop, Ajmer

(iii) Railway Workshop, Bikaner

(iv) Carriage Workshop,Jodhpur

(i) Locomotive Workshop,Golden Rock

(ii) C&W Workshop, Perambur

(iii) Locomotive Workshop, Perambur

10. South Central Railway

(i) Lallaguda Railway Workshop

(ii) Carriage Workshop, Tirupati

(iii) Wagon Workshop,Guntapalli

11. South Eastern Railway (i) C&W Workshop, Kharagpur

12. South East Central Railway (i) Railway Workshop,Raipur

(ii) Nagpur Railway Workshop

13. South Western Railway (i) Carriage Repair Workshop,Hubli

(ii) Mysore Railway Workshop

14. Western Railway (i) Bhavnagar Railway Workshop

ii) Loco, Carriage & Wagon Workshop, Dahod

(iii) Railway Workshop, Junagarh

(iv) Carriage Repair Workshop, Lower Parel

(v) Railway Workshop, Mahalaxmi

(vi) C&W Workshop, Pratapnagar

15. West Central Railway (i) Coach Repair Workshop, Bhapal

(ii) Wagon Workshop, Kota

16. Central Railway (i) Carriage Workshop, Matunga

(ii) Locomotive Workshop, Parel

(iii) C&W Workshop, Kurduwadi

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PRODUCTION CONTROL ORGANISATION (PCO)

PURPOSE: To obtain a most economic combination of resources i.e. the best use of man,

machine and materials.

Best use of Men, Machine & Materials:

(i) Best use of Men - Assign appropriate person to a location in appropriate number.

(ii) Best use of Machine

• Machines should be optimally utilized with no idle time

• Machines should be maintained as per the schedule

• Machines should be in good working conditions

• Machines should deliver products in minimum time with minimum wastage

with accuracy

(iii) Best use of Material

Materials should be selected as per required specifications

Materials should have good past record of performance

We should select a best method of doing a work so that a product can be finished in

minimum time in minimum cost with desired quality.

Production Engineer

The Head of the Workshop, Chief Workshop Manager(CWM) is assisted by the Production

Engineer (PE) who is responsible for efficient planning and functioning of the Production

Control Organization (PCO). The broad function of this department is the function of the

following Offices/Sections :-

a) Progress Office

b) Planning Office

(i) Drawing Office

(ii) Rate fixing

c) Inspection

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Progress Office

Main Function of Progress Office are:

• Assign work order number to a work.

• Arrange for printing of documents as required (IS-1 to IS-34)

• Release all documents to Shops

• Specify date of completion (PDC)

• Draw raw materials from Stores against each requisition

• Coordinate progress of manufacture of components

• Preparation of monthly report of production and their deliveries

• Inter-section and inter-shop movement of components.

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Planning Office

(a) Planning Section

• Study of drawing and specifications

• Estimation of billed-off materials for a job

• Taking make or buy decision

• Preparation of Scroll process Sheet(IS-1) indicating sequence of

operations

• Section or load centre where the operation is to be carried out

• Study the layout of shops where a particular component is to be

manufactured

• Select suitable machines

• Deciding requirement of special tools , Jigs and Fixers

• Ensuring availability of handling facilities

(b) Rate Fixing Section

• responsible for fixing allowed time for various operations involved in the

process sheet

• maintenance of synthetic data for fixing rates (time) for individual operation

• indicating allowed time in the process sheet for each operation inviolved

• to scrutinize all the completed piece work cards

• issue of excess time cards

Fixing of Allowed Time (AT)

Observed Time :- The actual time recorded during time study on completion of the element.

Performance Rating of Workers: -

• It is the assessment of the skill and effort applied by a worker while completing a work &

every worker should be rated independently.

• It is based on the principle that an average worker working under the non incentive

conditions just to earn his basic wage, is said to be working at 60 rating ( or he could be said

to be producing 60 units of work per hour)

• The same average worker while working under incentive conditions can work at such a

speed and with such effort to earn 33.33 % incentive i.e. at an 80 rating ( or producing 80

units of work per hour)

• This rating is done by the rate fixers of the rate fixing department.

Normalizing: -

• After completion of the time study, the actual times of all the elements in the work cycle should

be converted to the time at 80 rating i.e. the time which the average worker should take to do

each element when working under a incentive scheme.

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In Normalizing, the actual times of all the elements in the work cycle should be

converted to time at 80 rating.

This conversion is done by the following formula:

Normal Time = Actual time(observed time) x Observed Rating

80 (i.e. incentive rating)

Allowances - The following allowances are added to the normal time on an

cumulative basis:

i) Fatigue • As it is not humanly possible for any person to work continuously with a set-

speed, an allowance to cover fatigue is added.

• Since this varies with the types of work, an allowance upto 12½ % is given.

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Contingencies Allowance: -This includes cleaning swarf, grinding of tools,

using of spanners, procuring cutting compound etc. and for this purpose, an

allowance upto 10 % on the operating time is given.

(iv) Production bonus:- An allowance of 33⅓% is added as production

bonus.

(ii) Gauging on machining:- 5% allowance is added for all machining

operations where gauging is necessary.

Allowed Time = Normal Time + Allowances

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Example : Let the normal time of all the elements as a result of number of studies

(average) = 1 Hour.

Solution : - Nomal Time = 1 hr.

Add allowances as under.

(a) Fatigue 12.5 % = 1 x 0.125 = 0.125 hrs.

= 1 + 0.25 = 1.125 hrs.

(b) Contingency 10 % = 1.125 x 10 = 0.1125 hrs.

100

= 1.125 + 0.1125 = 1.238 hrs.

c) Bonus 33⅓ % = 1.238 x 100 = 0.413 hrs.

3 x 100

= 1.238+ 0.413 = 1.651 hrs.

(d) Gauging 5 % ( not on jobs) = 5 x 1.651 = 0.083

100

= 1.651+0.083 = 1.734 hrs.

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Allowed time for this job = 1.734 hrs.

Time Taken = 75 % of the allowed time of 1.734 hrs.

= 1.301 hrs.

Time saved = 1.734 hrs.—1.301=0.433 hrs.

Preparatory Time • The preparatory time is added per batch.

• This is the time taken by a worker in collecting and drawing tools, raw materials etc.

Extra Time: Extra time over the allowed time can be allowed due to:

(i) Excess machining work required on castings, forgings, bar etc.

(ii) Hard material.

(iii) Defect in machine for which the worker is not responsible

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Incentive Bonus Rates • Time saved or lost will be evaluated at the Incentive Bonus hourly rates as fixed by the Railway

Board for different categories of staff from time to time.

Designation

Pay Range

(Rs.)

Hourly Rate

(Rs.)

Jr. Engineer Gr. I 5500-9000 26.45

Jr. Engineer Gr. II 5000-8000 24.00

Senior Technician 5000-8000 24.00

Supervisor 4500-7000 21.65

Technician Gr. I 4500-7000 21.65

Technician Gr. II 4000-6000 19.25

Technician Gr. III 3650-4590 17.55

Technician Gr. III 3050-3575 14.65

Semi skilled 2750-4400 13.20

Unskilled 2550-3200 12.25

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(c) Drawing Office Main Functions are:

• Custodian of all drawings .

• Preparation of part drawing to facilitate manufacturing operations.

• Designing/drawing various Jigs and Fixers, template, gauges, etc. for

economical manufacture of components.

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Inspection:

Important functions are:

• Inspection of components , assemblies etc. on completion of each operation to

ensure the production as per the drawings and specifications.

• Bringing to the notice of the concerned authority of deviations from Drawings and

Specifications for rectification and rejection.

• Certification on job cards and route cards regarding quantities passed or rejected.

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Forms used in Railway Workshops:

IS-1: Scroll Process Card

• Compiled by the planner.

Contains the sequence of operations required for man.

A.T filled up in the approximate columns.

This form is the basic record and is retained in the planning office.

IS-2: Master Process Card

• Exact replica of IS-1.

• This card is thicker than IS –1 for use as a permanent reference in the

planning office.

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IS-3: Route Card

• Constitutes the authority for manufactures .

• It is prepared in one copy.

• It then accompanies the batch of components throughout their process of

manufacture.

IS-4: Rout Card (Replacement)

• Identical to IS-3.

• Its use is confined to replacement work.

• It will be used for the manufacture of additional quantities against the

rejections.

IS-5: Material Requisition

• Used for drawing materials for the items for which rout card is used.

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IS-6 : Material Tag

• Exact replica of IS- 5 , except that its use is confined to replacement

work like the IS –4.

IS-7 : Material Requisition (Replacement)

• It has the same heading as IS-5 as well as IS 3. This will move with

IS- 3 and IS- 5 to the shop PD Cell.

• This card will be attached to the materials supplied form the store

IS-8 : Material Tag (Replacement)

• Exact replica of IS –7, except that its use is confined to replacement

work.

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IS-9: Job Card

• It will move with the route card upto the PD cell of the shop

where the operation is to be performed.

• The time of start and finish will be punched on the job card.

• Finally, the job card be passed on to the rate fixer, to record time

allowed and time taken for an operation .

IS-10 : Job Card (Replacement)

• Exact replica of IS 9 except that their use is confined to the replacement work.

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IS-11: Squad Summary card

• Used for squad work

• One card is supplied to the each squared for each operation on the batch order

• The card is punched ON at start and OFF at finish of the operation

IS-12: JOB Card for Squad work

• Issued blank to the shop.

• Issued to each man in the squad covered by IS 11

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IS-13: Proceeding Time Card

• Issued black to the time booth clerks.

• Time put in by each operator for each job card is transcribed on this

card by the time booth clerk on the last date of the month.

• These cards are prepared to be retained with time booth clerk until

the jobs are completed.

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IS-14: Inspection Form

• Used by the Inspector while inspecting jobs

• After inspection, it tells the quantity offered for inspection, quantity

passed, quantity rejected & the reason for rejection.

IS-15: Advice note of returned Stores

• Issued blank to the shops.

• Used for return of rejected materials to the stores.

• It bears relevant IS 14

• Made in triplicate to PD cell, Stores & Accounts.

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IS-17 : Request for Investigation

IS-18 : Duty Certificate

IS-19 : Idle Time Slip

IS-20 : Idle Time Card

IS-21 : Suspended Job Slip

IS-22 : Resumption of suspended Job Slip

IS-23 : Entrusting Job in progress to another operator

.

IS-16 : Process of Time Alternation

• Issued to the rate fixing section.

• When there will be change in the allowed time for an operation

this form is used by the rate fixer for approval of PE/APE.

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IS-24: Gate Attendance Card

IS-25: Essential Indirect Worker Card

IS-29: Appendix ‘ C’

IS-30: Appendix ‘D’

IS-31: Night Shift G.A.Card List

IS-32: Pattern Foil

IS-33: Material Movement Slip

IS-34: Daily Outturn Statement

IS-26: Plus Card

IS-27: Appendix ‘A’

IS-28: Appendix ‘B’

Elements of Costing System in Workshop

i Material Cost

ii Labour Cost

iii Oncost

List of materials with their cost

Labour Cost

63

ON COSTS

Expenditure which cannot be charged direct to the cost of articles

manufactured or work done are termed “On Cost”.

Types of On Cost :

1. Proforma On Cost

2. General On Cost

3. Shop On Cost

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1. Proforma On Cost

- Includes all On cost which is not included in cost of work done in Railway Workshops but

which would be included in commercial costing. Items included in Proforma On Cost are :

(a) Share of expense for the Rolling Stock management in Zonal Headquarters

Office and Establishment in Offices of Mechanical Department of Workshops.

(b) General Superintendence of all Service Departments such as Financial,

Personnel and Material Management etc. including Officers and Office

Establishment of Security Department and Medical Services.

c) Contribution to Provident Fund in respect of non-pensionable staff.

d) Gratuity and Special contribution to Provident Fund in respect of non-pensionable

staff.

e) Pension liabilities – Pensionable Staff.

f) Payment under Workmen’s Compensation Act.

g) Depreciation of plant and buildings.

h) Repairs of M&P other than those charged to cost of manufacture and repairs to

buildings ,Yards etc.

i) Cost of materials used and labour expended on the maintenance of Electric lighting

throughout the Workshop,.

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2. GENERAL ON COST:

General On Cost denotes cost other than Proforma on cost, that is incurred in

common with all the Shops or Departments in Workshop.

a) Leave, sick, hurt and Holiday pay paid to workshop employees whose wages are

not charged to shops ie.Yard Establishments.

b) Wages, Overtime etc. of staff such as Workshop apprentices, Tool Keepers not

attached to Shops.

c) Freight charges that cannot be directly allocated to jobs.

d) Electrical power which is not possible to allocate to shops.

e) Hydraulic and Pneumatic power and gas that cannot be allocated to shops.

f) Working expenses of Crane and shunting engines, lorries, autotrucks, traversers

etc. provided for use of the workshop when not chargeable to Shop on cost.

g) Water charges that cannot be allocated to shops.

h) Experimental work when not appropriately charged directly to job itself.

i) Yard Lighting.

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3. SHOP ON COST

Shop on cost includes all on cost incurred within accounting unit, such as a shop or a

department or a section. Items included are :

a) Wages, Overtime etc of Workshop apprentices attached to shops, Chargemen ,

Mistries , unskilled labour except when employed as direct labour tally men, store

men, Oilers , Shop Clerks etc.

b) Shop scrap ( credit) ie. scrap which cannot be allocated to job.

c) Defective and spoilt work in the case of experimental work.

d) Power charges whether electric , pneumatic, gas or Hydraulic which can be directly

allocated to shops.

e) Consumable stores for shop use viz oil for lubrication, sponge, emery / glass cloth,

soap etc.

f) Small tools for shop use.

Costing of a Component – Water Expansion Tank (Rear)

Sl.N

o

Raw Material PL. No. Quantity in

Kg.

Rate (in Rs.)

per Kg

Shop

1 3.15 mm. MS

sheet 90525358

64.57 25.52

SMS (72 man-hour)

2 5 mm. MS sheet 90402443

34.28 62.59

BFS (2.17 man-hour)

3 40 mm. bore

pipe 62986065

0.06 191.12

-

4 25 mm. bore

pipe 62986089

0.40 89.37

-

5 15 mm. bore

pipe 62986120

0.40 49.55

-

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Costing of a Component – Water Expansion Tank (Rear)

(i) Material Cost : a) 3015 MS sheet

PL No = 90525358

Quantity = 64.57 Kg.

Rate = Rs.25.52, Total cost ( in RS.) = 1647.83

b) 5 mm. MS sheet

PL No = 902443

Quantity =34.28 Kg.

Rate = Rs 62.59, Total cost (in RS.) = 2145.59

c) 40 mm bore pipe

PL No =62986065

Quantity =0.06 mtrs.

Rate = Rs.191.12, Total cost (in RS.) = 11.47

d) 25 mm bore pipe

PL No = 62986089



e) 15 mm bore pipe

PL No = 62986120



Total Material Cost = a) + b) + c) + d) + e)

= Rs 1647.83 + Rs.2145.59+ Rs. 1.47+ Rs. 35.75+ Rs.19.82

= Rs. 3860.45

(ii) Labour Cost :

a) Sheet Metal Shop(SMS)

Total man-hour = 72 man-hours

Hourly Rate = Rs 170.54, Total Cost = Rs 12278.88

b) Brass Finishing Shop (BFS)

Total man-hour = 2.17 man-hours

Hourly Rate = Rs 171.63, Total Cost = Rs 372.44

Total Labour Cost (DL) = a) + b)

= Rs 12278.88 + Rs 372.44

= Rs 12651. 32

(iii) Oncost Sheet Metal Shop (SMS):

LOC = 30% of DL = Rs. 3683.664

SOC = 24% of DL = Rs. 2946.93

Shop Oncost = Rs. 3683.664 + Rs. 2946.93 = Rs 6630.60

GOC = 12% of DL = 12% of 12278.88 = 1473.47

Total Oncost = Rs 8104.07

Brass Finishing Shop(BFS)

LOC= 42% of DL = Rs. 156.42

SOC = 30% of DL = Rs. 111.73

Shop Oncost = Rs. 156.42 + Rs. 111.73 = Rs 268.15

GOC = 12% of DL = 12% of 213.31 = Rs 44.70

Total Oncost = Rs 312.85

Therefore, Estimated cost of the component

= Material cost + Labour cost + Oncost

= Rs. 3860.45 + Rs. 12651.32 + Rs 8104.07 + Rs 312.85

= Rs 24928.66

Costing for own Railway :

(i) Material cost

(ii) Labour cost

(iii) Oncost (expect Proforma Oncost)

(iv) Contingency = 1% of total cost

For Commercial Costing for other than Railways

Following charges are taken into consideration –

Proforma oncost = 45% 0f the DL

Profit = 10 % of total cost

Excise = 3 – 5% of total cost

Estimate charge = 2% of total cost

VAT = 5 % of Grand total cost

72

WORK ORDER SYSTEM IN WORKSHOP

• Workshop Expenditure is analyzed with the aid of the Work Order System

representing different units for different Heads of Expenditure.

• There exists a separate unit for each sub- detailed head of financial accounts, to

which Workshop expenditure is chargeable.

• Separate units are also provided to ascertain the amount that has to be accepted,

adjusted or billed for.

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WORK ORDERS USED IN WORKSHOP :

1. Revenue Standing Work Orders –

• Those are intended for collecting Revenue expenditure but excludes the

cost of addition, alternation and improvement to machinery and plant.

• These Worker Orders are never closed .

• Controlled by Progress Department.

2. Special Work Order –

• Issued for special work.

• They are issued on the receipt of requisition.

• These Work Orders are closed after completion of the job .

• Controlled by Accounts Department.

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Revenue Standing Work Orders are of two kinds :

1. Work Orders for Repair and Maintenance.

2. For Stores Stock

Standing Work orders for Repair and Maintenance are divided into following sections :

i. Manufacturing Work Orders – are used in Process Shop like Foundry and Saw Mill producing

semi manufactured materials

ii. On Cost Work Orders - Shop On Cost and General On Cost

iii. Repair to Rolling Stock –Diesel and Electric Locomotives

iv. Repair to Machinery and Plants

v. Other Departmental Work (Divisional)

(vi) Other Departmental Work (Non-Divisional) work done for Other Railway

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Work Order Number

Any standing work order for repair and maintenance has 8 digits arranged in 4

groups:

(a) 1st & 2nd digits indicate control work order i.e. Main Head of Work order series.

(b) 3rd & 4th represent Shop number within the Workshop.

(c) 5th , 6th & 7th digits indicate detailed identification of Work.

(d) 8th digit is the self checking digit.

Ist 2nd 3rd 4th

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Examples: Diesel Loco – 55 (i) POH to Body

(ii) POH to Under Carriage

including coupling

(iii) POH to power Pack(Engine)

(ii) POH to Wheel, Bearing &

Axles

Repair to Machinery & Plant -56

(i) Repair & maintenance of all

types of machines

(ii) Repair, maintenance &

maintenance of cranes of all

types

(iii) Repair , maintenance &

overhaul of Gauges, jigs &

fixtures etc

5 5 7 0 1

5 5 7 0 2

5 6 5 6 1

5 6 5 6 7

5 6 5 6 5

5 5 7 0 6

5 5 7 0 7

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Shop Oncost -52 (i) All consumable stores materials

(ii) Electric current supplied to Shop

(iii) All experimental work (labour & material)

(iv) Wages, overtime, etc. of chargemen,

MCM, Khalsi & shop clerks (labour)

General Oncost -53

(i) Wages, Overtime, etc. to yard staff

(ii) Freight charges not chargeable to any job

(iii) Repair to furniture etc. (labour & material)

(i) Yard lightening

5 2 4 5 5

5 2 4 5 7

5 3 0 0 4 8 1

5 2 4 5 6

5 2 4 5 6

5 3 0 0 4 8 6

5 3 0 0 4 9 2

5 3 0 0 4 8 7

78

WORK ORDER REGISTER

- All Works carried out on Requisitions should be registered and serially numbered

in Work Order Register (W 826)

- Separate Register for different Department., Divisions etc.

Format of Work Order Register :

1. Work Order no. and date

2. Date of commencing Work

3. Date of completion

4. Description of Order

5. By whom ordered ( Reference No. )

6. Shops through which the work has to go

7. Head of account to which to be charged.

8. Remark as to dispatch

79

LOAD CHART

- Issue of all Work Orders should be carefully regulated by Production Staff with

the help of Load Charts so that no Job Order is left outstanding in the Shops for

more than 3 months.

- Load chart to be monitored on Personal Computers.

LOAD CHART

Description

of Work

Particulars of Work Name & number of machines on

which Work is to be done

Reqn.No.

and Date

Part

No.

Qty Operation Month Week

THANK YOU

80

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