Welcome to Wagon Repair Shop,Kota

^{Heavy corrosion repairs on the
covered wagons roof having riveted construction have been
observed due to inherent problem of water seepage
between the roof angle and the roof plate. In order to
eliminate this problem welded type construction of
roof, as adopted in the latest covered wagons was
proposed to RDSO vide Drg. No. WM-980/K. The proposal has been
approved by RDSO and has since been implemented for the
repair of covered wagons. This has also resulted in saving of
time on drilling and riveting required in the repair
using riveted construction.}

^{Kota workshop developed a rigging device to eliminate manual shunting of wagons from stripping section to fitting section by rigging up a winch using drum and gear box of a condemned EOT crane. This reduced the wastage of manpower for shunting.}
WINCH FOR WAGON SHUNTING	1st STAGE TO SHUNT THE WAGON

IInd STAGE TO SHUNT THE WAGON	IIIrd STAGE TO SHUNT WAGON

^{The shop has designed and fabricated one storage cum transportation pallet for Oxygen and DA gas cylinders. The transportation of this pallet is done using tractor hauled hydraulic carrier. This arrangement is likely to save around 15 to 20 Manpower, which were other wise, engaged daily in transporting the gas cylinders manually. This will also eliminate Physical strain on the workers and improve the productivity.}
^{1. Oxygen and DA gas cylinder transportation pallet}	^{2. Tractor hauled hydraulic carrier engaging to the pallet}

^{3. Lifting the pallet by the carrier}	^{4. Transportation being done using pallet and tractor hauled hydraulic carrier.}

^{The Double cup of cartridge roller bearing are rejected for various defects viz. flaking, spalling, brinelling, pitting, rusting, electric current damage and cup broken etc. The rejection rate is about 12%. Kota Workshop initiated to attend such rejected double cup having minor defects as per Association of American Rail Road (AAR) and collected technical know-how from M/s NEI-Jaipur and successfully repaired 18 Nos and out of these, 08 Nos double cups were sent to M/s NEI-Jaipur for inspection. and were certified OK vide letter No.SLS:AB:REP:Gen dated 07.07.2005.} ^{The rejection rate is expected to come down by 2% - 3%. Net saving is expected to be Rs. 30 lakhs per annum approximately once implemented fully.}
Reclamation of double cup – Light defect	Reclamation of double cup – Buffing process

Reclamation of double cup - Reclaimed

^{There is no provision of releasing load on pillar cranes (Electric Hoist) during power failure in Kota Workshop. The lifted item is remaining in hanging position during power failure. This was a very unsafe condition. A suitable arrangement has been developed to release the lifted load up to floor during power failure or in any emergency by releasing the brake shoe of the electric hoist manually.}
Arrangement Of Releasing Load During Power Failure

^{To
give inputs to the safety of workers at workplace, Shop Safety
Councils have been formed in each shop by
nominating two artisan staff from the shop floor
apart from the SSE in-charge of the shop. This council will
identify and propose corrective measures for ensuring
better safety. The participation of grass root level artisan
staff will be ensured through this mechanism. The activities
of these shop councils will be monitored through a
quarterly Safety meeting.}

^{In
compliance of CME-JBP’s letter No. WCR/W/G/01 dated 17.10.05
& Inspection note of CRWS/DTC BPL on
25.11.05,}

^{Yoga classes have been started
since 18.11.05 for one hour in the morning in BTC for the
staff and supervisors. 19 employees are attending Yoga
classes regularly including 15 drug
addicts.}

^{(H)
Library of Management Books : Knowledge is
strength. A manager needs to be updated about various
management techniques to manage effectively and survive in
this competitive world. A library of management books have
been started with following books to start with.
Managers at all levels are being encouraged to
make use of this library. This will expose them to various
case studies, which will help to harness their
full potential.}

^{1.
Harvard Business Review compilation of articles on "The
Mind Of the Leader"}

^{3. Harvard Business
Review compilation of articles "When Your Strategy
Stalls".}

^{6.
"What They Still Don’t Teach You At Harvard Business
School" by Mark H. Mc
Cormarck.}

^{A shield has been
introduced to motivate the staff to up-keep the shops to
best standards since January-06. The salient
features for awarding this shield are as under
:}

^{1. Each
shop/section will be inspected by a nominated committee
of three AWMs every month and marks will be given
on the following points :}

^{(i) General
house keeping.}

^{(ii) Arrangement
of new, reclaimable and scrap
items.}

^{(iii) Awareness
regarding safety in shops and utilization of safety
equipments by
staff.}

^{(iv) Maintenance
of shop related area of
park/gardens.}

^{(v) Status of
the implementation of ISO:9001 & ISO:14001 in
shops.}

^{Arrangement of Quality slogan boards and
Safety Posters.}

^{2. This shield will
be awarded on 15 August & 26 January to the
shop/section who will obtain cumulative maximum marks
for the period January to June and July to
December every year.}

^{3. The shield
will be given permanently to the shop/section, who gets
this shield consecutive three
times.}

^{The nominated
committee carried out inspection of the shops/sections
on 23.01.06 & 24.01.06. Lifting Shop was
found the best shop and awarded this performance shield
on 26 January-06 on the occasion of 57th Republic
day celebration on Kota Workshop Sports
Ground.}

^{This will inculcate
the feeling of competition among the staff of all
shops/sections for improvements in their work areas,
leading to improvement in overall performance of
workshop.}

^{Kota
workshop is doing steam cleaning of Tank wagons since 1997-98
before placement of wagons in shop for POH/ROH repairs.
One boiler is being used for this purpose. Furnace oil is
stored in ordinary condemned 4-wheeler tank wagon to
feed the boiler. This used to freeze in winter season in
pipe line. The frozen furnace oil was heated up by
conventional system manually from out side by burning
waste jute dipped in waste Kerosene/hydraulic oil etc. This
method is prone to fire hazard and as such a foolproof
system of heating the furnace oil in cold weather has been
evolved to avoid incidences of fire. The conventional tank
wagon has been replaced by a condemned TOH wagon having
heating coil inside the barrel . This will provide heating
facility when ever required mainly in cold season by
circulating steam through the heating coil. This improved
system of furnace oil heating will ensure safe and
pollution free working environment at steam cleaning
plant.}

^{Dust shield is used in bogie
on center pivot top to protect the whole assembly. This is a
stock item on PL No. 38983138 and procured from trade.
The item is required to be manufactured in shop whenever it is
out of stock in stores for turning out the wagons in time
to achieve the targeted outturn. Dust shield is manufactured
from 1.6 mm thick sheet. Previously, the sheet was cut
manually by fitter with the help of chisel and hammer.
This was a time consuming process. The existing method has
been improved and now the sheet is cut on shearing
machine which has saved 1-28 hrs per piece and also reduced
fatigue.}

^{Steel commode for Brake vans
is a stock item on PL No. 36433421 and procured from trade as
per Drg. No. CA/LF 1821. The item is required to be
manufactured in shop whenever it is out of stock in stores to
turn out the wagons in time to achieve the targeted
outturn and fulfill the demand of the customer. The item is
manufactured from 1.6 mm thick sheet. Lid and cover are
the round components of commode. Previously,lid & cover
were cut manually with the help of chisel and hammer
from 1.6 mm sheet.}

^{This was a tire some
and time consuming process. The existing method has been
improved and die has been prepared to manufacture the
lid & covers for commodes. 25 numbers have been
manufactured by this improved method successfully on
trial basis. Now, lid & covers are manufactured on
Crank press on die.}

^{The manufacturing of lid
& covers on crank press by using die is a faster and
accurate process which will save considerable time and
also with reduce fatigue.}

^{To develop human resources, in house
training programmes have been started. These training
programmes are being conducted with the help of the
supervisors who are working in these areas, to train the
artisan staff involved in operation and maintenance
of that particular assembly/components. This type of
training programme will be very effective as the trainer and
the trainees are belonging to particular area in which
the trainer has good knowledge and trainees who have to
perform the job are made aware about the correct
practices. In May-06, three such courses were conducted for
operation and maintenance of distributor valve and
in June-06, two courses about the Single Wagon Test Rig
and two courses for EOT crane
drivers.}

^{Air hose Support is a stock
item on PL No. 37980610 and procured from trade as per Drg.
No. SK 73552. The item is required to be manufactured in
shop whenever it is out of stock in stores to turn out the
wagons in time to achieve the targeted outturn and fulfill
the demand of the customer. The item is manufactured from
MS flat 50x10 mm. Previously, slotting and radius formation
was done manually by oxy cutting which was not so
accurate. The existing method has been improved and die has
been prepared to form the slot and
radius.}

^{500
numbers have been manufactured by this improved method
successfully on trial basis. Now, the item is manufactured on
crank press on die. The manufacturing of Air hose support on
crank press by using die is a faster and accurate process,
which will save considerable time and also with reduce
fatigue.}

^{Efforts have been started to clear the debris in form of iron and miscellaneous scrap lying embedded for years. About 1860 M2 area has been taken in hand for clearing behind Foundry Shop along with line No. –1. 35 M2 area has been cleared which has generated 10 MT scrap in June-06 and making a total of 1710 M2 area cleared and about 430 MT scrap generated up to June-06. The remaining area of about 150 M2 is likely to be cleared by the end of July-06.} ^{A proposal for clearing these debris and vegetation through JCB is under vetting with the associate finance.}

1.2 Special Efforts : On demand from the division, by putting special efforts 25 Brake vans have been turned out after POH in addition to 30 brake vans turned out in the month of Feb. to April-06 continuously, against a normal outturn of 15-20 brake vans and the priority of customer is being fulfilled by shop.

1.3 Yoga Classes : 22 employees including the suspected drug addicts are attending yoga classes regularly for 45 minutes being conducted at BTC.


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