WAGON REPAIR SHOP, KOTA

Item A

OUTTURN

Item-A

395

405

425440

450

424435 435

443.5

464.8

390

400

410

420

430

440

450

460

470

2011-12 2012-13 2013-14 2014-15 2015-16 upto Jan-16

Av

g W

ag

on

s/M

on

th

Years

Target Outturn

OUTUTRN (Monthly Average)

Item-A

MONTHLY OUTTURN (2015-16) Target – 450 Wagon

451 452

442

461465

503

455452

507

460

400

420

440

460

480

500

520

Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Jan-16

Wag

on

(Ve

hic

le U

nit

s)

Month

Outturn Target

Target 450

167 174204 191

235

160

124

69 85

97

0

50

100

150

200

250

2011-12 2012-13 2013-14 2014-15 2015-16 upto Jan-16

Avg.

Wag

ons

/ m

onth

Years

BOXN/BCN group v/s BTPN OutturnBOXN/BCN BTPN

Focus on increasing BOXN/BCN

POH

Item-A

Average Man hrs

BOXN-856 hrs BCN-1107 hrs BTPN- 351 hrs

41 57212

1228

0

200

400

600

800

1000

1200

1400

2012-13 2013-14 2014-15 2015-16 upto Jan-16

Wag

on

s

Years

Stainless steel Wagon

POH of Stainless Steel Wagons Item-A

OUTUTRN GROUP WISE (Monthly Average)

16

6

17

5 20

3

19

1 23

4

20

6

17

1

12

6

13

4 16

0

14

38

63 73

37

40

53 4

2 45 35

0

50

100

150

200

250

300

350

400

450

500

2011-12 2012-13 2013-14 2014-15 2015-16 upto Jan-16

Avg

. W

ag

on

s / m

on

th

Years

Others BLC /BLL TANK BOXN /BCN

Item-A

• Twin pipe conversion of BOXNHL, BCNHL and BVZI

wagons

• This year 164 BCNHL wagons fitted – departmentally-

with 2 Piece sliding door by Jan-16 end.

• First BOXNHAM rake made ready in Feb-16 with new

design Spring Loaded Side Bearer.

OUTTURN RELATED WORKS

Item-A

(21 in 2014-15, 758 in 2015-16)

Twin pipe conversion of BOXNHL wagons

Item-A

KOTA workshop is turning out 100% BOXNHL wagons

with twin pipe brake system since Sep-2015

KOTA workshop is turning out 100% BCNHL wagons

With twin pipe system since Nov-2014

Twin pipe conversion of BCNHL

wagons

Item-A

Retro fitment of two piece sliding door

in BCNHL wagon

– 172 Nos. (8 in 2014-15, 164 in 2015-16)

Item-A

KOTA workshop is turning out 100% BCNHL wagons with

modified doors from Aug-2013

• 172 nos. (8 in 2014-15, 164 in 2015-16)

Strengthening of BCNHL side walls to prevent bulging and jamming of sliding doors

Item-A

KOTA workshop is turning out 100% BCNHL wagons with

modified doors from Sep-2013

Modification is innovated

by KOTA workshop vide

letter no.

M 443/1/21 dated

22/07/2014 and

approved by RDSO vide

letter no. MW/BCNHL-

DOOR dated 09/04/2011

• KOTA workshop is turning out 100% BVZI wagons with

twin pipe system since MAY-2012

Twin pipe conversion of BVZI

wagons.

Item-A

Conversion of BOXN to BOXNHAM wagons

Item-A

BOXNHAM operational speed is 100/75 Kmph &

BOXN Ordinary operational speed is 75/60 Kmph

First BOXNHAM rake made ready in Feb-16 with new

design Spring Loaded Side Bearer.

Conversion of BOXN to BOXNHAM wagons – New design spring loaded side bearer

BMBS system being fitted in BOXNHAM

Item-A

Item B

Quality Parameters

POSITION of HOT axle cases (as per RDSO)

Year 2015-16 (upto Oct-15)

Item-B

WorkShop Outturn

Total

No of

Hot

Axle

Per

1000

wagon

outturn Rank

No of

Hot axle

(

90 Days Sick marking of KTTW as per IRCA

Year Quarter Outturn Sick Marking

% of Sick

% of Sick Avg

Rank in IR

2013-14 Total 4375 50 1.14 1.14 1st

2014-15

1st 1164 12 1.03

1.01 1st 2nd 1238 14 1.13

3rd 1211 11 0.91

4th 1153 11 0.95

Total 4766 48 1.01

2015-16 1st 1080 14 1.30

1.26

2nd 1292 16 1.24

Total 2372 30 1.26

Item-B

POSITION of Train Parting (as per RDSO)

Year 2015-16 (upto Nov-15)

Item-B

Work Shop

Outtu

rn

Total

No of

Train

Parting

Per

1000

wagon

outturn Rank

No of

Train

Parting

(

MAINTENANCE OF

INFRASTRUCTURE

Item-C

MAINTENANCE OF INFRASTRUCTURE

• DyCE post filled on 02 May 2014.

• Workshop has now started doing Engineering

tenders which were earlier done by Kota division.

• The 4 Engineering tenders are awarded by

DyCE/WRS/KTT

• Out of which 2 works has been completed and

2 works are running.

• The 3 Engineering works are under tendering

process.

MAINTENANCE OF INFRASTRUCTURE

• No of M&P value more than 10 Lakhs – 56 Nos.

• Total Break down hours of these M&Ps for period (Apr-15 to Jan-16) – 1034 hrs.

Item-C

Item D

CLEANLINESS

CLEANLINESS

1. IMS Certificate

2. Areas coved

under IMS

Mech.

Elec.

Store

Accounts

Establishment

Item-D

CLEANLINESS • KOTA workshop has been holding

ISO 9001 Certification since 29/12/1999 ,

ISO 14001 Certification since 08/03/2007 and OHSAS 18001 Certification since

05/01/2010.

• KOTA workshop has obtained IMS

Certification on 12/08/2013 which is valid

upto Aug-2016.

Item-D

CLEANLINESS • KOTA workshop is under process to obtain

ISO-5000 (Energy Management System)

• Certification audit conducted on

08 to 10 Feb 2016 by Mr Jayant Shridakar

Representative of

M/s LMS Certifications Pvt. Ltd. Lacknow.

• Recommended for ISO-5000 certification.

Item-D

CLENLINESS

Cleaned water Booth

Item-D

CLENLINESS

Cleaned toilet

Item-D

CLEANLINESS-ENVIRONMENT CONTROL SYSTEM

ETP & Incinerator

Item-D

ETP Incinerator

• Environment Lab Portable Carbon BOD High Value Mono Oxide Analyzer INCUBATOR Sampler Digital TDS Meter Sound Level Test Meter Spectro Photo Meter

Item-D

ENVIRONMENT CONTROL EQUIPMENT

CLEANLINESS Item-D

U-Racks: For Storage of Pipes and Rods.

Before After

Advantages:

• Use of Vertical space and less floor area requirement.

• Safety from rusting, dust etc.

• Portable - can be moved anywhere manually.

Buried scrap site Digging

Buried Scrap Disposal: Scrap buried under 2-3 feet since last 20-30 years disposed off on “As is where is basis”.

• Quantity Disposed: 1382 Mts.

• Value realised: Approx. 2.76 Crores

CLEANLINESS Item-D

Item E

HOUSEKEEPING

HOUSE KEEPING

1. No. Of Injuries in the current financial

year 2015-16 = 28

2. Availability of manual of safe practices - Yes

3. Availability of Auto racks – No.

4. Scrap disposal 2013-14 10424.7 MT

2014-15 10374.1 MT

2015-16 8855.43 MT(jan16)

5. % Green area in workshop - 40%

Item-E

GREENERY IN WORKSHOP

Green area in workshop – 40%

Item-E

GREENERY in WORKPLACE 100 plants planted in last two months

CWM office entrance gate

Item-E

Greenery

Heritage park

Item-E

GREENERY IN WORKSHOP

Greenery in Workshop

Item-E

GREENERY IN WORKSHOP

• Gardens

Item-E

GREENERY IN WORKSHOP

ITEM-F

AMENITIES FOR STAFF

AMENITIES FOR STAFF

• No of Employee = 2269

• No of lockers available = 2468

• No of meal served per day on canteen = 250

• % of payment through ECS/Bank = 100% employees

• No. of RO plants for drinking water = 10 Nos.

Item-F

• ATM in Workshop premises

AMENITIES FOR STAFF Item-F

AMENITIES FOR STAFF • Water coolers with RO plant

Item-F

• New Staff Canteen

AMENITIES for STAFF

AMENITIES FOR STAFF • Staff Canteen

Item-F

AMENITIES FOR STAFF • Staff Canteen (separate ladies cabin)

Item-F

AMENITIES FOR STAFF medical card

Item-F

MEDICAL CAMPS IN WORKSHOP

STAFF WELFARE Item-F

Innovations Initiatives

Good work done Other items

SOLAR POWER

“Solar power of 500

KW capacity planned at KOTA workshop”

• Tender floated - to open on 08/03/2016

• Kota is the first wagon workshop to float tender

for solar power.

INNOVATION

CNG Cutting trial and demo by GAIL

INNOVATION CNG Cutting in Workshop started as a Pilot

project

INNOVATION In house manufacture of Hydraulic operated work

bench for Overhauling of BMBS Brake Cylinder

This is

First in IR

Ladder for welding/painting on BCNHL wagon roof

INNOVATION

TRAINING CENTRE

Class Room Air brake System Working Model

Welding Lab Welding Lab

MOTIVATION and ENCOURAGEMENT

• Man of the Month Award Display Board

Competitive Environment

• Inter shop competition & Shield For

1. Safety

2. Cleanliness &

House keeping

3. Quality

4. Attendance

LPG Valve Model BTPN Valve Model

TRAINING CENTRE

Drum Pallets: For Storage and Transportation of Drums.

Before After

Advantages:

• More drums at a time, hence saving of Diesel in Transportation.

• Safe working.

• Utilisation of Vertical space in storage

HOUSE KEEPING

SPECIAL SAFETY MEASURES

Gate Pass system by web camera

Web Camera

Gate pass with Photo

• CCTV Surveillance system at workshop gate

SPECIAL SAFETY MEASURES

• Incoming & Outgoing Areas

SAFETY POSTERS

VIGILENCE SEMINAR IN WORKSHOP

STAFF WELFARE • Gold plated coin to retired employees

STAFF WELFARE • TOUCH SCREEN KIOSK

NEW INFRASTURURE ADDED Extension of Store depot

Roof re-sheeting of various shops Cost 1 Cr.

NEW INFRASTURURE ADDED

APM, LSD Test Bench

New (important) M&P Added

Excavator & loader Rs. 17.36 Lakhs

New (important) M&P Added

Static Weigh Bridge Rs. 21.36 Lakhs

Weigh Bridge Digital Control Unit

New (important) M&P Added

Wagon Model in CWM office entrance gate