G.275/Wssr-071718/2017-18 Work Study to Review the Staff Strength at Boiler Shop-Goc

G.275/WSSR-071718/2017-18

WORK STUDY TO REVIEW

THE STAFF STRENGTH

BOILER SHOP-GOC

SOUTHERN RAILWAY

PLANNING BRANCH

G.275/WSSR-071718/2017-18

WORK STUDY TO REVIEW THE STAFF STRENGTH

AT BOILER SHOP -GOC

STUDIED BY

WORK STUDY TEAM OF G.275/WSSR-121617/2016-17 PLANNING BRANCH

AUGUST - 2017

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I N D E X

SERIAL CONTENTS PAGE NUMBER NUMBER

(i) ACKNOWLEDGEMENT 1 (ii) TERMS OF REFERENCE

(iii) METHODOLOGY

(iv) SUMMARY OF RECOMMENDATIONS 2

CHAPTERS

I INTRODUCTION 3-8

II PRESENT SCENARIO 9-17

III CRITICAL ANALYSIS 18-22

IV PLANNING BRANCH REMARKS ON CO-ORDINATING 23 OFFICER’S VIEWS

V FINANCIAL SAVINGS 24

ANNEXURES

I BOILER SHOP DETAILS 25-34

II TRAINING DETAILS 35

III IR CODE FOR MECH WORKSHOPS 36-37

IV CO-ORDINATING OFFICER’S VIEWS 38

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(i) ACKNOWLEDGEMENT

The work study team acknowledges the valuable guidance given by Dy.CME/GOC,PE/GOC,APE/GOC, SSE/Planning, SSE/Boiler Shop and the staff of Shop which was very helpful in completing the study in time.

(ii)

AUTHORITY Annual programme of work studies for the year 2017-18

(iii)

TERMS OF REFERENCE

Work study to review the staff strength at Boiler Shop/GOC

(iv)

METHODOLOGY

The work study team has applied the following techniques in conducting the work study.

(1) Collection and compilation of Data.

(2) Observation of present system of working.

(3) Interaction with Dy.CME/GOC,PE/GOC,APE/GOC, SSE/Planning, SSE/Boiler Shop and the staff of Shop

(4) Discussion with Officers and Supervisors

(5) Provision as per AT/TT/yardstick/requirement as deemed fit.

(6) Evaluation of the manpower requirement for the current workload as Well as to meet the Production Schedule for the Financial Year 2017-18.

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(v) SUMMARY OF RECOMMENDATIONS

Category Sanction Actual Required Surplus SSE 8 6 6 2 JE 4 1 1 3

Recommendations Two posts of SSE in Grade pay Rs.4600/- and Three posts of JE in Grade pay Rs.4200/- are found excess to the requirement, may be surrendered and credited to the Bank of Surplus Posts.

( 5 Posts)

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CHAPTER-1 1.0 Introduction: 1.1 Golden Rock Railway Workshop

The Golden Rock Railway Workshop (officially Central Workshop, Golden Rock) is situated in Ponmalai (Golden Rock), Tiruchchirappalli in the Indian state of Tamil Nadu, is one of the three mechanical railway workshops serving the southern zone of the Indian Railways.

This repair workshop is basically a "Mechanical Workshop" which comes under the control of the Mechanical Department of the Indian Railways. The other two mechanical workshops of Southern Railway are located in Perambur, Chennai. They are "Carriage Works, Perambur" and "Loco Works, Perambur".

1.2 This central workshop was set up in 1897 by South Indian Railways at Nagapattinam mainly to cater to the requirement of steam locomotive maintenance. South Indian Railways decided to shift the workshop to Trichinopoly, presently known as Tiruchchirappalli, owing to its locational advantage. Consequently, foundation stone was laid by Mrs. R.P. MUNRO on 20.10.1926. It was shifted to Tiruchchirappalli in 1928 because of its strategic location. The Central Workshop, Golden Rock is functioning at Tiruchchirappalli since then.

The total area of this workshop is around 200 acres (0.81 km2), out of which 26 acres (110,000 m2) is covered under roof. At present 6,091 employees are working in this workshop. This workshop is primarily engaged in the activities of DSL Loco POH, heritage steam locomotive POH, coaching stock maintenance and wagon manufacturing and other sundry activities.

This workshop does have a long traverser way around 600 metres long and 80 feet (24 m) wide. This workshop was involved in repairing of Royal Air Force's air planes during World War II.

This workshop when built had state-of-the-art facilities rarely seen in those days. It had its own powerhouse which generated electricity for the workshop and the colony. In fact, Railway colony, Golden Rock was one of the first places to be lit by electrical lights in Tiruchchirappalli city those days. 4

1.3 The organizational set up of Boiler Shop/Central Workshop /GOC is as below :

CWM

Dy.CME WPO

WM PE

AWM APE

SEs

JEs

1.4 BOILER SHOP 1.4.1 This Shop is responsible for POH / conversion of X class locomotives. In view of the UNESCO's world heritage site status given to the Nilgiri Mountain Railways, maintaining and augmenting the rolling stock for this Railway has gained significance. The Golden rock workshops has been entrusted with the responsibility of carrying out the POH of X-class locomotives (special locomotives which have a toothed cog which engages with the racks available in the railway track in very steep gradients)and manufacturing of new locomotives. 1.4.2 At the time of POH, the original coal-fired boiler of the loco is converted into oil fired loco without altering the external looks to preserve the heritage value. The conversion has become necessary in view of the logistics, economy and availability of coal for the loco. At present the workshop has also secured the order for manufacturing 4 X class locomotives. 1.4.3 Apart from the regular Reclamation / Manufacture of DSL components viz., Equalising beams, Side buffers, Cattle guards, Main Reservoirs, Lube oil filters, Dust guard, ECG Guard, Sand box, etc., 1.4.4 Reclamation / Manufacture of Coaching components viz., Brake beams, Equalising stays, Buffer plungers, Battery fuse box, Body part pillars, etc., 5

1.4.5 Reclamation/ Manufacture of Components pertaining to other divisions under A, C orders. 1.4.6 This present work study is to review the staff strength at Boiler Shop of this Workshop. 1.4.7 This work shop is an incentive based shop working under the Chittaranjan Pattern Scheme of Incentive.

1.5 CHITTARANJAN PATTERN SCHEME: 1.5.1 Introduction Piece work bonus systems were in existence in certain workshops like Jamalpur, Kancharapara and Perambur prior to Independence. The Railway board decided in 1949 to introduce some form of incentive scheme in Railway workshops to afford direct financial incentive to workers who exceed a minimum level of performance.

The first formal incentive scheme was introduced in Chittaranjan Locomotive Works in December 1954. Time was the basis of this scheme and the time standards used were pre-determined after systematic work measurement.

The scheme was considerable success and it was extended to Integral Coach Factory in 1960.

1.5.2 Salient Features of Chittaranjan Pattern of Incentive Scheme: Under the incentive bonus scheme, the basic wages are guaranteed to all the works. Time is yardstick for measuring work. The various operations in the workshops are subjected to time study measurement. The allowed time are so fixed that the workman of normal ability may earn 33-1/3% bonus over and above his basic wages in respect of period spent on piece-work jobs. This allowed time includes all allowances such as fatigue, general handling, and gauging and production bonus allowance.

The scheme is based on the concept that an average worker while working under non-incentive conditions is assumed to be working at a rating of 60 units. 6

The same worker while working under incentive conditions would be expected to improve his ratings to 80 units i.e., 33-1/3%more. It is expected that an average worker would complete an operation in ¾ of the allowed time. The time saved/lost on the time allowed in each operation is calculated separately for each worker and the gain or loss cannot be carried over to the next month.

1.5.3 The various terms in use and their meaning is given below.

The incentive workers are classified as Direct, Essentially Indirect and Indirect Workers. Supervisors are directly responsible for idle time arising out of lack of work and lack of tools. Apprentices are not eligible for participating in the incentive bonus scheme.

DW - Direct workers: They are so called because they play a direct role in producing output. ‘Direct role’ means that their role is confined to those mandatory operations that need to be performed as per ‘CAMTECH’ on the arising to produce the out turn. It does not include ancillary activities such as procurement of materials, tools etc that need to be done to perform the operations. They earn bonus ranging from 1% to 49% based on the time saved on doing a particular operation.

EIW - Essentially Indirect Workers: They supplement the efforts of the DWs in producing out turn by procuring materials, picking up tools, erecting implements etc. Since their role is not directly linked to the out turn and is only supplementary in nature, they are entitled to only 80% of the bonus earned by the DWs they assist.

IW –Indirect worker: Their role is confined to such of those activities that are in no way linked to the out turn, such as keeping the shop floor clean etc. They do not get any incentive.

Outturn: The results of incentive working will be determined on basis of the total quantity ‘Passed’ in respect of each operation, as recorded on the job card.

AT –Allowed Time: As and when an arising rolls in to a work shop for POH, operations that need to be performed as mandated are determined and the time taken to complete such 7 operations are computed based on the computation sheet that lists the time required to perform various operations. This is called as Allowed Time. As such, AT denotes the workload of an incentive shop. AT is fixed based on time study and takes in to consideration various factors, such as infrastructure, skill set etc, that determine the capacity of a worker to produce an output.

Time Study: AT for each operation is fixed through time study. It is a technique for determining, as accurately as possible, from limited number observations, the time necessary to carry out a given activity at a defined standard of performance. While carrying time study the actual time of each element is normalised depending upon the rating performed by the worker.

Rating: Rating is the assessment of the skill and effort involved in each element. Every element should be rated individually. The principle of rating is that, an average worker, working at non incentive conditions, at such an effort just enough to earn the basic pay, is said to be working at a 60 rating. This can be interpreted as saying that he is producing 60 units per hour. The same average worker when working under incentive conditions, is capable of working at an 80 rating and is said to be producing 80 units of work per hour so as to earn 33-1/3 % more ((80-60/60)%).

TT – Time taken: This is the time actually taken by a DW to finish an operation as mandated.

TS – Time saved: AT – TT = TS.

Bonus %:

This is the percentage of bonus paid to the DWs based on the Chittaranjan pattern Scheme. This is equal to TS x 100 / TT. While the scheme mandates that every DW should earn a bonus of 33.33%, it may vary anywhere between 0 to 50%. Bonus less than 33.33% indicates that AT of an operation is too less to save time and bonus more than 50% means that AT is too high that a worker 8 could do the operation in much lesser time with consummate ease. In both the cases AT has to be reviewed.

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CHAPTER – II 2.0 PRESENT SCENARIO:

2.1 BOILER SHOP The boiler of a locomotive is made of a steel alloy and holds thousands of gallons of water. The boiler must be treated with care at all times, as it must withstand tremendous amounts of heat, pressure and vibration. The fireman should take care to minimize the thermal stresses placed on the boiler when safety permits.

2.2 Oil Burning Locomotives

Oil burning locomotives in the steam era mainly used "Bunker C" fuel oil. (Bunker C is also known as Type 6 or Number 6.)While some preserved steam locomotives of today (circa 2005) still use Bunker C, most have switched to various alternative fuels as Bunker C can be difficult to locate, transport, and store. Alternatives include Number 4 fuel oil, kerosene or diesel oil (and sometimes a mixture of diesel/kerosene), others employ used motor oil.

Regardless of the kind of oil used, most locomotives store the fuel in a tank on the tender. The oil tank is equipped with steam heat coils to heat the fuel before combustion. This is done to keep the oil viscosity such that the oil can flow freely to the combustion chamber. Bunker C fuel oil is very thick and difficult to use without pre-heating.

The fire in an oil burning locomotive is controlled with two valves: The fuel valve, which controls the flow of oil to the atomizer, and the atomizer valve, which controls the steam to force the oil into small droplets for burning.

The fireman must control the amount of steam, oil, and air in the combustion chamber to produce the most efficient fire to boil the water. The fireman observes the colour of the smoke emitted from the smoke stack to determine what the fire needs. Thick, foul smelling black smoke indicates that the fire is not burning correctly due to too much fuel oil. The fireman can increase the draft of air using dampers and the blower or reduce the amount of oil to the burner. Blue smoke indicates too much steam is being admitted to the atomizer, and he 10

must reduce the steam pressure. A light grey smoke indicates proper adjustment, while no smoke at all means the fire is too light and should be increased.

It is worthy to note that under some circumstances, the fireman can cause a series of hollow booms or small explosions though maladjustments of the fire. If one were to be watching with the fire doors open at such a time, one would see that the flame is being ripped away from the burner and into the flues. This also can cause heavy amounts of soot to be deposited in the flue, reducing the efficiency of the boiler. The soot can be cleaned by throwing sand into the combustion chamber, but this causes undesirable wear to the flues and any super heaters.

2.3 The staff strength in the Boiler Shop is 66 as on 18/08/2017 :-

The staff distribution is as follows: Staff deployed for each activity:

a. For coaching activity - 29 Staffs (45% of total staff) b. For DSL activity - 20 Staffs (31% of total staff) c. For X class activity - 10 Staffs (16% of total staff) d. For Divisional activity - 05 Staffs(08% of total staff) e. EIW - 02 Staffs TOTAL - 66 Staff.

Note: (1) The above brake up particulars have been obtained based on the last 27 months actual booking data’s ie., from April-2015 to June-2017.

(2) Out of 10 staff (as mentioned in above.c) involved for ‘X’ class activities only one staff at Boiler shop and remaining 9 staff are working at Erecting Shop.

2.4 No. of OT hours allowed for last 2 years:

1021 OT hours have been allowed for maintenance works during May week holidays works in the year 2015. 1630 OT hours have been allowed for maintenance works during May week holidays works in the year 2016. 11

2.5 No. of CR/ DR issued:

CR - 34 Man-days DR - NIL

No. Training details of employees - Enclosed in Annexure-II

2.6 Failure statistics of shop Status of M/c idle hours pertain to Ele.& Mech. available with EMW and MMW.

2.7 No. of staff deployed for online attention, material collection, training etc., for the last 2 years.

a. For On line attention – 649 Man days b. For Material collection- 64 Man days c. For training- 55 Man days

2.8 Activities already outsourced / proposed for outsourcing: PU painting of Steam locos is outsourced.

Contract /AMC - NIL Details of sub-units – NIL

2.9 Machineries Details :- Sl. GOC MC ID M/C DESCRIPTION Shift Machine OLD M/C No Commnd. NO. 1 314017124 RADIAL DRILL & TAPPING 1 02/01/1950 BS D 12 2 314017290 RADIAL DRILLING M/C 1 19/08/1957 BS RD 29 3 314026046 DOUBLE ENDEDGRINDING 2 21/09/1964 BS G 4 4 314040020 RAPID HACK SAW 1 01-01-1934 BS HS 2 5 314101020 PUNCHING & SHEARINGM/C 2 30/04/1990 CRS S 2 6 314103030 PLATE BENDING ROLLER 1 01-01-1946 BS RL 3 7 314103041 PLATE BENDINGM/ 1 22/09/1951 BS RL 4 8 314105025 LATESPLITTING HEARS 1 01-01-2010 BS S 2 9 314105049 SPITTING SHEAR 1 19/03/1958 BS S 4 10 314105050 GUILLTINE SHEARINGM/C 2 11-01-1974 BS S 05 11 314129017 PLATE STRAIGHTENROLLS 1 01-01-1928 BS RL 1 12 314151060 EOT CRANE 7.54 TONSAC 2 22/07/2008 BS CR 706A 13 314151760 EOT CRANE (1 TON)(AC) 2 05-12-1992 BS CR 776 14 314151930 EOT CRANE (25 TON)(AC) 2 28/08/1996 BS CR 793 12

15 314157037 JIB CRANE (1 TON) 1 15/02/1994 FY EH 03 16 314158613 HAND OPRTD. OVERHD. CRANE 1 01-02-2008 BS CR 761 17 314259030 HYDRAULIC TEST PUMP 1 01-01-1989 BS HTP 15 18 314301197 AIR COMPRESSOR (500/14.15 CFM CUM 2 07-01-1988 DCS AC 19 19 314301215 SCREW AIR COMPRESSOR (530/14.99 2 02-10-1989 BS AC21 CFM/CUM) 20 WELDING PLANT(DC/MMA) 600 AMPS BS AC 9 21 WELDING PLANT (DC/MMA)600 AMPS BS SC 11

22 WELDING PLANT (DC/MMA) 600 AMPS B SAC 116

23 WELDING PLANT (DC/MMA) 600 AMPS BS SAC 117

24 WELDING PLANT(DC/MMA) 600 AMPS BS SAC 168

25 314403152 WELDING PLANT (AC/MMA) 350 AMPS 2 01-01-1967 BS WP 115

26 314403437 WELDING PLANT (AC/MMA) 300 AMPS 2 01-01-1962 BS WP 43

27 314403589 WELDING PLANT (AC/MMA) 450 AMPS 2 09-12-1974 BS WP 158

28 314404193 WELDING PLANT (DC/MMA) 600 AMPS 2 02-01-1989 BS WP 219

29 314405630 WELDING PLANT (AC/MMA) 600 AMPS 1 02-05-2002 BS WP 363

30 314405641 WELDING PLANT (DC/MMA) 600 AMPS 1 05-05-2002 BS WP 364

31 WELDING PLANT (DC/MMA) 300 AMPS BS SL 72

32 WELDING PLANT (DC/MMA) 300 AMPS BS WP 193

33 WELDING PLANT (DC/MMA) 300 AMPS BS WP 239

34 314457021 OIL FURNACE 1 01-01-1936 BS OF2

35 314457070 RIVET HEATING FURNACES 1 01-01-1928 BS OF 7 36 314508170 HYD. TUB. SWELLING & REDUCIN 1 01-01-1928 BS TSW 1 37 314508181 RIVETTIG HAMMER 1 01-01-1926 BS H 1

38 314508193 TUBE DSCALING MACHIE 1 01-02-1928 BS TSC 01 39 314508200 GANTARIES FOR DRILLING 1 01-02-1938 BS DG 01 40 314612130 HYDRAULIC RIVETING MACHINE 1 03-01-2016 BSHRM 13 41 WELDING PLANT (DC/MMA) 300 AMPS BS WP 53

42 WELDING PLANT (DC/MMA) 400 AMPS NEWBSWP 0

43 WELDING PLANT (DC/MMA) 300 AMPS BSWP 28

2.10 Allowed Time for each activities / Jobs:-

314 - BOILER SHOP SL. OPERATION DESCRIPTION UNIT AT No. COMPUTATION No.326 - DSL Reservoir

DSL air reservoir(Large) dish end remove by gas cut 1 NO 25.08 clean, assy. weld and Hyd. test(BG) Lub. oil filter mark, gas cut, Mod. Wing nut provision, 2 NO 33.44 weld, repair &Hyd. test COMPUTATION No.327 - DSL EQUALISING BEAM 1 Eq. Beam welding NO 2. 09 2 Eq. Beam grinding. NO 4.18 Eq. Beam Corroded portion and damaged portion (if 3 NO 0.905 necessary) weld & grind. 4 Clean and Paint NO 0. 316 COMPUTATION No.328 - ICF/BG COACHES COMPONENTS

Equalising stay for ICF/BG (16 +33 ) Mark, Cut, Level, 1 NO 7.106 Assemble ,Tack weld ,Weld. Manuf. of ECC guard marking, cut, level bend, 2 NO 32.604 assemble, expand metal mark, cut, assemble, weld manufacture of outer frame for ECC guard marking 3 NO 10.032 cutting levelling welding bending Repair of side load pad Dust guard level the bottom 4 plate, side plate, side rib plate mark cut bend NO 5.852 assemble, weld Manuf., of half round guard mark, cut, bend, drill, 5 NO 4.598 grinding, clamp provide Manufacturing of dust guard base plate mark, cut, 6 NO 17.556 clean burr, bend, assemble, and weld Manufacturing of indication board mark cut, corner 7 NO 5.016 mark, cut bend ,weld and grind PER 8 Addition cylinder Rack cylinder side lagging 146.3 BOILER PER 9 Pivot lagging Manufacture & assembly 146.68 BOILER PER 10 Steam pipe lagging Both side & manufacturing 125.4 BOILER 11 New X-class doom NO 141.284 REPAIR & RE-CONDITION OF AUXILARY RESERVIOUR 12 NO 28.792 FOR BG COACHES 200 LIT. CAPACITY PER 13 Mounting seating, stud clearing 6.622 BOILER 14

PER 14 Fitting of regulator valve 60.326 BOILER Fitting of gauge column cock, pressure gauge cock, PER 15 191.277 washout plug, blow off cock clack box, dome joint B OILER

16 Fitting of safety valve, steam stand NO 20 .9 17 Repair and Reconditioning of old brake beam NO 14 .564 18 Remove the bushes from equalizing stay NO 1. 067 Manufacture and painting of Belly Panel Board (Item 1 19 NO 7.624 = Large Board, Item 2 = Inner Fold Board) COMPUTATION No.329 - DSL CATTLE GUARD & MISCELLANEOUS 1 Buffer plunger rivet & grind NO 5. 016 2 Loco side buffer repair & recondition NO 10 .952 3 Repair and modified cattle guard for diesel loco (BG) NO 69 .033 COMPUTATION No.332 - BOILER MOUNTING 1 Fit up laggings. NO 91 .96 COMPUTATION No.333 - REPAIR & RECONDITION OF DLS GEAR CASE Repair and recondition of gear case BG & MG 1 cleaning, scrapping of cardium compound and by HALF 0.836 burning 2 Boss, remove cut by gas out including gasket ribs HALF 0.334 Pinion support block remove by gas cut including 3 HALF 0.276 gusset ribs 4 Wiper felt ring wheel side remove by gas cut HALF 1.564 5 Wiper felt ring motor side remove by gas cut HALF 1.564 6 Wiper felt ring pinion side remove by gas cut HALF 0.777

Preparation and assemble of new felt ring, worn out 7 portion on side plate mark, gas cut, clean burr and HALF 1.672 grind the gas cut portion of Boss & pinion supports. Side periphery plate mark cut file, side bend by bend 8 to suit and remove the old damaged portion assembly HALF 1.571 T/weld and weld. Wiper ring with side plate wheel side assemble and 9 HALF 1.254 tack weld 10 Weld complete (8mm fillet) HALF 1.17 Wiper ring with side plate motor side assemble & 11 HALF 1.254 T/weld 12 Weld complete (8MM fillet) NO 1. 17 13 Wiper felt ring portion side assemble - T/weld HALF 1.254 14 Weld complete (8 mm fillet) HALF 1.17 15 Check the alignment motor side HALF 1.254 16 Check the alignment - wheel side HALF 1.254 15

Preparation of gusset ribs (3 Nos.) - Mark ,shear , 17 NO 0.836 flatten, clean burr & grind Preparation of end plate blocking piece both side - 4 18 HALF 0.836 Nos.- Assemble weld & grind 19 Assemble, tack & weld boss & gusset - 3 Nos. NO 1. 588 20 Manufacture of lids complete (small) for BG HALF 2.508 21 Manufacture of lids complete (large) - MG NO 3. 344 Preparation of bottom baffle strips of sizes, worn out, 22 HALF 2.09 cracked portions & weld Preparation of bottom baffle - remove bend, 23 PER BOX 3.344 resistance & distortion , check up to gauge & suit Matching top & bottom final check up & rectification 24 after assembly with end recess fitting of clamps & Sq. NO 10.032 head bolts M/F and supply of bulb cotters (RM size 25 NO 0.695 3.15X10X200mm COMPUTATION No.334 - MISC. Buffle collector support plate, mark shear cut, bend, 1 NO 3.177 weld grind 2 Buffle collector frame (round type and square type) NO 7.148 3 Packing pieces large and small NO 0.8 36 4 Destination board , mark shear cut bend clean burr NO 2.508 5 Sizes of clamps 5mm manuf.1/4,,1/2,3/4, NO 1. 881 Manuf.of clip BG & MG mark, shear, bend, drill set to 6 NO 2.508 shape 7 Manuf.of bottom square cover mark, shear, bend NO 1.672 RTTM belt guard for (BG&MG) mark, shear, drill 8 assemble 1 to 7 weld and provide side clamp 2 Nos., NO 24.244 weld 2 to 4 for BG Door for governor room mark, cut, drill provide 9 NO 11.4 handle, assemble, and weld 10 Manufacture of shim N O 0.95 Partition plate for ALCO & WDS 6 Loco mark ,cut by 11 NO 11.4 gas , bend ,assemble, and weld Battery box cover clamp mark, shear drill, bend and 12 NO 0.557 grind 13 Manuf. of axle box grease keep complete NO 6. 688 14 X class boiler tubes NO 44 7.842 Manuf. of flange for steam pipe mark cut by gas and 15 NO 1.846 de-burr 16 Body part pillar mark shear 2 x 310 x 528 mm long NO 0. 125 17 Sand box for all locos new manufacture NO 20 .064 18 Spring Seat piece DSL/Loco 6 x 35 x 240mm NO 0. 334 Repair and recondition of Cabin top for 'X' class Loco 19 NO 421.79 POH 16

20 EXPRESSOR FAN GUARD NO 28 .5 21 Wall Plate for DSL Loco NO 3. 105 22 Strip NO 0. 696 23 Super Heater element pipe assembly NO 9. 707 24 Bracket for brake beam 13 Tonnes for ICF/BG NO 1. 131 25 M.S. Plate NO 1.185 26 M/F and supply of air dryer guard (AB-DSL) NO 2.493 27 M/F and supply of safety bracket for commode chute NO 0.719 M/F and supply of engine hood centrifugal cleaners 28 NO 0.719 side door plate 29 M/F and supply of rain guard plate (1 set=5 piece) set 8 .36 30 M/F and supply of flat NO 0. 676 31 M/F and supply of shim for CBC couplers (Up to 4mm) NO 1.673 M/F and supply of shim for CBC couplers (5mm to 32 NO 3.736 10mm) 33 Exhaust funnel modification Chimney NO 13.333 34 M/F and supply of Battery Fuse box NO 7. 283 35 Manufacture of Body part pillar for ICF BG Coaches NO 3. 62 Manufacturing of Bracket for Vestibule Garbage bag Mfg. of 1. Outer Bracket-1 No. 2. Inner Holding 36 Bracket-1 No. 3. Half Bracket-2 Nos. 4. Bracket-4 Nos. NO 4.02 5. Vertical Clamp-1 No. 6. Hinge pipe-2 Nos. Set and assemble and purchase, weld and grind COMPUTATION No.335 - X class BOILER construction 1 Manufacture of vacuum reservoir for oil firing system NO 35.783 Internal main steam pipe with elbow joint for header 2 NO 263.464 lapping and assembling 3 Brazing of rack & adhesion piston head NO 71.998 COMPUTATION No.328 - X-CLASS LOCO 1 PIECE WORK FOR BOILER SHOP NO 1.000

2.11 Man hours for each activity pertaining to Boiler/X-class locomotives 314 - BOILER SHOP SL. OPERATION DESCRIPTION UNIT AT No. 1 Addition cylinder Rack cylinder side lagging PER B OILER 146.3 2 Pivot lagging Manufacture & assembly PER B OILER 146.68 3 Steam pipe lagging Both side & manufacturing PER B OILER 125.4 4 New X class doom NO 14 1.284 5 Mounting seating, stud clearing PER B OILER 6.622 6 Fitting of regulator valve PER B OILER 60.326 Fitting of gauge column cock, pressure gauge cock, 7 PER BOILER 191.277 washout plug, blow off cock clack box, dome joint 17

8 Fitting of safety valve, steam stand NO 20 .9 9 X class boiler tubes NO 447.842 Repair and recondition of Cabin top for 'X' class Loco 10 NO 421.79 POH COMPUTATION No.332 - BOILER MOUNTING

1 Fit up laggings. NO 91 .96

COMPUTATION No.335 - X class BOILER construction Manufacture of vacuum reservoir for oil firing 1 NO 35.783 system Internal main steam pipe with elbow joint for 2 NO 263.464 header lapping and assembling Brazing of rack & adhesion piston head NO 71.998

COMPUTATION No.328 - X-CLASS LOCO 1 PIECE WORK FOR BOILER SHOP NO 1.000

2.12 In this Workshop the maintenance and the earth moving equipment maintenance is carried out by the Millwright Shop.

2.13 Activities carried out a. POH of X class Steam Loco and Boiler; b. Reclamation / Manufacture of DSL components viz., • Equalising beams • Side buffers • Cattle guards • Main Reservoirs • Lub oil filters • Dust guard • ECG Guard • Sand box, etc., c. Reclamation / Manufacture of Coaching components viz. ▪ Brake beams ▪ Equalising stays ▪ Buffer plungers ▪ Battery fuse box ▪ Body part pillars, etc., d. Reclamation/ Manufacture of Components pertaining to other divisions under A, C orders.

CHAPTER – III

3.0 CRITICAL ANALYSIS

3.1 Average TT/DW/Month: As per Mechanical Code, for a Workshop governed by the Chittaranjan Pattern of Incentive Scheme, the average available Man hours per employee per month is 200 + 67 = 267 Man hours. The Railway Board is fixing Target for workshops based on the norms of 267 Man hours per employee per month. This has only been taken into consideration in the work study. The detailed working for the above is given below.

Total number of days in a year .. 365 days

No. of Sundays in a Year (approximately) .. 52 days

Available working days in a Year .. 313 days

Less no. of Holidays ` .. 20 days

Nett working days available in a Year .. 293 days

Total Man hours available in a Year .. 293 x 8 = 2344 Hrs.

Average Man hours per employee per month .. 2344/12 = 195.33 or .. say 200 hrs Add 33-1/3% under incentive scheme .. 67 hrs Total .. 267 hrs.

The details of incentive scheme, basis, working hours etc are given in paras201, 208, 401 & 402 of Chapter II & IV of Mechanical Code. (copy enclosed as Annexure-III).

This figure indicates the work actually performed by a DW in terms of man hours. For the sake of calculation as per the CPS, this should be 200 man hours. (365 x 8 man hours per day – 52 (Sun) x 8 – 20 (Declared Holidays) x 8) = 195 = 200 (Approx) Hrs per month per DW. Any figure less than this indicates that the worker has remained idle for such number of hours exceeding the figure up to 200 hrs.

Add 33-1/3% for incentive shops - 67 hrs. Total - 267 hrs. As per the Mechanical Code (for workshops) 267 hrs are available per employee per month.

3.2 Man power Requirement Boiler Shop The manpower requirement in respect of Incentive shops are calculated based on the Allowed time. Normally the average allowed time will be taken for the last three financial years and the manpower requirement would be decided accordingly.

3.3 Methodology adopted to arrive the requirement of Man Power for Incentive shops. The month wise total Allowed time for work discharged for each shop / activity were collected from financial year 2015, 2016 and up to June 2017. This prime factor is divided by the average monthly man hours of 267 (which is the denominator) as prescribed in the Mechanical code for workshops to arrive at the Direct workers (DWs) required. As per Mechanical code for workshops the Leave reserves for the DWs are worked out at the rate of 12.5% and for Essentially Indirect Workers / Indirect Workers (EIWs / IWs), it varies from 10% to 15%.

3.3 IW/EIW staff calculation per month In Mechanical code Chapter IV of para 431, the details regarding % of unskilled workers to be engaged as IW & EIW are given for various Sub-shops.

It is observed that in CW/GOC, EIWs / IWs were allowed to the extent of 15%. Instructions were issued on several occasions from Headquarters to see that the percentage of EIW is reduced to the barest minimum and guidelines were given in Chapter-4 of the mechanical code for considering EIW % of each shop. Considering the practice followed at present while assessing the requirement of manpower, EIW is allowed at the rate of 10%. As per mechanical code.

The Allowed Time for various activities at Boiler Shop is collected from Planning Section, for the period from Mar’2015 to June 2017 (27 months). This prime factor is divided by the average monthly man hours of 267 (which is the denominator) as prescribed in the Mechanical code for workshops to arrive at 20

the Direct workers (DWs) required. As per Mechanical code for workshops the Leave reserves for the DWs are worked out at the rate of 12.5%

Let Load discharged (Allowed Time) = AT Let Idle time booked = IDL Average monthly Man-hours = 267 DWs required to complete the above AT = AT + IDL = X 267

LR for DWs (12.5%) = X x 12.5 = Y 100 Therefore total DW required = X + Y 100 EIW & IW @ 12.5% = ( X +Y ) x .125 = Z

Total Artizan staff required = X + Y + Z

3.4 BOILER SHOP PERFORMANCE FROM APRIL2015 TO JUNE2017

BOILER SHOP 2015-16

AT TT TS % Apr-15 19850.220 13342.500 6507.720 48.77 May-15 14687.172 9862.000 4825.172 48.93 Jun-15 19142.496 12829.500 6312.996 49.21 Jul-15 19208.818 12885.500 6323.318 49.07 Aug-15 19112.325 12811.000 6301.325 49.19 Sep-15 19098.000 12798.000 6300.000 49.23 Oct-15 16479.934 11046.000 5433.934 49.19 Nov-15 17649.528 11828.450 5821.078 49.21 Dec-15 19992.605 13387.780 6604.825 49.33 Jan-16 16982.832 11382.290 5600.542 49.20 Feb-16 18271.274 12243.000 6028.274 49.24 Mar-16 18017.802 12059.150 5958.652 49.41 218493.006 146475.17

BOILER SHOP 2016-17

AT TT TS % Apr-16 17947.488 12035.120 5912.368 49.13 May-16 12767.480 8549.800 4217.680 49.33 Jun-16 18537.922 12402.120 6135.802 49.47 Jul-16 18173.728 12166.110 6007.618 49.38 Aug-16 16539.521 11073.240 5466.281 49.36 Sep-16 18070.576 12101.990 5968.586 49.32 Oct-16 17878.181 11959.920 5918.261 49.48 Nov-16 17142.567 11470.200 5672.367 49.45 Dec-16 17687.415 11840.370 5847.045 49.38 Jan-17 16334.467 10936.190 5398.277 49.36 Feb-17 17319.751 11590.820 5728.931 49.43 Mar-17 16939.013 11343.820 5595.193 49.32 205338.109 137469.7

BOILER SHOP 2017-18

AT TT TS % Apr-17 18434.647 12331.740 6102.907 49.49 May-17 12492.999 8381.410 4111.589 49.06 Jun-17 18254.245 12224.820 6029.425 49.32 49181.891 32937.97

3.5 Calculation of Men required for Boiler Shop :- Total Allowed Time For 27 Months (APRIL2015 TO JUNE2017) 218493.006+205338.109+49181.891=473013.006 AVERAGE/MONTH= 473013/27 =17519

Since the average incentive earnings in the shop is more 49 % the man days is calculated as 200 + (49% of 200) = 298. Hence 298 man days is taken for arriving the required manpower.

Average Direct Workers Required = 17519/298 = 58.78 Say 59 MEN

LR for DW @ 12.5 % = 7.34 Say 7 MEN

Total DWs staff = 66 STAFF

EIW & IW @ 10% = 6.6 say 7 men

Total staff required for Boiler Shop(59+7+7) = 73 men

The time taken for completing the target was less than the AT since the incentive earnings is 50% in every month. Even then, on the higher side and in consideration of Target, the AT is considered for man power calculation.

Requirement of Supervisors

The requirements of Supervisors are found excess to the requirement since the requirement of staff is 73 and the actual is only 65. Hence the existing Supervisors is allowed to continue and the vacant posts may be surrendered and credited to the vacancy bank.

3.6 SANCTION Vs REQUIREMENT

Category Sanction Actual Required Surplus SSE 8 6 6 2 JE 4 1 1 3

Recommendations Two posts of SSE in Grade pay Rs.4600/- and Three posts of JE in Grade pay Rs.4200/- may be surrendered.

(5 Posts)

CHAPTER - IV

4.0 PLANNING BRANCH’S REMARKS ON CO-ORDINATING OFFICER’S VIEWS

4.1 Co-ordinating Officer’s Remarks: The surrender proposal of 5 posts in supervisory cadre of Boiler shop is not agreed to and may be reviewed to 3 posts (SSE-2 & JE-1) based on the reasons furnished below:

1. The activities of Boiler shop is not only confined to Boiler alone but dealt with other related activities such as coach POH, DSL Loco POH, Divisional work orders etc., and induction of new activities which require specific attention at various stages.

2. As per Railway Board guidelines, every shop has to obtain the IMS related certification activities of QMS, EMS, OHSAS & 5S and time to time new certification processes have to be initiated for which the role of SSE/JEs are very crucial and needs to be considered.

3. On considering with the above facts, the supervisory requirement of Boiler Shop have been arrived and furnished below:

Section Requirement SSE JE Total Administration 1 1 Coach POH Components 1 1 2 DSL POH components 1 1 Steam Loco POH attention 1 1 2 Divisional components attention & Misc.activities 1 1 2 Total 5 3 8 LR @ 12.5% 1 - 1 Grand total 6 3 9

Planning Branch’s Remarks : The activity of Divisional Components attention & Misc. activities can be managed with the existing supervisors of Boiler Shop. Hence, 1 post of JE may be surrendered in addition with the surrender of 2 SSE & 1 JE.

Revised Recommendation: Category Sanction Actual Required Surplus SSE 8 6 6 2 JE 4 1 2 2

Two posts of SSE in Grade pay Rs.4600/- and Two posts of JE in Grade pay Rs.4200/- are found excess to the requirement, may be surrendered and credited to the Bank of Surplus Posts. ( 4 Posts)

.

CHAPTER - V

5.0 FINANCIAL SAVINGS:

5.1 If the recommendations of the study report are implemented, the Annual Financial Recurring Savings will be as follows.

Sl. Designation Grade No. of Money Annual No Pay (Rs.) posts value Financial (Rs.) Savings (Rs.)

1. SSE 4600 02 97396 2337504

2. JE 4200 02 76856 1844544

Total 04 4182048

.

ANNEXURE-III

INDIAN RAILWAYS MECHANICAL CODE (for workshops):

431. Introduction of Incentive Scheme.�The proposal to bring the direct workers, essentially indirect workers and staff of service shops under the coverage of Incentive Scheme shall be dealt with on the basis indicated in the broad guidelines laid down by the Railway Board from time to time and shall be sanctioned by the General Managers under their own powers.

Following points should be kept in view while introducing incentive scheme in shops/sections of a workshop:�

(i) Whether a list of items to be manufactured or repaired in the section/shop in which incentive scheme is proposed to be introduced has been prepared.

(ii) Whether adequate load to meet the increased capacity generated as a result of introduction of Incentive scheme has been ensured.

(iii) Whether the computation and the time studies have been carried out on Chittaranjan pattern.

(iv) Whether the allowed times have been approved by the Production Engineer/Works Manager.

(v) Whether quota cards have been introduced and the allowed time established before any system of payment by results can be introduced, the allowed times computed from basic data should be checked to see that they compare favourably with those actually required to carry out the job.

(vi) Whether the strength and categories of indirect workers and essential indirect workers have been approved by Chief Mechanical Engineer.

(vii) Whether the strength and the categories of staff of indirect workers including those declared essentially indirect have been fixed as a result of proper analysis.

The following targets should be worked to the extent possible in respect of unskilled staff engaged as indirect workers including essential indirect workers.

Strength of unskilled workers engaged as indirect workers Name of the sub-shop including essential indirect worker Erecting 15% of the total strength of the erecting/shop. Boiler 10% of the total strength of the Boiler shop. Tender 15% of the total strength of the Tender shop. Fitting 15% of the total strength of the Fitting shop. Copper & Tin 15% of the total strength of the Copper & Tin shop. Welding 12�% of the total strength of the Welding shop. Motion 10% of the total strength of the Motion shop. Saw Mill 30% of the total strength of the Saw Mill shop. 27

Carriage Building 10% of the total strength of the Carriage Building shop. Carriage Repair 10% of the total strength of the Carriage Repair/Shop. Paint 10% of the total strength of the Paint shop. Trimming 10% of the total strength of the Trimming shop. Wagon building 12% of the total strength of the Wagon Repair shop. Wagon repair 15% of the total strength of the Wagon repair shop. General Iron Foundry 20% of the total strength of the General Iron Foundry. Brass Foundry 25% of the total strength of the Brass Foundry. Smith & Forge 10% of the total strength of the Smith & Forge shop. Machine 10% of the total strength of the Machine shop. Wheel 10% of the total strength of the Wheel shop. Tool Room 10% of the total strength of the Tool Room. Mill Wright 25% of the total strength of the Mill Wright.

(viii) Whether the strength and categories of staff of direct workers have been determined with reference to the work load on the different load centres and sections. The No. of effective hours available per shift per month will be taken as 200 and with the addition of 33 1/3% representing the average efficiency under incentive scheme, 267 man hours per man per month shall be the basis for working out the number of direct workers.

(ix) Whether the number of supervisors has been determined according to actual need keeping in view the supervisory ratio authorised by the Railway Board from time to time.

(x) Whether regular supply of raw-materials has been ensured. Also whether arrangements have been made with the stores departments for their reservation before the release of work orders.

(xi) Whether a system of periodical oiling of machines, tools and plants and other preventive maintenance measures have been introduced.

(xii) Whether a proper system of inspection has been introduced.

(xiii) Whether the punching clocks have been installed and booths erected.

(xiv) Whether production forms on the Chittranjan Locomotives Works pattern have been introduced.

(xv) Whether Adrema machines or computers have been brought into use.

.

INDIAN RAILWAY CODE FOR THE MECHANICAL DEPARTMENT (WORKSHOPS)

CHAPTER II

ATTENDANCE IN WORKSHOPS

201. Hours of Work.� The hours of work in Railway Workshop which come within the definition of "Factories" given in the Factories Act, 1948 or have been declared to be "Factories" under that Act, are regulated by the provisions of Sections 51-56 of the Act. For convenience of reference some of more important limitations provided in the said Sections of the Act, are stated in paragraphs 202 to 208.

209. Working Hours.�The normal working hours of labour in Railway Workshops are eight and a half hours of week days and five and a half hours on Saturday making a total working week of 48 hours equivalent to an 8-hour day. Any departure from an 8-hour day involving payment of a day's wages for less than 8 hours work requires the specific sanction of the Railway Board, but the actual working hours and their distribution between the days of the week may be altered in accordance with local requirements subject to the limitations stated in paragraph 201.