CHAPTER-I 1. INTRODUCTION 1.1 Work Study on “The requirement of staff against various activities at Tool room of WRS/Kota” includes as a ‘Crash Study’ for the year 2017-18. 1.2 The foundation stone of Wagon Repair Workshop, Kota was laid in Nin November, 1957 and the shop was commissioned in October, 1960. The Workshop is equipped to undertake POH and ROH of all types of BG wagons on Indian Railway. 1.3 The organizational structure of Workshop is as under:- CWM (SAG) Dy.CME ( R) Dy.CME ( P) Dy.CMM SMM WM Sr.AFA ( R) (W&S) AWM AWM AWM AEE APO AMM AMM (R ) (G) (M) (W) (W) (X) (G) (SAG) 1.4 Various shops in WRS Kota 1. Body Repair shop 2. Paint shop 3. Machine and Tool Room shop 4. Smithy shop 5. Millwright Shop 6. Wheel shop 7. Tank Lifting 8. Box shop. 9. Cartridge Taper Roller Bearing shop (CTRB) 1.5 Tool Room Tool Room acts as service providing shop to other shops of Wagon Repair Workshop Kota. Staff working in Wagon Repair Workshop, Kota, is classified as Direct Worker, Indirect Worker and Essential Indirect Worker. All the staff of Tool Room are deployed under classification of Essential Indirect Worker. 1.6 Innovations & Improvements (a) Kota workshop developed a rigging device to eliminate manual shunting of wagons from section to fitting section by rigging up a winch using drum and gear box of a condemned EOT crane. This reduced the manpower required for shunting. (b) 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 otherwise, engaged daily in transporting the gas cylinders mainly. This will also eliminate Physical strain on the workers and improve the productivity. (c) Riveting process in Kota Workshop has been improved by providing Pneumatic Supporting Device supplied by M/s Mary Enterprises- Kolkata. By using this new device constant pressure is applied on rivet head resulting better formation of head and proper gripping with the mating parts. Thus this improved method appears more reliable. The pneumatic supporting device has been introduced for riveting of 24 mm dia rivet for the fastening of Spring plank with Side frame of Casnub bogie. This process shall also be adopted for other important locations like side bearer assembly and support plate for CBC etc. (d) Reclamation of Double cups for CTRB: the Double cup of cartridge roller bearing are rejected for various defects viz. flaking spalling Brinelling, pitting, rusting, Electric current damage and Cup broken during overhauling. 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 (ARR) 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. 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. GM/WCR and CME/WCR were shown these repaired double cups during their inspection and this attempt by Kota workshop was highly appreciated by them. (e) Manufacturing of Bolster liners from scrap steel: Manganese steel liners (IS3885) are being extensively used in Casnub Bogie Bolster and side frame. This item has been a stock item but out of stock since last one year due to trade failure. Hence it was decided to manufacture these liners from scrap spring steel flat size 120 x 16 mm x 8 mm (IS3885) released from broken spring top plate. 30 MT spring flats were re-rolled and 17000 liners have been manufactured up to Nov.05 This has resulted:- (i) Saving of approx Rs. Forty thousand per annum (ii) Elimination of the problem of dependency on trade (iii) Improvement in quality of repairs. ****** CHAPTER-II 2. EXISTING WORKING 2.1 Machines and equipment in Tool Room 1. HMT Centre Lathe 2. Kirloskar Centre Lathe 3. Universal Milling Machine 4. Universal Milling Machine 5. Heavy duty Shaping Machine 6. Modit Extra Heavy duty Shaping Machine 7. Fixed Drill Machine 8. Surface Grinding Machine 9. Twist Drill Grinder Machine 10. Power Hacksaw Machine 11. Duplex Grinder Machine 12. Carbide Tip Tool Grinder Machine 13. Bench Grinder Type Machine 14. Universal Grinder Machine 15. Electric Furnace Machine 16. Cooper Smith Health Furnace Machine 17. Ashoka Double End Grinder Machine 2.2 Items Manufactured & Repaired in Tool Room (A) Items manufactured in Tool Room through Work Order 1. Punch for shackle suspension 2. Stud for sloter M/c 3. Bush for tower wagon 4. Drilling jig for packing liner 5. Socket and adopter 6. Die for Horn Check 7. Fixtures 8. Teeth cutting of Gear 9. Punumatic hose pipe connection 10. Draft gear Removable puller 11. New catch piece for wheel lathe 12. Pin for tower wagon 13. Bush for tower wagon 14. Roller arrangement assembly for Rail carier 15. Vale plate power hammer 16. Template for axle guard 17. Bolt mfg. as per sample 18. Adopter Bolt for Pilot sleeve 19. Gauge for Bk. 20. Venkas Puller Ramp and sleeve mfg. 21. Key way for shaft of centre lathe 22. Sanp for Horn check Rivetting 23. Release chock for EK DV mfg. 24. Box spanner for Nut 25. Swaring die 26. Alenkey bolt 27. Wheel dia gauge 28. Gas pipe joint connector 29. Boring Bar 30. Hexagonal Nut 31. Nozzle as per sample 32. Housing base planner gauge 33. Ch shank light with wear of big CBC gauge 34. CC v tool, CC Knife tool &carbide tipped centers 35. Name punch of WCR Kota. 36. Flange for testing plant of BD valve 37. Bolster gauge for modification of stand 2.3 (B) Items Repaired in Tool Room through Work Order 1. Jig & die repair 2. Die for bolt forging machine 3. Snap 20 mm. 22 mm Rep. 4. Cutters drills Hacksaw Blade grinder 5. Key for chuck rep. 6. HMT Axle lath M/c. centre rep. 7. Chuck tool post & die head rep. 8. Aprin & turret gear box wheel harding 9. Trimnal ague TG/CAS/01 Repair 10. Drilling Jig Rep. & Die Repair 11. Grinder cutter, drills, Hacksaw blade Die 12. Edge made in blade of Eye rolling machine 2.4 (C) LSO Items Calibration of gauges Repair and renovation of cash safe Calibration of pressure gauges Pneumatic cutting chisel. 2.5 Existing pattern of work at Tool Room:- Various machine operations carried out on lathes, shaper, sloter and milling machine, drilling, grinding, marking, filling assembling, heat treatment, calibration etc. are performed for the manufacturing and repair of different regular items on internal work orders of different shop. The actual role of Tool Room is to assist or provide their services to other shops in the manner of repairing and manufacturing of various tools and parts. Whenever any shop requires services from Tool Room, they sent the Work Order through Progress Cell to SSE/Tool Room for compliance. After that, the work is assigned to the related trade staff after making necessary entry. After completion of allotted work the same will sent back to the concerning shop/section. 2.6 A- General Work Distribution for Repairs & Maintenance activities 1. Calibration of IMTEs as per the requirement of ISO: 9001;2000 in T/ Room and outside. 2. In Tool Room Store for Checking receiving and issuing different tools and other maintenance work for proper record keeping etc. 3. Maintenance of Dies available in Machine Shop. 4. Maintenance of Dies for Smithy Shop. 5. Maintenance of Chucks, tools, fixtures, gauges, templates, etc for different Shops 2.7 B- General Work Distribution for Manufacturing activities Manufacturing activities includes pure manufacturing of new items like Dies, tools, Jigs, fixtures, Gauges, Templates, etc. 2.8 Fitter: Manufacturing and assembling new dies, Tools, Jigs, Fixtures gauges templates etc. and others parts required for maintenance purpose. 2.9 Turner: 1. Manufacturing different parts for manufacturing and maintenance of Tools, Dies, jigs, Fixtures, Gauges, templates etc as per the requirement. 2. Hackshaw cutting operation and other miscellaneous work including material handling. 3. Different welding activities carried out in Tool Room during manufacturing and repair of Dies, Tool, jigs, Fixtures, Gauges, templates, etc. 2.10 Machinist: 1. Milling machine being used for manufacturing different gears required by MWT Shop for the maintenance of machines. 2. Surface machining on different components required for manufacturing & repairing die, punches, jigs, fixtures, gauges, templates, key slots on shafts required by MWT and machining operation as per requirement are performed. 3. Machine for rough blocks, flats, components, to the required dimensions for manufacturing and repairing the dies, Tools, Jigs, Fixtures, gauges, templates etc. 2.11 Grinder : 1 Dress up of grinding wheels of grinding machines situated in various shops in WRS Kota. Teeth cutting operation required on different forms as per the requirement of die punches, catch piece of wheel lathes, etc. on universal grinder. Other misc. grinding activities required in new/old serviceable dies, punches, jigs, fixtures, gauges, templates etc. 2.12 Driller: All type of drilling work required during repair and manufacturing of dies, tools, Jigs, Fixtures, gauges, templates, etc. 2.13 Furnace : Heat treatment of various tools (CC and high speed steel V- tools, knife tools, parting tools, chisel and punches for Pneumatic Buster machines being used in different shops and other items such as catch pieces, wheel press shoe etc.