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I
PROJECT REPORT
ON
COMPARISON AND ANALYSIS OF
PRODUCTIVITY OF STRUCTURAL
SHOP OF ENGINEERING WORKSHOP
MANMAD, SABARMATHI, LALAGUDA
AND ARAKKONAM
by
BALIJA ASHOKCE/ Workshop/ AJJ
Southern RailwayAssisted by
K. Rajendran/ AWM/ EWS/ AJJM. Govindaraju/ SSE/ EWS/ AJJ
G. Ravichandran/ SE/ EWS/ AJJ
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II
Note
No.151/920608.05.09
Sub : Allotment of project : (course no. 9206)
The following topics are allotted for Project :
SN Names of Trainees(S/Sh)
Topic GuidingFaculty
1 Balija Ashok,
CE/W/SR
Comparison and Analysis of
Productivity of structural shop of
engineering workshop
Manmad,Sabarmathi,Lalaguda andArakkonam
SPB2
2 Praveen Kumar
Mishra,
CE/Wks/BB
Motivation and related issues of the
Civil Engineering Cadre (Group A,B
and Supervisors)-Survey and Study
SPB2
3 D R Shyam Sundar,
CTE/ECOR
Study of liner bite of rails under
different conditions with field datacollection analysis on SER,ECOR
SPT2
4 Subhodh KumarJindal,
CE/Cont/Central
Efficiency of training of Group C and Dstaff on Indian railways with special
emphasis on NWR and suggestions forimprovement
SPW
5 Anil kumar pandey,
CE/TMC/NWR
Mechanisation of Track Maintenance
on Indian Railways 2012 CaseStudy for improvements
DN
6 Ravi Mohan Sharma,CTE/TMC/NWR
Working conditions of track machinefield staff(A study on NCR and NR) and
suggestions for improvements
PTM
7 Gopal Khairwar,
CE/TM/Hubli/SWR
Site constraints in construction of
limited height subway including
comparing methods of construction
SPB1
8 Rajesh Arora,
CPDE/WCR/JBP
Study and uses of accidents on
Unmanned level crossings in WCR andremedial measures
SPT1
9 Anurag Kumar
Sachan,
CE/G/WR
Engineering and operational aspects
involved in the work of remodeling of
ADI yard and its impact A case study
SPP
10 Vijay Kitke,
CGE/SCR
Study of liner bite of rails under
different conditions with field data
collection analysis on CR and SCR
SPT2
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1
ARAKKONAM ENGINEERING WORKSHOP
Work shop location : Arakkonam (Rural)Southern Railway
Work shop Established on : 1905 Main Products : Riveted type girders
Welded type girders,
PPF Shelters and FOBSteel Channel Sleepers
Dip lorry, Push Trolley, Motor Trolley, Glued
Joint, LB Gate,
Points & Crossings Assemblies, SEJ
Number of Staffs : 1082 Age Profile of the Staff : 55 Years (avg) Total Tonnage during the
Year 08-09 : 4338.715 MT/Year
Equated Unit : 5028.527 / YearSTRUCTURAL SHOP
No of Staff : 104 Outturn for the Year 08-09 : 634.25 MT/Year Equated Unit : 634.25 /Year Future proposal : To be increased to 1200 MT/Year
after augmentation of infrastructure
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OUT TURN FOR THE YEAR 2008-09
Sl No Name of the ShopAchieved During the Year
2008-09 (MT)
1 Machine Shop 7.86
2 Foundry 406.81
3 Fitter 332.72
4 Signal Fitter 387.28
5 Structural
Girders 634.54
Light Structural 298.13
6 Glued Joint 215.65
7 Tinker 6.82
8 Millwright 44.24
9 Pts & Xings 1356.51
10 Blacksmith 656.30
TOTAL 4346.58
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3
7.86
4
332
38
298.
215.65
6.82
44.24
0.00
200.00
400.00
Machine Shop
Foundry
Fitter
Signal Fitter
Girders
Light Structural
Glued Joint
Tinker
Millwright
Pts & Xings
Blacksmith
Production-Shopwise
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OUT TURN OF STRUCTURAL SHOP FOR THE YEAR 2008-09
Sl No Name of the Shop
Achieved During
the Year 2008-09(MT)
1 Structural shop
a) Girders 634.54
b) Light Structural 298.13
TOTAL 932.67
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5
FLOW LINE PROCESS OF ARAKKONAM ENGINEERING WORKSHOP
`
Stud Drawin s
Tem latin
Tack Weldin
Cuttin & Drillin
Initial Assembl
Final Weldin - SAW
Markin
Riveting
Final Assembly
Inspection
Des atch
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PRODUCTIVITY OF ENGINEERING WORKSHOPS / ARAKKONAM FOR THE YEAR 2008-09
No.of staffOut turn for
year 2008-09Sl.
No.Description
Sup. Tech. Total MT EQ.U
(A) (B) ( C ) (D) (E) (H) (I)
I DIRECT STAFF :
1 Foundry shop 5 136 141 406.8 285.2
2 Fitter shop 3 46 49 332.7 495.6
3 Signal Fitter shop 2 46 48 387.3 529.2
4 Structural shop 5 82 87 932.4 1054.9
5 Glued Joint Section 2 34 36 215.7 208.3
6 Tinker shop 1 22 23 6.8 68.7
7 Millwright shop 7 96 103 44.2 141.8
8 Points & Xings shop 5 78 83 1356.5 1202.8
9 Blacksmithy shop 5 117 122 656.3 1042.0
a Total :- 35 657 692 4338.7 5028.5
II INDIRECT STAFF :
1 Welding shop 3 72 75
2 Paint shop 1 27 28
3 P.C.O. Staff 28 9 37
4 Night Shift 1 0 1
5 Tool Room 1 0 1
b Total Indirect Staff :- 34 108 142
c Staff diverted to FBW 0 37 37
d TOTAL STAFF ( a+b-c) 69 728 797
e
Staff for productivity calculation duly
deducting absenteeism, m/c breakdown &
power failure (in Hours)
7322
f Total Eq.Units achieved during the Year 5028.5
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g Total no. of days in the Year 365
h Actual no. of working days in the Year 292
DescriptionAverage upto
the Year
Productivity of EWS/AJJ in Equated
Units/man/month0.9
PRODUCTIVITY OF STRUCTURAL SHOP
e
Staff for productivity calculation duly
deducting absenteeism,m/c breakdown &
power failure
1180
f Total Eq.Units achieved during the Year 1054.893
g Total no. of days in the Year 365
h Actual no. of working days in the Year 292
Description Average upto the Year
Productivity of Structural shop in Equated
Units/man/month1.1
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8
ACTIVITIES OF GIRDER FABRICATION IN ARAKKONAM
SAW ON OPEN WEB GIRDER COMPONENT (VERTICAL)
DP TEST ON OPEN WEB GIRDER COMPONENT (VERTICAL)
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SURFACE DEFECT IDENDIFIED BY DP TEST
OPEN WEB GIRDER ASSEMBLY
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METALIZED DECK STEEL GIRDER
ASSEMBLY OF S HALLO W TYPE GIRDER
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LAYOUT OF STRUCTURAL SHOP
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LALLAGUDA ENGINEERING WORKSHOP
Work shop location : Lallaguda(Urban)secunderabad
South Central Railway
Workshop Established : 1964 Main Products : Rivetted type girder
Welded type girders up to 30m Span
Fish belly type Rivetted GirderGlued joints 52Kg& 60 Kg (G3 L)FOB, Steel Channel Sleepers
Rail dolleys, Diplorry, Motor Trolley.
Number of Staffs : 220 Age Profile of the Staff : 40-45 Years Total Tonnage During the
Year 08-09 : 2436.18 MT/ Year
Equated Unit : 1403.6 /YearSTRUCTURAL SHOP
No of Staff : 117 Outturn for the Year 2008-09 : 200.20 MT/Year Equated Unit : 232.23/Year Future Proposal : To be increased to 360 MT/Year after
augmentation of infrastructures
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OUT TURN FOR THE YEAR 2008-09
Sl No Name of the ShopAchieved
During the Year
2008-09
1 Structural
a)Riveted Girder in MT 129.10
b) Welded girder in MT 71.10
2 Others (P.Way items) in MT 97.04
3 Glued Joint in MT (6291 Nos) 2138.94
Total Tonnage in MT 2436.18
OUT TURN 2008-09 - LALLAGUDA
0.00
500.00
1000.00
1500.00
2000.00
2500.00
a)Riveted
Girder in MT
b) Welded
girder in MT
Others (P.Way
items) in MT
Glued Joint in
MT (6291Nos)
Production - Shop wise
AchievedMT
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OUT TURN OF STRUCTURAL SHOP FOR THE YEAR 2008-09
Sl No Name of the ShopAchieved
During the Year2008-09
1 Structural
a)Riveted Girder in MT 129.1
b) Welded girder in MT 77.1
Total (in MT) 200.2
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FLOW LINE PROCESS OF LALLAGUDA ENGINEERING WORK SHOP
`
Receipt of work orders
Studying of drawings
Placing of indents & procurement through stores
Templating
Inspection of materials
RDSO/CONSIGNEE inspection
Fabrication
Despatch of finished products
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PRODUCTIVITY OF ENGINEERING WORKSHOPS / LALLAGUDA FOR THE YEAR 2008-09
No.of staffOut turn for year
2008-09Sl.
No.Description
Sup. Tech. Total MT EQ.U
1 Structural shop 5 111 116 200.2 232.23
2 Glued Joint Section 2 87 89 2138.94 1171.37
3 Mechanical Shop 1 11 12 97.0 Nil
Total :- 8 209 217 2436.18 1403.6
Total Eq. Units achieved during the Year 1403.6 /Yr
Total Tonnage achieved during the Year 2436.18/ Yr
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ACTIVITIES OF GIRDER FABRICATION IN LALLAGUDA
JIG FOR SAW
COMPONENTS FOR STEEL GIRDERS
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I SECTION FOR FISHBELLY GIRDER
JIG FOR I FORMING
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DRILLING OF S TEEL PLATE GIRDERS
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LAYOUT OF STRUCTURAL SHOP
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MANMAD ENGINEERING WORKSHOP
Work shop location : Manmad(Urban),Central Railway.
Work Established : 1906 Products : Open web Girder
Welded type girder,Truss, Glued jointsJoggled Fish plate
Number of Staffs : 878 Age Profile of the Staff : 45-55 Years Total Tonnage During the
Year 08-09 : 7129.36 MT
Equated Unit : 12063.35/YearSTRUCTURAL SHOP
No of Staff : 494 Outturn for the Year 2008-09 : 2803.82 MT Equated Unit : 3424.4 MT Future Proposal : To be increased to 3600 MT/Year
after augmentation of infrastructures
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OUT TURN FOR THE YEAR 2008-09
Sl No Name of the Shop
AchievedDuring the
Year 2008-09(MT)
1 Structural Girders 2803.82
2 Light Structural 389.74
3 Others* 3935.80
TOTAL 7129.36
* Others inclusive of Glued joint, BS, BNR, M.Shop, Misc Works of EUR & Channel Sleeper
OUT TURN 2008-09 - MANMAD
0.00
500.00
1000.00
1500.00
2000.00
2500.00
3000.00
3500.00
4000.00
4500.00
Structural Girders Light Structural Others*
Production - Shop wise
AchievedMT
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OUT TURN OF STRUCTURAL SHOP FOR THE YEAR 2008-09
Sl No Name of the ShopAchieved Duringthe Year 2008-09
(MT)
1 Structural Girders 2803.82
2 Light Structural 389.74
TOTAL 3193.56
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FLOW LINE PROCESS OF MANMAD ENGINEERING WORK SHOP
`
Templating
Cutting
Initial assembly
Tack assembly
Initial assembl
Riveting
Jig
Final assembly
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PRODUCTIVITY OF ENGINEERING WORKSHOPS / MANMAD FOR THE YEAR2008-09
No.of staffOut turn for year
2008-09Sl.
No.Description
Sup. Tech. Total MT EQ.U
1 Structural shop 37 457 494 3193.56 4051.55
2 Others 41 343 384 3935.80 8011.80
Total :- 78 800 878 7129.36 12063.35
Total Eq.Units achieved during the Year 12063.35
Total Tonnage achieved during the Year (in MT) 7129.36
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ACTIVITIES OF GIRDER FABRICATION IN MANMAD
PICTORIAL REPRESENTATION OF PLATE STRAIGHTENING MACHINE
DYE PENETRANT TEST OF FILLET WELD
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DRILLING OF COMPONENTS USING FERRULES
HIGH S PEED DUAL NOZZLE PUG CUTTING MACHINE
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PICTORIAL VIEW OF STOCK YARD
INSPECTION OF FERRULES
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LAYOUT OF STRUCTURAL SHOP
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SABARMATHI ENGINEERING WORKSHOP
Work shop location : Sabarmathi(Urban),Near Ahamedabad
Western Railway.
Work Established : 1958 Products : Open web Girder
Welded type Girder
Fish Belly Girder
Number of Staffs : 656 Age Profile of the Staff : 35-50 Year Total Tonnage for the
Year 2008-09 : 6011.39 MT/Year
Equated Unit : 4742.35 /YearSTRUCTURAL SHOP
Number of Staffs : 376 Outturn for the Year 2008-09 : 1645.89 MT/Year Equated Unit : 2072.60 /Year Future Proposal : To be increased to 2250
MT/Year after augmentation
of infrastructures
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OUT TURN FOR THE YEAR 2008-09
Sl No Name of the ShopAchieved Duringthe Year 2008-09
(MT)
1 Structural
Open web girder 1343.39
Riveted Plate Girder 198.70
Welded Plate Girder 103.80
2 Glued Joint 3430.00
3 Steel Channel Sleeper 897.00
4 SEJ Set 38.50
TOTAL 6011.39
OUT TURN FOR THE YEAR 2008-09 - SABARMATHI
1343.39
198.70 103.80
3430.00
897.00
38.500.00
500.00
1000.00
1500.00
2000.00
2500.00
3000.00
3500.00
4000.00
Open web girder Riveted Plate Girder Welded Plate Girder Glued Joint Steel Channel Sleeper SEJ SetProduction - Shop wise
Achieved MT
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OUT TURN OF STRUCTURAL SHOP FOR THE YEAR 2008-09
Sl No Name of the ShopAchieved
During the Year2008-09 (MT)
1 Structural
a) open web girder 1343.39
b) Riveted Plate Girder 198.70
c) Welded Plate Girder 103.80
TOTAL 1645.89
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FLOW LINE PROCESS OF SABARMATI ENGINEERING WORK S HOP
`
Templating
Cutting
Initial assembly
Fitting
Drilling
Final assembly
Riveting
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PRODUCTIVITY OF ENGINEERING WORKSHOPS / SABARMATI FOR THEYEAR 2008-09
No.of staffOut turn for year
2008-09Sl.
No.Description
Sup. Tech. Total MT EQ.U1 Structural shop 21 355 376 1645.89 2072.60
2 Others 25 255 280 4365.50 2669.75
Total :- 46 610 656 6011.39 4742.35
Total Eq.Units achieved during the Year 4742.35
Total Tonnage achieved during the Year(in MT)
6011.39
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ACTIVITIES OF GIRDER FABRICATION IN SABARMATHI
PICTORIAL REPRESENTATION OF I SECTION FOR PLATE GIRDERS
PICTORIAL REPRESENTATION OF OPEN WEB GIRDER
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SUBMERGED ARC WELDING JIG FOR STEEL PLATE GIRDERS
SUBMERGED ARC WELDING JIG FOR STEEL PLATE GIRDERS HAVINGBOTH SIDES TRACK FOR DOING FILLET WELD
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PICTORIAL REPRESENTATION OF DRILLING OF COMPONENT ON BOTH
TRACKS
PICTORIAL REPRESENTATION OF FORMING I-SECTION FOR FISH BELLY
GIRDER
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LAYOUT OF STRUCTURAL SHOP
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COMPARATIVE STATEMENT OF STRUCTURAL SHOP OF ALL
WORKSHOPS 2008-09
Description AJJ LGD MMR SBI
Present Production of Structural
shop in MT
634.25 200.20 2803.82 1645.89
Proposed Production of Structural
shop in MT1200.00 360.00 3600.00 2250.00
COMPARITIVE CHART OF WORKSHOPS
634.25
200.20
2803.82
1645.89
1200.00
360.00
3600.00
2250.00
0.00
500.00
1000.00
1500.00
2000.00
2500.00
3000.00
3500.00
4000.00
AJJ LGD MMR SBI
WORKSHOP UNIT
inMT
Present Production Proposed Production
TOTAL OUT TURN OF ALL WORKSHOPS FOR THE YEAR 2008-09SlNo
Name ofthe Shop
Achieved During the Year 2008-09 (MT)
ARAKKONAM LALLAGUDA MANMAD SABARMATHI
TOTAL 4346.58 2470.35 7129.36 1645.89
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CONCLUSION
Arakkonam : Flow line has to be improved, since one more covered shed is
required. Welders and gas cutters have to be augmented. Augmentation of Speed Gas Cutting Equipment, Compressors,
Plate Bend Removal Machine, Drilling Machines are essentialfor increasing production. Since Arakkonam workshop is having all type of other shops such
as Mill Wright, Fitter shop, Crossing shop, Motor Trolley shop,glued shop, foundry, black smith shop along with structural shop.
With available shed and machineries along with re-employment ofother shop staff, present production of 50 T / month will beincreased to 100 T/ month during Aug 2009 ( 1200 T / Year ).
Lallaguda : Land constraint is affecting for further development of this shop. Flow line cannot be further improved due to non availability of
land. How ever with available man power and machines, the present
structural shop capacity of 220.2 MT/ Year can be increased to 360
MT/ Year.
Manmad : The flow line is excellent, since it has got three parallel long shed
of 260 m length. Feeding of material is very good. It has got Speed Pug Gas Cutting Machine, Shear Cutting
Machines, Plate Straightening Machines, Ferrules System ofDrilling, and more numbers of Drilling Machines along with 17
numbers ofEOT Cranes. Their structural shop capacity can be increased from 2803.82 MT
to 3600 MT/Year per year by suitable deployment of additional
staff.
Sabarmathi : The flow line is moderate since two bays are narrow. It has got more number of Drilling Machines, Good Fixtures &
Jigs, Cutting Machines, and Plate Straightening Machines. Onemore additional shed may be erected along with second bay to
increase the production. However final assembly yard requiresimprovement.
It is proposed to increase the production of girders from 1645.89MT/Year to 2250 MT/ Year with in 3 years.
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RECOMMENDATIONS
1.Works Manager and Asst. Works Managers should be trainedin Basic Principles of Design of Steel Structures inIRICEN/PUNE.
2.Annual SEMINAR CUM WORKSHOP to be conducted inrotation on ALL-INDIA basis for AWM/ WM/ Dy CES for
dissemination of knowledge and what is going in different shopsof Indian Railways.
3.Supervisors and other critical staff such as welders, gas cuttersshould be given periodical training in reputed institutions other
than railways also for absorbing latest technology in respective
fields.
$ $ $