Wagon Rehabilitation Shop –

Bottlenecks & Suggestions For

overcoming them

By:
Shadab Jamal 2K301
Abhishek kumar singh 2K302
Ashutosh prasad 2K303
Ritwik Sharma 2K304
 Objectives
• To study the reasons for under performance
of WRS – 1.
• Suggestions and recommendations for
increasing its productivity.
 ORGANISATION
WRS-1 WRS-2 WRS-3
SSE 6 2 2
SE 7 5 8
JE 16 13 17
WELDING 46 31 60
MACHINES
D A POINTS 26 18 15
OXY POINTS 30 34 28
WORKERS 475 450 520
 Steps involved in POH
1. Initial inspection of sick wagons for POH
2. Cleaning and marking the shortcomings
3. Body separation and body fitting
4. Placing the body over the pit
5. Stripping of CBC , air brake arrangement
etc.
6. Repairing of under frame member like
center seal , sole bar
7. Repairing of end wall , side wall and floor
8. Assembling the wagon body
9. NTXR examination
10. Fixing the anomalies
11. Wagon ready for loading
 Bottlenecks in the shop
1. High absentee rate in the shop (on an avg.
30% are always away from work )
2. Only four hours of effective work (time
consumed in assembling the equipment)
3. Lack of co ordination between welding
and fitting section
4. Lack of accountability
5. High downtime of EOT cranes
6. Lack of skill and leadership in the
supervisory staff.
7.No proper arrangement of removal of scrap
from the shop.
8.Unauthorized encroachments along the shop
wall leading to space congestion
9.Lack of proper lighting arrangements.
10.Improper pits with low heights and
congested bays.
11.Inefficient material movement and over
dependency on EOT cranes.
12.Inefficient material movement between the
wagon shop and B.S.T.
13.Substandard main switches used for
welding and EOT cranes
14.Water logging during rainy season.
15. The under frame obtained after stripping
operation is not fit for carrying out
rebuilding and has to be reworked
16.Damaging of welding cables
17. Lack of motivation in workers
18. Improper utilization of available space
19. Procrastination in heavy repair wagons
 Suggestions
Problem: High absentee rate in the shop-on an
avg. 20-25% are always away from work .
Solution:
• Strict control over grant of leave to workers.
• The concerned SSE should send the daily
report to the Dy. CME
Problem: Only four hours of effective work:-
2. Late arrival of workers
3. High equipments setting times in both
halves
4. Workers found sleeping during working
hours
Date : 30-05-08
Time : 12:27
Solution :
• Most of the workers come by workers train
hence shift timings/train timings should be
adjusted accordingly.
• Dedicated welding machines for each pit
along with the shelf where worker can
safely put his equipments.
• High penalty for workers found sleeping
during duty hours.
• Surprise visits by officials.
Solution :
• Most of the workers come by workers train
hence shift timings/train timings should be
adjusted accordingly.
• Dedicated welding machines for each pit
along with the shelf where worker can
safely put his equipments.
• High penalty for workers found sleeping
during duty hours.
• Surprise visits by officials.
Problem :
Lack of co ordination between welding and
fitting section:-
3. Welding staff not under control of SSE
Solution :
Both the welding and fitting staff should be
placed under the control of single person
on the shop floor.
Problem : Lack of accountability

Solution : both the sections should be equally

responsible for the dispatch of wagons.
At present only the fitting section is
responsible.
Problem : High downtime of EOT cranes

Solution :
• Recruiting/deputing dedicated electrical
staff for the maintenance of EOT cranes.
• System should be setup to phase out old
EOT cranes and procurements of new
cranes.
Problem : Lack of skill and leadership in the
supervisory staff.
• Supervisory staff not qualified enough.
• Lack of supervisory staff during day shifts.
Solution :
• Most of the supervisory staff should be
booked during the day shift.
Problem : No proper arrangement of removal
of scrap from the shop.

Solution :
• regular removal of scrap should be ensured.
• person concerned for removal of scrap
should report to SSE
Problem : Unauthorized encroachments along
the shop wall leading to space congestion

Solution :
These encroachments should be demolished .
This will result in recovery of lot of space
and also make the shop spacious and well
ventilated.
Problem : Lack of proper lighting
arrangements

Solution :
• Workers should be provided with miner’s
helmet for working on under carriage.
• Sufficient lighting bulbs should be placed at
proper locations.
Problem : Improper pits with low heights
pedestals and congested bays

Solution : Construction of fixed pits with

pedestals of proper height so that workers
can work conveniently under the wagons.
Problem : Inefficient material movement
between the wagon shop and B.S.T.

Solution : Better availability of trucks for

transportation should be ensured.
Problems : Substandard main switches used
for welding and EOT cranes:-
• The main switches supplied are blown off
during use.

Solution : standard switches of rated wattage

should be used.
Problem : Water logging during rainy season:-
• Arc welding not possible due to improper
earthing logging during rainy season

Solution :
• Proper arrangement for drainage should be
made
• Proper flooring and roofing should be done
Problem :
Damaging of welding cables

Solution :
• Dedicated equipment for each pits so that
there is no need for long cables.
• Workers should be motivated to act more
responsibly and take better care of
equipments.
Problem : Lack of motivation in workers
Solution :
• Incentive scheme should be better
monitored.
• More amenities for workers such as
drinking water, gloves, ear plugs, helmets
etc. should be provided.
Problem : Improper utilization of available
space

Solution : the number of pits can be increased

by making use of space available between
WRS 3 and WRS 1
Problem : Procrastination in heavy repair
wagons:-
• Tendency among the shop staff of delaying
heavy repair work.
Solution :
The outturn position should be made pit
specific so that any wagon occupying a pit
for unusually long periods can be detected.
Problem : The under frame obtained after
stripping operation is not fit for carrying out
rebuilding and has to be reworked.
This increases time required by fitting people
to rebuild the wagon again.

Solution : The supervisor should ensure that

the stripping operation is of superior quality
and doesn’t require rewoking.
250

200

150 WRS 1
WRS 2
100 WRS 3

50

0 2007 2007 2007 2007 2007 2007 2007 2007 2007 2008 2008 2008 2008 2008
April may june july aug sep oct nov dec jan feb mar april may
• Increasing number of pits-
The space available between WRS 1 and
WRS 3should be utilized for increasing
capacity.
• Relocation of pits-