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Study on
Utilization of Wagon loading system
at
OCL INDIA LIMITED
Studied & submitted by
UDAYKUMAR SASTURE
Date of Visit: 23rdto25th Jan-2013
TECHNICAL SERVICES
NEW DELHI
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EXECUTIVE SUMMARY
The study on wagon loading system has been carried out in order to see the
feasibility in increasing of no. of cement rakes from the present level 60 nos per
month.
During the study the following bottlenecks force to increase the number of
shunting:
1. Subhash chowk and Railway gate, people and vehicle traffic obstructingthe shunting of rake.
2. The single track line at railway gate restricted the entry of rakes (Clinker.Gysum,slag, cement, coal and furnace oil wagon) one at a time
3. The curvature of track line is more than 12 degree as against the std. 6 to7 degree hence the no. of shunting will be more.
Based on the time study it is found and possible to load the rakes up to 75 to 80
(potential 85 nos.) nos every monthas against the present level 60nos with the
following recommendation:
Rake arrangement :Presently there is a gap time in receipt of rakes for loading and it works
out to 260 hrs to 359 hrs in a month.
It is recommended to arrange the rakes at an interval of every 6 to 7hrs in
liaison with railway authority so as to ensure the availability of rakes for
loading.
Packer feed rate :It is observed that the present packer feed rate works out to 157TPH as
against the designed capacity 240 TPH. This requires discussion withPacker supplier M/s ENEXCO and study to improve the packer output
rate further.
Wagon Tippler line -11 :There is a space for extension of track by another 100 to 150 meters
which facilitates to accommodate 10 or12 no. of wagons more in addition
to the present 24nos ( Total-34 to36), thereby the shunting will reduce to
2 times per rake. This help in availability of loco for cement rake loading.
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Seek line in exchange yard:The extension of the existing seek line track facilitates to convert this
track to use for stable rake formation in case the power of railway
authority delays in taking the entire rake formed earlier in turn affect the
other rake formation as the no. of line available is two.
Fly over at railway gate:The flyover at railway gate help in shunting of the wagons at a faster rate
as this is the junction point, without hindering public moment.
As a result of above the no. of rake loading shall increase to 80nos from presentlevel of 60 Avg./month, thereby the Sales volume and value increases to 54000
tons and 1.62 crore (approx.) respectively on monthly basis.
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Study on Utilization of Wagon loading system
at OCL INDIA LIMITED
1.0OBJECTIVE:To study the utilization of packing machines and its associated activities right from the
receipt of Railway wagon, wagon placement and loading in order to suggest
improvement actions for further increase in the no. of Cement Rake loading
2.0Methodology:Time study
To arrive at the cycle time of the wagon loader. Basic data of last six month. Identification of bottleneck
3.0OBSERVATIONs & RECOMMENDATION:The finished Product (cement) of different grades is being dispatched by
Rail and Road
Based on the six month data analysis it is works out that about 70% of cement being
dispatched through Rail and rest by road.
The rake of cement and other raw materials( Slag, Gypsum, coal)to be loaded/unloaded
are bringing to the exchange yard from the main station ( Rajgangpur) located at
distance of 2.0 km away.
The intimation of receipt of railway wagon is being received 2 hrs. Well in advance.
The cement Rakes comprises of the following types of cement wagon
BCN, BCNA & BCNAH :Each rake consists of 42 nos, of wagon of mixed combination of above types.
The no. of cement bags to be loaded in wagons varies from 1238 to 1278.
EXCHANGE YARD:
The cement wagons to be loaded of 42nos is being brought to exchange yard or
directly to the packer loading platform from railway station depending on the
loading platform empty condition by our power loco only.
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There are four lines in exchange yard being used as junction:
To form the stable cement rake after being loaded, to handover the railwayauthority.
To bring the Raw materials wagons to be unloaded from railway station.The time taken to bring the wagons from railway main station to the exchange Yard
is as follows: Min.
Move with the loco to railway station in case of cement wagon : 07.00 Attached to the rake and coupling : 02.50 Awaiting for Vacuum Pressure build up to 6kg and Release : 15.00 Start move to exchange yard : 17.00
Total (Min.) : 41.50
The cement rake of 42 wagons is divided in to three parts at exchange yard as:
- Wagons 12 nos- Wagons 12nos and- Wagons 18nos
Bottlenecks in exchange yard:
1. Subash chowk which is heavy public moment road, the no. of wagonswill accommodating on the approved line of railway authority is
limited to 36 nos as against the 42nos cement wagons/ 59 nos of raw
material wagons.
2. The line-1 and line 2 are critical line cannot be used for keeping thewagons for longer time. These lines are main shunting lines of
wagons to be loaded / unloaded, are taken inside and outside plant.
3. There is only one rail line available to take rail wagons inside &outside the plant from the exchange yard through rail gate.
- Cement for loading and,
- Slag, Gypsum & Coal for unloading inside the plantThere is also a public cross road between exchange yard and main rail
entry gate of the plant.
The entire cement rake is divided in to three parts and taken inside the plant in the
shortest time (2 to 3 minutes) for the convenience of the public movement to avoid the
agitation at Railway gate as well as Subhash chowk.
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OPERATION OF RAKES INSIDE THE PLANT:
The cement wagons to be loaded are taken inside plant (packing plant) at the four loading
platform as follows:
Track Line -4:
The no. of cement wagons to be loaded is allocated 12 or 14 nos as against Max
20nos. The wagon positioned in the form 3-3-3-3 and time taken to position the
Same is 15 to 17 minutes.
Track Line -5 :The no, of cement wagons to be loaded is allocated 12 or 14nos as against Max
20nos. The wagon positioned in the form 3-3-3-3 and time taken to position the
Same is 15 to 17 minutes.
The line 4 and 5 is used for loading of cement wagon by the packers -1 and 2.
Track Line -1 :The no. of cement wagons to be loaded is allocated 8 or 9 nos as against the 19
nos. Max. The wagon positioned in the form 2-2-2-3 and time taken to position
the same is 15 to 17 minutes.
Track Line -1A :The no, of cement wagons to be loaded is allocated 8 or 9 nos as against 19 nos.
max. The wagon positioned in the form 2-2-2-3 and time taken to position the
same is 15 to 17 minutes
The line 1and 1A is being used for cement wagon loading using the packers -4 and 5.
Sl.No Packers No. of loaders Platform
01 Packing Machine-1, 16
spouts, and discharges on
two side. Make Enexco,
DesignCapa-240TPH,5rpm
Total 4nos - 2 nos for each belt
discharge of packers
Track Line -4
& 5
02 Packing Machine-2, 16
spouts, discharge on two
side. Make Enexco ,Design
capa-240TPH,5rpm
Total 4nos - 2 nos for each belt
discharge of packers
Track Line -4
& 5
03 Packing Machine-3, 16
spouts, discharge on two
side. Make Enexco,240tph
Design,5rpm
Total 4nos - 2 nos for each belt
discharge of packers
Track Line -1
& 1A
04 Packing Machine-3, 16
spouts, discharge on two
side. Make Enexco,240TPH
,5rpm
Total 4nos - 2 nos for each belt
discharge of packers
Track Line -1
& 1A
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GAP TIME BETWEEN THE RAKES:
Presently the cement rakes being received one after another and thereby it is observed that
a gap time between the two rakes. The gap time works out to 260 to 359 hrs every month
out of total available 720 hrs to 744 hrs. in a month. During this time the packer machine
are mostly ideal utilizing for loading of trucks. The manpower engaged for loading of
cement is on rake basis.
It is recommended to plan the arrangement of the rakes on continues basis in consultation
with the railway authority to reduce the gap time ( an Avg. 4 hrs to 5 hrs.).
The time between receipts of one rake to another should be of 6 hrs. This will help to
increase no. of cement rakes loading by another 15 to 20 nos more. Thereby the no. of
rakes shall increase from Present level 60 nos to 75 - 80 on every month.
There will be increase in dispatch quantity further by 54000 tons-Max by following the same
pattern of loading
Presently the no. of rakes presently handling/month on an avg. 95 to 101 as follows :
Cement 62 Rakes Slag- 11 rakes Coal - 13 rakes Gypsum- 04 rakes Clinker 11 rakes
PACKER FEED RATE:
Based on the time study the loading of cement wagon using the loader has been carried out
at the feed rate of 157 TPH as against the rated capacity of 240 TPH. This is due to because
of the following:
Problem in the nozzle. Early filling of bag. No falling of the bag. Higher Cement blain
Further the productivity level can be improved by closely attending the nozzle
related problem. Further this helps in reduction of loading time of cement
wagon.
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TWO RAKE LOADING AT A TIME:
The loading of two rakes, one each at loading platform is possible but the cycle time
increases to 480 minutes as the number of loading point at a time will be reduced to 4times
from earlier 8 times. The total cycle time required for handing over to railway authority will
be 10hrs with including the shunting time as against the permissible time 9 hrs. .This shall
force us in to the demurrages threshold. This could be tried after improving the feed rate
of packer more than 175 to 180 TPH.
TRACH LINE 2 an 10:
These line tracks are buried with the slag about 35% of its total length. It suggested to clear
off the track line from slag so as to utilize these entire length of track lines for keeping of the
empty wagons.
SEEK LINE IN EXCHANGE YARD:
In exchange yard the seek line length may be extended to use for stable rake formation, as
this would help in handling no. of rakes in case when the power engine of railway authority
delays to take the stable rake from Exchange yard.
RAW MATERIAL UNLOADING LINE-11:
The wagon tippler line 11 to be extended further by 100 to 150 meter towards boundary
wall in order to accommodate more no. of empty wagons of coal/wagon/slag would
facilitates in handling of raw material n type wagons.
CLINKER LOADING LINELINE-9:
The clinker wagon loading system requires loco permanently which is also restricts the non-
availability of loco for cement wagon SHUNTING. The existing side arm charger is not in
operation. The track length of clinker wagon line 9 is limited to 13 to 14nos which
prolonging the loading time and multiple handling of the N-type -wagons.
The following bottlenecks are in the inside the railway gate:
1. The upward gradient of the railway track limit the pulling of the loaded wagons up to18 nos.
2. The track line curves are 15 degree which is more than the standard 6 to 8 degree,this further increases the handling of wagons in shorter length.
3. If clinker wagons to be loaded the wagons from raw material track line-11 to Line-9is to be carried out at railway gate junction only
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Wagon loading Cycle time:
Based on the time study the cycle time of the wagon loader has been works out as
follows:
Placement and preparatory work: Actual
Placement of wagon on the Line 4 15 .0 minmin
Placement of wagon on the line 5 14.24 minPreparatory work of wagon loader 03.45 min
Cycle time: Wagon loader.
Loader 1stcycle 14.04 Min 13.56 min 2NDCycle 07.06 Min 06.50 min. 3rdcycle 05.37 Min 05.46 min.
Total A 26.47 Min 26.52 min
Changeover of loader to second door is being done without the stoppage of packer
operation
Loader 1stcycle 10.10 Min 08.00 Min 2ndCycle 06.10 Min 06.52 Min 3rdcycle 05.50 min 06.00 Min
Total B 22.10 Min 20.52 Min
Avg cycle time per Wagon 48.57 Min 47.44 Min
Total time taken for loading of the entire rake : 280 Min.
Product change over 05 Min
Stoppage hrs 130 Min*
Rake shunting 20 Min
Move to Exchange yard 24Min
Form a stable rake line 10 Min
Total rake cycle time work out to: 501 minutes
* 0.20 W/l 3 Telescopic problem
0.30 RP-1 NZ-12 Ventilation fault
0.30 RP-1,NZ-7 Pressure pipe problem
0.20 W/L 8 Belt problems.
0.20 W/L 5 bag diverter
0.20 W/l 9+10 discharge belt jammed
0.70 W/L 13 and 14 electrical prob
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WAGON LOADING SYSTEM AT OCL INDIA LTD.
SL.NO. Observation Recommendations Tar
gate
date
Respons
ibility
S/s
Remarks
01 Based on the time
study, Packer feed rate
works out to157 TPH
as against the Design
capacity 240 TPH. Avg.
It should be 190 TPH.
Wagon loader 9 to 16
needs attention to
smoothen the
operation
Make Functioning of16 spouts
effectively.
Bag falling afterattaining the
required weight of
50kg
No bag falling. The RPM of the
packer is found 2
rpm as against the
design 5 rpm
02 Rake Arrangement:
Presently it is found
that there is a gap time
in arrival of rake to
rake works out to 8hrs
to 10 hrs i.e varies
from 260hrs to 360 hrs
in month
The rake to be arranged in
consultation with Railway
authority at an interval of
every 6 to 7th
Hr one each.
This helps in loading of
rakes by 15 to 20 more i.e
54000 tons per month by
following FIFO basis. There
will be increase in the sale
quantity by 54000 ton per
month.
03 SEEK LINE EXTENTION
IN EXCHANGE YARD:
This line is used for
keeping the wagon to
be repaired.
The extension of seek line
help to utilize in stable rake
formation in case power of
railway authority delays in
taking the stable rake from
the exchange yard
04 Track line -11:
Raw materialunloading has
limitation to
accommodate 24
wagons after
unloading by wagon
tippler
There is a space available toextend by 100 to 150
meters will help to keep 10
to 14 wagons more
continuously to reduce the
shunting frequency.
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WAGON LOADING SYSTEM AT OCL INDIA LTD.
SL.NO. Observation
Recommendations
Tar
gate
date
Responsibility
S/s
Remarks
05 Clinker loading wagon :
It is found that the loco
is engaged exclusivelytill
the rake is loaded.
Shunting is required for
every 24 nos of wagons.
It means three time
shunting. The extention
of rake length is possible
but we have to procure
land .
WINCH Machine
working to be
made to release
the loco for other
wagon shunting
06 Track lines -2 and 10:
These lines of some
length are buried with
the slag, the same could
be cleared off to keep
empty wagons in
emergency case
07 Two Rake loading:
Possible but it will
increase the loadingcycle time to double due
to reduction in no. of
loading point to 4 as
against earlier 8.
No. of wagon can be
placed on 4 & 5 to the
extent of 20Max on each
line and on line 1 &1a 19
wagons each side
No of gangs will
increase frompresent 2 nos to 3
or 4
Two rake loading
could be tried after
improvement in
the packer feed
rate to at least 190
TPH
08 Railway gate :There is a Single track
line to take all type of
wagon inside the plant.
The public and vehicle
moment affected largely
to the shunting wagons.
Sometime entire rake is
divided in to three parts
It is proposed tohave a flyover at
railway gate
facilitates in
smooth operation
of the wagon
shunting without
the interruption of
the public moment,
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