1

WORK STUDY REPORT

ON

REVIEW OF STAFF WORKING

IN

ELECTRIC LOCO SHED

LUDHIANA

2017-18

WORK STUDY TEAM

SH. LALIT KUMAR : AWSO LEADER SH.RAM PARSHAD : CWSI MEMBER SH. YOGESH KR. BADHWAR : SWSI MEMBER

DATE OF START : 05.04.2017

DATE OF COMPLETION : 12.05.2017

GUIDANCE

BY

SH. ASHOK KUMAR AGARWAL: SWSO

NO.16-CP/3/WS/2017-18 CENTRAL PLANNING CELL, NORTHERN RAILWAY,

BARODA HOUSE, NEW DELHI.

2

EXECUTIVE SUMMARY

The study was allotted to the Central Planning Cell, HQ office on the directive of SDGM/NR

to identify redundant activities with a view to eliminate wasteful expenditure and to

improve manpower productivity of Electric Loco shed Ludhiana.

STAFF POSITION

The total sanctioned and on roll strength of Group ‘C’ & ‘D’ staff of Electric Loco Shed,

Ludhiana is as under:-

S.N. Category

S/S O/R Vac.

1 Gr. ‘C’

429 388 - 41

4 Gr. D unskilled

153 175 +22

Total

582 563 -19

No. of posts identified as surplus and recommended for surrender: -

Gr. ‘C’ = 06 posts

Gr. ‘D’ = 20 posts Total = 26 posts

FINANCIAL IMPLICATIONS

Anticipated recurring savings = 124.58 lakh per annum.

Capital savings = Nil

Total savings = 124.58 lakh per annum

582 563

19

556

26

0

100

200

300

400

500

600

700

SS OR VAC Proposed Staff Surplus

No. of. Staff

3

INDEX

SN Contents Pages

From To

1 Synopsis

- 4

2 Summary of recommendations

- 5

3 Acknowledgement

- 6

4 Introduction

- 7

5 Brief description, staff position,

workload, critical analysis, requirement of

staff, recommendations & General observations.

8 13

6 Financial Implications

- 14

7 Work study report detailed chart

- 15

8 List of annexure

- 16

*****

4

SYNOPSIS

In Rail operation, locomotives play a vital role in haulage of passenger/freight trains. In

the changing scenario, the steam locos were totally phased out in the year 2000 and now a

days all the trains are hauled by Diesel and electric locos. This study deals with Electric loco

sheds which are essentially required for maintenance and up keep of these locomotives. Electric

locomotives are latest designed fleet to haul longer route trains at higher speed with in-house

manufacture of state of the art, three phase traction motor driven with high horse power. The

high speed 6 axle passenger locomotive with three phase technology is capable of hauling long

distance mail/express trains of 24 coaches with reliability and punctuality at the desired level.

The maintenance of electric locomotives is carried out by different electric loco sheds over the

entire Indian Railways. Electric loco shed Ludhiana is one of the maintenance sheds over

Northern Railway which carries out minor inspection schedules like IA, IB, IC along with AOH &

IOH schedules.

Due to various innovations/modernizations and system developments, the various

maintenance activities need to be streamlined with a view to effect economy in expenditure

with improved manpower productivity. Consequently SDGM/NR desired to conduct a work

study on “Review of Staff strength working in Electric Loco Shed Ludhiana over Firozpur

division”.

The team collected the staff position and workload maintenance sections from the shed

and examined critically. The team kept in mind, the periodicity of various maintenance

schedules, modifications being incorporated, geographical conditions, existing working

conditions and bench mark/norms as laid down by Railway Board and given due consideration

while assessing the requirement of manpower. Keeping in view of above, the team identified 26

posts as surplus and recommended for surrender. After acceptance and implementation of the

report in toto a net recurring saving to the tune of 124.58 lakh per annum will be achieved

by the railway administration.

*******

5

SUMMARY OF RECOMMENDATIONS

Rec

No Recommendations

Refer

para

no.

Accepting/

Implementing

authority

1

It is proposed that 26 posts in different categories and

grades are identified as surplus, under the

administrative control of Sr.DEE/TRS/Elect. Loco shed

Ludhiana and recommended for surrender as follows:-

SN Category Grades in Surplus posts

1 Tech.III 5200-20200-1900 06

2 Gr.D staff 5200-20200-1800 20

Total 26

2.1.2

ADRM/FZR

Sr.DEE/TRS/LDH

Sr.DPO/FZR

*****

6

ACKNOWLEDGEMENT

The work study team is highly grateful to Sh. Ashutosh Pant ADRM/FZR, Sh. Neeraj

Gupta, Sr.DEE/G/TRS, Elect. Loco Shed LDH, Sh Manish Narwal DEE/G Elect. Loco Shed

LDH and Sh. Jusuf Kabir, DPO/C/FZR for giving their valuable guidance during the

conduct of the study. The team is also thankful to SSE/Tech. & other functionaries for

providing relevant data/information and extending their full, co-operation during the

conduct of study.

*****

7

1.0.0 INTRODUCTION

1.1.0 Electric loco shed Ludhiana is an important shed of Northern Railway. These days

electric traction is the principal mode of motive power which hauls Rajdhani,

Shatabdi and Superfast Mail/Express trains over Northern Railways. The entire

network of division comprises of both electric and diesel locomotives.

1.2. Electric loco shed Ludhiana was inaugurated on 10.11.2002 with homing capacity

100 electric locomotives. It is having both conventional (WAP4) & (WAG7) and 3-

phase locomotive (WAG9H) and get the opportunity of maintaining state of the

art technologies equipped in 3-phase locomotives ie IGBT based converters etc

and started homing from October, 2015.

Conventional locomotives (WAP4 & WAG7) are equipped with micro Processor

Static inverter &ARNO converter Vigilance control device & ESMON in all

locomotives of various make.

At present loco holding of ELS/LDH is 181 locos (WAP4-15 & WAG7- 152 &

WAG9- 14) against the homing capacity of 150 electric locomotives. Further

augmentation of homing capacity from 150 to 175 electric locomotives is under

process.

1.2.0 The Ludhiana shed provides reliable electric locos for hauling passenger and

freight trains over Firozpur Division. To keep the wheels of electric locos on move

efficiently, this shed carries out inspection as well as periodic schedules and out

of course repairs. The periodicity of maintenance schedule has been enhanced

and notable innovations/modifications are being incorporated in design features

of electric locomotives along with replacement of components/parts. This has

resulted in lesser maintenance efforts and more reliability but the staffing pattern

has not been changed yet.

1.3.0 Consequently, SDGM/NR has assigned a work study on “Review of staff strength

working in Electric loco shed/LDH over Firozpur Division” with a view to eliminate

wasteful expenditure without hampering the smooth functioning of electric loco

shed.

1.4.0 TERMS OF REFERENCE

The work study has been conducted under the following terms of

reference: -

i) To review staff strength vis-à-vis workload. ii) To suggest ways and means to identify redundant/unproductive activities

to eliminate wasteful expenditure. iii) To suggest ways and means to improve the efficiency and productivity of

the system.

8

1.5.0 METHODOLOGY ADOPTED

The following method study and work measurement techniques were adopted to conduct the study: -

i) Data collection and its critical analysis. ii) Work sampling, analytical estimation, spot observations, physical checks

and yardstick in vogue, if any, to assess the performance of staff. iii) Held discussions at various levels.

*****

2.0.0 BRIEF DESCRIPTION, STAFF POSITION, WORKLOAD, CRITICAL ANALYSIS,

EXISTING AND PROPOSED STAFF, GENERAL OBSERVATIONS AND

RECOMMENDATIONS

2.0.1 BRIEF DESCRIPTION

The Electric Loco Shed Ludhiana was set up by Railway Electrification

Organization (REO) as a part of LDH-ASR-JAT Electrification scheme and was

designed for holding of 150 electric locomotives. The prime objective of setting

this shed was to maintain electric locomotives required for hauling important

mail/express trains over LDH-JAT & LDH-ASR route. At present, the holding has

increased to 181 locos and this includes WAP-4 & WAG-7 type of locos. The

locomotives of LDH shed are hauling prestigious Rajdhani/Shatabdi/Duranto

trains on electrified routes. This shed dealt in maintenance of Goods as well as

passenger locos.

2.0.2 Electric loco shed Ludhiana meet expectations of the Railway Administration as

well as in the public interest it cares for the reliability safety and availability of

electric locomotives well in time to run the nominated trains.

Maintenance practices have been reviewed and after technical up-gradations

some old activities have been dispensed with, which has resulted in substantial

savings of manpower as well as material.

2.0.3 The average loco holding of electric loco shed LDH during FY 2016-17 is as

under:-

WAP 4 = 15

WAG 7 =152

WAG9H =14

Total = 181 locos

9

2.0.4 MODIFICATIONS CARRIED OUT IN THE ELS LDH FOR IMPROVEMENT ARE AS

UNDER:-

The traction motor bellow welding, footsteps welding, anti spin valve sealing,

washer for dumper, brake electronic card modification, PT fuse checking

modification, BPEMS working isolation from rear cab, Earth fault in control circuit

tube lights and cab lights, C-145 interlock modification and oil level marking in

transformer for different temperature.

ACHIEVEMENTS:

A) Development of New Electronic labs for testing of ICB cards and their centralized records.

B) Decongestion of shop floor area in Medium repair bay, light repair bay. C) Commissioning of various test benches for 3 phase loco equipment and

conventional loco equipments.. D) Commissioning of new traction convertor gate unit test bench. E) Load testing facility for motorized wheel sets of 3 phase locomotives.

2.0.5 STAFF POSITION

The team collected detailed staff position of supervisors and other Group C & D

staff from Chief OS/TRS/LDH which is placed in the report at Annexure-II & the

summarized staff position is tabulated as under:-

S.N. Category S/S O/R Vac.

1 Supervisor 69 52 17

2 Artisan Staff 310 300 10

3 Ancillary 41 33 8

4 Gr. D unskilled 153 175 +22

5 DRG, Lab TLC 9 3 6

Total 582 563 -19

The above table reveals that the on roll strength is 563 against the sanctioned

strength of 582 and 19 posts are lying vacant.

10

2.0.6 Sections and their Description at ELS LDH:

SN Sections and nature of work 1 M1 This section deals with the overhauling of axle boxes, super structure

doors, windows, cattle guard, rail guard, CC coupler, buffer etc.

2 E2 Section deals with the micro processor control system (MPCS), loco control ckt, VCD, head light, flasher light, marker light, B/L box, failure

analysis, trouble shooting and their remedies.

3 PNE This section deals with the braking system, air drier, valves, air system O/H, air brake system OH & testing of equipment.

4 Lab. Section deals with laboratory testing of material, UST, RDPT tests,

Hardening test etc.

5 E4 This section is also known as Relay section, electrical relays of different

type like PC-8, air flow relay, pressure relay, protection relay &

electronic speedometer.

6 PPO This section deals with the planning i.e., placement of locos, to provide

to traffic after made ready, record keeping, loco failure & schedule

maintenance record etc.

7 Trans-

former Sec.

This section deals with the overhauling of transformer

8 Bogie

M6

This section deals with the dismantling & assembly bogie, bogie frame is

maintained by the contractor & rest of the work is done by the departmental staff.

9 Aux

section

This section deal with the auxiliary motors, blowers, compressors, DBR

(Dynamic braking system) and overhauling of SIV(Static convertor) The maintenance of compressors are done by the contractors.

10 TFP This section deals with connection tightening of transformers, bushing,

pipe line leakage checking, centrifuging of transformer, oil during AOH section, tap changer, OH & Maintenance of Control SMGR(Servo meter

for tap changes) OH & maintenance, CGR(Contractors, radiators air cooled forced) RPS(smoothening reactors).

11 EP This section deals with the electro pneumatic maintenance & OH, EMC,

EP, CPF, Reverser contractors, OH shunting contractors, SJ(inductive shunts for making DC

12 AOH Checking, maintenance securing, thimbling (changing if required) of all

power contactors, rectifier block AC to Dc VCB-vacuum ckt breaker which is a medium of supply 25000 V to VCB. Roof maintenance

(instrument fittings & waterproof) AC & DC panel to avoid surge, maintenance of jali, blower & net etc. and painting work in AOH section

13 GEN The general section deals with all the M&P maintenance, pit wheel lathe,

vehicle cleaning contractor, complaints & power panel etc.

14 Store This section deals with procurement of store item stock & non stock as well as local purchase, work contactor, work orders etc.

15 Tech Record keeping of technical datas, instructions furnished by RDSO

16 QA This section deals with the quality assurance. After the loco made ready, super checking is done to ensure the fitness of the locomotives.

17 Office For proper co-ordinations between the staff & Officers.

18 Super- Visors

For supervision of locomotives.

19 Lab &

TLC

For quality assurance of material lab testing.

11

2.0.7 WORKLOAD

The main function of Electric loco shed, Ludhiana is to maintain Electric

locomotives by carrying out various schedules like- IA, IB, IC (Minor schedule)

and TOH & IOH ( Major sch.) for home shed locos and repair of foreign shed

loco whenever required. The total number of different types of locos based for

maintenance in this shed is 181. The failures of electric loco occur during run due

to various reasons despite good maintenance practices in shed/shops. The out of

course repairs given to such locomotives either of home shed or of other sheds

vary both in quantity as well as in frequency.

The average loco holding of electric loco shed LDH during FY 2016-17 is as

under:-

WAP 4 = 15, WAG 7 =152, WAG9H =14 Total = 181 locos

The out turn of minor and major schedules carried out in electric loco shed,

Ludhiana for the last one year i.e., Apr’16 to Mar’17 is placed as Annexure No.

III in the report. The summarized position of the same is given below:-

TABLE NO. 1(OUTAGE F.Y.2016-17)

Out turn of Apr’2016 to Mar’2017

Types of schedules

IA IB IC TOH IOH Total

No. of locos 273 244 243 37 17 818

Avg./Month 22.75 20.33 20.25 3.08 1.14 68.16

The above table reveals one year out turn of different types of schedules carried

out for number of locos with average per month.

2.0.9 Loco Failure/Punctuality loss, month wise analysis is as under:

Month 2015-16 (LH-168) 2016-17 (LH-181)

April 1 4

May 7 4

June 3 4

July 4 2

August 1 3

Sept 3 4

Oct 1 1

Nov 3 2

Dec 2 4

Total 25 28

Average per month 2.77 3.11

Punctuality/100 loco per month

1.64 1.71

12

Detail of contractual work going under ELS/LDH is as under:-

SN Name of work Total quantity in Nos

Total value in

1 Rewinding of stater, auxiliary motor of WAG5 & WAG7 loco.

MVMT-24 MVRH-8

MVSI/MVSL-45 MPH-06, MCP-40

147600/-

2 Mechanical repair of Hitachi traction motor stator, magnetic frame type HS-15250 A (having 6 type of different sch. work)

Sch-01=75 Sch-02=30 Sch-03=50 Sch-03=50 Sch-04=62 Sch-05=62 Sch-06=20

7262000/-

3 For repair of top & bottom gear case mounting lugs og Hitachi Stator Magnet frame.

250 348750/-

4 Repair/rehabilitation of 05 Nos copper coils transformer type HETT type 5400 KAV main transformer of loco

04 6044080/-

5 Cleaning of ELS LDH including collection & disposal of waste & garbage for period of two years

-- 1151360/-

6 Comm. Including turning, deburing, chamfering & edging of both ends of segments etc.

480 717541/-

Total 15671331./-

The above table reveals that the total expenditure on the above

repairing/cleaning and overhauling contracts comes to 15671331/-

13

2.1.0 NORMS FOR ASSESSING MANPOWER

The existing bench marking norms are considered to assess the required

manpower. The team also discussed this matter at various level and opines that

the application of IR bench marking norms will affect the manpower as well as

productivity.

Current bench mark norms of N.Rly. Elect. Loco shed LDH is 2.80 as per Railway

Board bench marking 31.03.2017 (copy attached).

2.1.2 PROPOSED REQUIREMENT OF STAFF

The manpower is calculated as per Railway Board current bench marking norms

of Ludhiana Electric Loco shed @ 2.80 men per loco.

The manpower required for 181 locomotives=181x2.80=506.8 men or say 507

men.

The work study team apprised that 03 WAG-9 locomotives recently have been

introduced in the electric loco shed holding. Apart from this, the JAT-UHP-SVDK

section is under electrification. This matter has discussed at various level and

work study team is of the opinion that seeing the expected work load some extra

staff is required and proposed for this work load which is as under:-

For misc. modification work =15 For recabling work =20 For newly introduced 03 locomotives @ 2.80 men/loco 8.4 say =09 For office work & daak courier =02 For CTA cell, store etc =03 Total =49

The total requirement comes to 507+49= 556 men.

The proposed requirement comes to 556 against the sanction strength of 582

and 26 posts are identified as surplus in different categories and grades and

recommended for surrender.

RECOMMENDATION NO.1

It is proposed that 26 posts in different categories and grades are identified as

surplus, under the administrative control of Sr.DEE/TRS/Elect. Loco shed

Ludhiana and recommended for surrender as follows:-

SN Category Grades in Surplus posts

1 Tech.III 5200-20200-1900 06

2 Gr. D staff 5200-20200-1800 20

Total 26

14

3.0.0 FINANCIAL IMPLICATIONS

After the implementation of the work study recommendations following are the financial implications.

SN Category Grade Rs. Refer

Recom.

No.

No. of

surplus

posts

Monthly

value

per

posts

Rs.

Anticipated

annual

recurring

saving Rs.

1 Tech.III 5200-20200+1900 1 06 43212/- 3111264/-

2 Gr. D staff 5200-20200+1800 1 20 38948/- 9347520/-

Total 26 12458784/-

No. of posts identified as surplus: -

Group ‘C’= 06 posts

Group ‘D’= 20 posts

Total = 26 posts

Anticipated recurring saving = 124.58 lakh per annum

Capital saving = Nil

Total saving = 124.58 lakh per annum

15

WORK STUDY REPORT DETAILED CHART

Department : - Electrical

Name of study : - Review of Group C & D staff working in ELS/Ludhiana.

Activity Centre : - Ludhiana Electric Loco shed

SN Sub activity Brief description of

workload

Actual

staff

deployed

Work Study

recommendation

Brief description

of workload

1 Inspection

schedule (IA, IB,

IC & Annual

overhauling,

monthly

overhauling and

intermediate over

hauling of electric

locos of home

shed and out of

course repair of

foreign locos is

undertaken by

ELS/LDH.

This shed ELS/LDH

carries out major and

minor schedules

which is as under

(From Apr’16 to

Mar’17)

IA= 273

IB= 244

IC= 243

TOH= 37

IOH= 17

S/S= 582

O/R=563

Vac= 19

The team

identified 26 posts

as surplus and

recommended for

surrender.

Gr. C = 06

Gr. D = 20

Total = 26

Due to adoption of

contractual

working in loco

shed as a policy of

Railway Board,

certain activities

are being

outsourced due to

which workload

has reduced

accordingly.

****

16

LIST OF ANNEXURES

S.N. Description Annex.

No.

1 Letter No. 16-CP/03/WS/17-18 for Review of

Group C & D staff working in ELS/LDH

I

2 Statement showing staff position of ELS/Ludhiana II

3 Statement showing workload of the FY 2016-17 III

4 Railway Board bench marking Feb 2017 IV

*****

17

Annexure-II

Statement showing Category & Grade wise staff position working under

the administrative control of Sr.DEE/TRS/ELS/LDH

S.N Category S/S O/R Var.

1 Artisans 271 257 -14

2 Ancillary artisan 43 37 -6

3 Unskilled Gr.D 132 143 +11

4 Unskilled ancillary Gr.D 8 5 -3

5 Supervisor staff 60 41 -19

6 Drawing 3 - -3

7 Laboratory 4 3 -1

8 TLC 4 - -4

9 Ministerial staff 25 22 -3

Total 550 508 -42

Annexure No.III

Statement showing workload ELS /LDH for the FY 2016:

Out turn of Apr’2016 to Mar’2017

Types of schedules

IA IB IC TOH IOH Total

No. of locos 273 244 243 37 17 818

Avg./Month 22.75 20.33 20.25 3.08 1.14 68.16

Loco holding of ELS/LDH:

WAP 4 = 15

WAG 7 =152

WAG9H =14

Total = 181 locos

*****