Annexure-XIX Details showing the workshops and their activities Name of workshop

Central Railway

Activities in the workshop

POH of wagons POH of Diesel Locos POH of BG coaches, EMUs and Tank wagons POH of Electric Locos Mid-life rebuilding of BG coaches POH of Diesel Loco, Coaches and wagons POH of Diesel Locos POH of BG Coaches and Wagons POHof IRS Coaches, Electric Loco and EMU POH of Diesel and Electric Locos POH of Coaches and Wagons POH of Coaches and Wagons POH of Diesel Hydraulic Locos POH of MG coaches and wagons POH of coaches and wagons POH of NG coaches and wagons Rail Spring manufacturing unit POH of BG & MG coaches POH of BG and MG coaches Manufacture of BG wagons POH of MG coaches and wagons POH of coaches and wagons

Staff strength (Approximate)

6400 6000 9400

1. Jhansi Workshop 2. Parel Workshop 3. Matunga Workshop (including Kurla)

4. Bhusawal Workshop 5. Bhopal Workshop 6. Kurdwadi Workshop Eastern Railway 7. Jamalpur Workshop 8. Liluah Workshop 9. Kanchrapara Workshop

1700 2000 600

11500 13000 13500

Northern Railway 10. Charbagh Workshop 11. Alambagh Workshop 12. Jagadhri Workshop 13. Amristar Workshop 14. Jodhpur Workshop 15. Bikaner Workshop 16. Kalka Workshop 17. RSK, Sithouli North Eastern Railway 18. Gorakhpur Workshop 19. Izatnagar Workshop 20. Samastipur Workshop 21. New Bongaigaon Workshop 22. Dibrugarh Workshop

4000 5400 6500 2900 2400 1500 700 Not Available

6300 2900 600 3400 2100

Name of workshop
23. Tindharia Workshop

Activities in the workshop

POH of NG steam locos, coaches & wagons POH of coaches and wagons POH of Diesel Hydraulic and Elec. Locos, Diesel cranes and containers POH of coaches and wagons POH of BG & MG diesel locos and MG coaches & wagons, manufacture of BG & MG wagons POH of BG coaches Manufacture of Push Button Single-Line Tokenless Block instruments, Universal Axle Counters, Point Machines, Route Relay Interlocking & Panel etc. POH of BG coaches and wagons POH of BG coaches POH of BG wagons POH of BG coaches POH of BG diesel locos, electric locos, coaches and EMUs & wagons POH of BG wagons POH of BG coaches POH of NG coaches, wagons and construction of NG coaches

Staff strength (Approximate)

250

Northeast Frontier Railway 24. Lumding workshop Southern Railway 25. Perambur Loco Wrokshop

Not available

3800

26. Perambur Carriage & Wagon 27. Golden Rock Workshop

9700 7600

28. Mysore Workshop 29. S & T Workshop, Podanur

2500 885

South Central Railway 30. Hubli Workshop 31. Lallaguda Workshop 32. Guntupalli Workshop 33. Tirupathi Workshop South Eastern Railway 34. Kharagpur Workshop

4600 4600 3000 980 12000

35. Raipur Workshop 36. Mancheshwar Workshop 37. Nagpur Workshop

2000 1500 950

Name of workshop
Western Railway 38. Lower Parel & Mahalaxmi Workshops 39. Kota Workshop 40. Dahod Workshop

Activities in the workshop

POH of BG coaches and EMUs POH of BG wagons Electrical loco rebuilding, BOX rebuilding POH of BG coaches and wagons including tank wagons POH of MG diesel locos POH of MG coaches & wagons POH of MG coaches POH of MG wagons

Staff strength (Approximate)

6000 3300 3400

41. Pratapnagar Workshop

850

42. Ajmer (Loco) Workshop 43. Ajmer (C&W) Workshop 44. Bhavnagar Workshop 45. Junagarh Workshop

4200 4400 1100 293

Summary Staff Strength

Details No. of Workshops

For staff strength less than 1000 For staff strength ranging from 1000 to 6000 For staff strength more than 6000

9 23 11

Annexure XX A Illustrative list of Units involved in major activities POH of BG Coaches Carriage and Wagons Workshop, Perampur Major Executive Offices 1. 2. 1. 1. 2. 3. 4. 5. 6. 7. Nil Workshop Accounts Office Common Shops 1 2 3 Minor Shop Paint Shop Road Transport Shop Yard Carriage Shop Major Shop 1 Mill Wright Shop 2 New Machine Shop 3 Carpentry Shop CWM Office - Information, Planning and Progress, Production Control, NTXR DCOS/ CW/ PER Chemist and Metallurgist (CMT) Train Lighting AC Deluxe Carriage Fitting Carriage Building Heavy Corrosion Repair Bogie Lifting Wheel and Tyre Shop

Minor Executive Offices Major Shops

Minor Shop

Annexure XX B Illustrative list of Units involved in major activities POH of BG Wagons Carriage and Wagon Workshop, Perambur Major Executive Offices 1. 2. 1. 1. 2. 3. 4. 5. Nil Workshop Accounts Office Common Shops 1 2 3 Minor Shop Paint Shop Road Transport Shop Yard Carriage Shop Major Shop 1 Mill Wright Shop 2 New Machine Shop 3 Carpentry Shop CWM/ LW/ PER Office - Information, Planning and Progress, Production Control, Budget Section, NCO DCOS/ CW/ PER Chemist and Metallurgist (CMT) Wagon Repair Shops Spring Shop Wheel and Tyre Bogie Shop Heavy Corrosion Shops

Minor Executive Offices Major Shops

Minor Shop

Annexure XX C Illustrative list of Units involved in major activities POH of BG Wagons Wagon Workshop, GTPL Major Executive Offices 1. 2. 1. CWM's Office - Planning and Progress, Production Control, Yard Office, Inspection, Safety and NTXR Sections Dy. Controller of Stores Chemist and Metallurgist (Allied activity) (Ultrasonic Testing of Wheels etc.) Wagon Shop Plating and White Metal Spring and Smithy Shop Wheel Shop Under Gear Stores Shop

Minor Executive Offices

Major Shops 1. 2. 3. 4. 5. Nil Workshop Accounts Office Common Shops 1 2 Minor Shop Paint Shop Yard and Transport Shop 1 2 3 4 Major Shop Mill Wright Shop Machine Shop Stripping Shop Scrap Section

Minor Shop

Annexure XX D Illustrative list of Units involved in major activities POH of AC Locomotives Loco Workshop, Perambur Major Executive Offices 1. 2. 1. 1. 2. 3. 4. 5. Nil Workshop Accounts Office Common Shops 1 2 Minor Shop Tool Room Yard and Transport Shop Major Shop 1 Smithy Shop 2 Machine Shop 3 Mill Wright Shop CWM/ LW/ PER Office - Information, Planning and Progress, Production Control, Budget Section DCOS/ LW/ PER Chemist and Metallurgist (CMT) AC Loco General Welding Wheel and Tyre Corrosion Repair (Carriage Repair) Shop Fabrication Shops

Minor Executive Offices Major Shops

Minor Shop

Annexure XX E Illustrative list of Units involved in major activities POH of Diesel Locomotives Loco workshop, Perambur Major Executive Offices 1. 1. 2. 1. 2. 3. 4. 5. Nil Workshop Accounts Office Common Shops 1 2 Minor Shop Tool Room Yard and Transport Shop Major Shop 1 Mill Wright Shop 2 Machine Shop (Production) 3 Smithy Shop CWM/ LW/ PER Office - Information, Planning and Progress, Production Control, Budget Section DCOS/ LW/ PER Chemist and Metallurgist (CMT) Diesel Shop General Welding Wheel and Tyre Corrosion Repair (Carriage Repair) Shop Fabrication Shops

Minor Executive Offices Major Shops

Minor Shop

Annexure - XXI Carriage and Wagon - Workshop/ Perambur Activity based programme as per proposed revised norms vis--vis Party days as per existing norms
POH of BG Coaches CWM/ CW/ PER Party days as (Information, revised norms Production Control and Planning, Progress, 8 Budget Sections) Train Lighting, AC Deluxe, Carriage Fitting, Carriage 14 Building, Heavy Corrosion Repair, Bogie Lifting, Wheel and Tyre Shops DCOS/ CW/ PER 8 including wards SAO/ W/ PER 2 NCO 2 34 per Party days as existing norms 3 per

Major Offices

Executive

Major Shops

3 **

Stores Office

0* 0 0 6

Accounts Office Neutral Control Organisation TOTAL

Major Offices

Executive

Major Shops

Stores Office Neutral Control Organisation Accounts Office

POH of BG Wagons CWM/ CW/ PER Party days as (Information, revised norms Production Control and Planning, Progress, 8 Budget Sections), NCO Wagon repair, Spring, wheel and Tyre, Bogie, 10 Heavy Corrosion Repair DCOS/ CW/ PER 8 including wards NCO 2 2 and 1 31

per

Party days as existing norms 3

per

3 **

0* 0 0 0 6

SAO/ W/ PER Chemist Mettalurgist TOTAL

** *

Major shops are inspected once in 3 years only as per existing norms The Stores is being inspected by Stores Audit at present and not by Workshop

Repair and supply of Coaches and Wagon wheels to Divisions, Tyre Mounting and repair of EMU Wheels and supply of New WAP wheels to RCF after profiling Party days as per Party days as per revised norms existing norms 6 *** 3 3 3 2 0 11 6

Major Office Major Shop Accounts Office

CWM/ CW/ PER Wheel Shop SAO/ W/ PER Total

***

Two days per activity. Three activities are clubbed together here as they all deal with the same shop. Repair and supply of Laminated Springs to Divisions and other Activities Party days as per Party days as per revised norms existing norms 4 1 3 1 2 0 9 2

Major Office Major Shop Accounts Office

CWM/ CW/ PER Spring Shop SAO/ W/ PER Total

Office/ Workshop not covered in the Activity Based Units Party days as Party days as Remarks existing per revised per norms norms Done along with inspection 20 0 of Executive Offices/ Shops

Office Common Major Shops

Personnel Branch Mill Wright Shop New Machine Shop Carpentry Paint Shop

Common Minor Shops

Road Transport Yard Carriage Total

Three minor shops in 4 years Average one per year. Party days

26

Summary - Carriage and Wagon Workshop, Perambur Party days as per Party days as per revised norms existing norms 34 6 POH of BG Wagons 31 6 POH of BG Coaches 11 6 Repair and supply of coaches and wagon wheels etc. Repair and supply of springs to 9 2 Divisions 26 6 Office/ Workshops not covered in the activity based units Total 111 26

Annexure XXII Details showing the Production units Name of the Production Unit Activity 1. Diesel Locomotive Works, Manufacture of Diesel Locomotive Varanasi 2. Chittaranjan Locomotive Works, Manufacture of Electric Locomotive Chittaranjan 3. Diesel Components Works, Patiala Manufacture of diesel and electric loco spare parts 4. Integral Coach Factory, Perambur Manufacture of coaches 5. Rail Coach Factory, Kapurthala Manufacture of coaches 6. Wheel & Axle Plant, Yelahanka Manufacture of Wheel and Axles

Annexure - XXIII Sample Inspection Plan for ICF based upon the CLW and DLW pattern Inspection Units - Abstract ICF/Shell Mechanical Department 1. Chief Mechanical Engineer 2. Production Planning CWE/Shell 3. Works Manager/Sheet Metal 4. Works Manager/Assembly 5. Works Manager/Manufacture 6. Chief Design Engineer/Mechanical 7. Material Management 8. Personnel Branch - Establishment ICF/Furnishing Mechanical Department 1. Production Planning CWE/Furnishing 2. Works Manager/ Manufacture 3. Works Manager/Assembly 4. Chief Design Engineer/Electrical 5. Material Management 6. Personnel Branch Establishment General Offices 1. General Manager including Publicity, Statistics, Vigilance, Hindi cell, PRO, Law office 2. Chief Electrical Engineer including SEE/Construction and ASTE 3. Medical Department including CMS, ADMO and Chief Health Inspector 4. Civil Engineering Department including XEN/Colony, XEN/Furnishing, AEN/Planning, Chief IOW Special Works and PWI 5. Security Commissioner 6. Senior EDPM 7. Basic Training School 8. Cash office Inspection Units - Detail ICF/Shell Mechanical Department 1. Chief Mechanical Engineer (a) Dy.CME/Planning, Exports and Industrial Engineering (b) SME/Planning/Shell

2.

3.

4.

5.

6.

(c) AME/Material Planning/Furnishing (d) AEE/Material Planning/Furnishing (e) AME/Export Production Planning/Shell (a) Chief Workshop Engineer/Shell (i) Dy.CME/Shell (ii) Production Engineer/Production (iii) Production Control Orgnaisation (Shop 50) (iv) Production Engineer Planning (v) Process Planning (vi) Time Study (vii) Tool Room (Shop 41) (viii) Dy.CME/Plant (ix) SME/Plant/Furnishing (x) Shops 40 and 80 (Millwright), Shop 48 and 88 (Road Transport) (xi) Dy. Chief Chemist and Metallurgist (xii) Shop 84 (Lab CMT) Works Manager/Sheet Metal (a) Shop 10 (Sheet Metal) (b) Shop 11 ( Heavy Sheet Metal) (c) Shop 18 (Window door under frame) (d) Shop 20 (Wall assembly) (e) Shop 23 (Bogie frame) Works Manager/Manufacture (a) Shop 12 (Wheel) (b) Shop 13 (Forge & Smithy) (c) Shop 15 (Spring) (d) Shop 16 (Machine) Works Manager/Assembly (a) Shop 21(Roof under frame) (b) Shop 22 (Body assembly) (c) Shop 24 (Bogie assembly) (d) Shop 25 (Paint) (e) Shop 26 (Final assembly shop) Chief Design Engineer/Mechanical (a) Dy. CME/Design (b) SME/Design, Standard Specification

(c) SME/Design, Product Development (d) SME/Design and Development (e) AME/Design Product Development (f) AME/Jigs and Tools (g) SME/Development and Procurement (h) Dy.CME/Inspection (i) SME/Quality Control (j) AME/Inspection 7 Material Management a) COS/ICF b) CMM/Shell c) Dy.COS/Shell d) DCOS/Purchase e) DCOS/Special Duty f) ACOS/Purchase g) ACOS/Purchase/S-II h) DSK/Shipping i) Receipt branch j) Receipt and Despatch, Wards k) ACOS/Shell Depot l) DSK/General m) DSK/Central Ledger n) DSK/Claims 8 Personnel Branch Establishment (a) PB/Shell (b) Time Office ICF/Furnishing Mechanical Department 1. Production Planning CWE/Furnishing a) Chief Workshop Engineer/Furnishing (i) Dy.CME/Furnishing (ii) Production Engineer/Production (iii) Production Control Orgnaisation (Shop 56) (iv) Production Engineer Planning (v) Dy.CEE/P/Furnsihing (vi) Tool Room 81

2. Works Manager/ Manufacture (a) Shop 32 (Carpentry) (b) Shop 33 (Machine) (c) Shop 38 (Anodising & Electro plating) 3. Works Manager/Assembly (a) Shop 27 (Proto type) (b) Shop 30 (Assembly) (c) Shop 34 (Trimming & Proto type) (d) Shop 36 (Paint) (e) Shop 37 (Air brake) 4. Dy. CEE/Electrical (a) Works Manager-I/Electrical (b) Shop 28 (Electrical shop for conventional coaches) (c) Shop 35 (Manufacture of AC coaches) (d) Works Manager-II/Electrical (e) Shop 39 (Train lighting) (f) Works Manager-III/Electrical (g) Shop 29 (Electrical shop for EMU & Motor coaches etc.) (h) Dy.CEE/Maintenance (i) Shop 45 (Electrical distribution and operation) (j) Shop 46 (Electrical repair) (k) Shop 85 (Electrical distribution shell) (l) Shop 86 (Electrical repair shop shell) 5. Chief Design Engineer/Electrical (a) Dy. CEE/Construction & Development (b) Dy. CEE/AC/DC/Design (c) AEE/Liason/1&2 (d) Dy.CEE/Inspection (e) AEE/Inspection (f) Shop 42 (Inspection/Shell) (g) Shop 82 (Inspection/Furnishing) (h) Shop 87 (Electrical inspection/Furnishing) 6 Material Management CMM/Furnishing (a) Dy.COS/Purchase/Furnishing (b) Dy.COS/Elecltrial/Furnishing (c) Dy.COS/Data Center

(d) DCOS/Purchase/Furnishing (e) ACOS/Construction & Development (f) ACOS/Purchase/Furnishing I & II (g) Dy. COS/Furnishing Depot including Receipt Branch (h) DSK/G (i) DSK/Ward 30 to 39 (j) Central Ledger Section/Furnishing (k) ACOS/FD (l) DSK/Claims/Furnishing Personnel Branch Establishment a) PB/Furnishing b) Time Office

Note: 1) Each block will be taken as one inspection unit. One inspection report will be issued on completion of inspection of each block. 2) The blocks have been designed combining the executive office and the shops under the control of that office as one unit. 3) The sequence of inspections will be maintained in the same order as the manufacturing activity to enable an over all view also. 4) There is no major and minor shops differentiation.

Annexure XXIV Sample Inspection plan for Diesel Locomotive Works dealing with manufacturing of locomotives Inspection Units - Abstract A Mechanical Department 1 Chief Mechanical Engineer 2 Dy. CME/ Planning and Production Control 3 Dy. CME/ Machinery and Plant (including 5 shops) 4 Dy. CME/ Tooling including Tool Room Shop 5 Chief Design Engineer 6 Chief Inspecting Officer (including 8 Inspecting Branches) 7 Chief Project Manager/ Mod. 8 Dy. CCMT including CRP Shop 9 Dy. CME (Spares) 10 Dy. CME/ Engine (including 7 shops) 11 Dy. CME/ Loco (including 8 shops) 12 Dy. CME/ Block (including 3 shops) Material Management 1 Controller of Stores 2 Chief Marketing Manager 3 CME/ M (Electrical and Mechanical) 4 DCOS (Purchase)/ Kolkata 5 DCOS (R&D)/ Sealdah 6 Dy. COS (D) and Ledger 7 Dy. COS (D)/ Receipts of Loco items only with 7 wards 8 Dy. COS (D)/ Receipt Branch for Loco and Non-Loco with 6 wards 9 Dy. COS (D)/ Storage ward - I for Loco items with 8 wards 10. Dy. COS (D)/ Storage ward - II for Loco items with 7 wards 11 Storage ward for Non-Loco items with 6 wards 12 Dy. COS (Despatch) with 5 wards 13. Dy. COS/ D/ Rejection, Warranty and Scrap etc. with 5 wards Personnel Branch - Establishment Civil Engineering and Electrical Misc. Executive Offices

C D F