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VIIITH SEMESTER INDUSTRIALTRAINING REPORT COMPLETED AT :- BHARAT WAGAON & ENGINEERING CO. LTD. (BWEL) , MUZAFFARPUR UNIT ( A Govt. of India Undertaking – Ministry of Railways) FROM :- 5TH OF FEBRUARY TO 28TH OF MAY

SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING BY NAME :- MUKESH KUMAR REG. NO. :- 1079175467 ROLL NO. :- 49 SESSION :- 2010-2014

DEPARTMENT OF MECHANICAL ENGINEERING

Delhi Institute of Technology Management & Research, Faridabad MDU, ROHTAK

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DELHI INSTITUTE OF TECHNOLOGY, MANAGEMENT

& RESEARCH, FARIDABAD

SUBMITTED BY:- MUKESH KUMAR MECHANICAL ENGG. VIIITH SEM REG. NO. – 1079175467 ROLL NO. - 49 BATCH - 2010-2014 SUBMITTED TO:- Mr. PAWAN TANEJA H.O.D.- MECHANICAL ENGINEERING

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SUMMARY OR ABSTRACT OF THE REPORT:-

The relationship between land and labour is nearly as old as human existence on the earth. As we cannot imagine the process of creation of wealth without labour, it is treated as more important. The satisfaction of worker is linked with the question of our existence & profitability. Increase in production is not possible without the fullest co-operation between management and labour and the most important determinant is a manager’s ability to minimize the conflicts and maximize the satisfaction of employers & employees. This situation may be created by taking intense are upon labour productivity, which is based on incentives, motivation compensation have been evolved over a period of time. More particularly with a view to motivate the worker & employee concerned.

The success of any organisation also depends upon the facts that effectively and efficiently the wage and salary administration is handled by the manager, that can turn the worker towards satisfaction level. If an ideal match between technical innovations and worker’s aspiration have been set-up, they may be capable of producing new idea developing and improving capital goods and modifying the available physical and financial resource in order to achieve greater productivity, satisfaction depends on the strategies adopted for wage and salary administration.

By observing the above points, it can easily be concluded that the importance of wage and salary administration at present day cannot be ignored. While working on this topic, my present aim is to evaluate the wage and salary administration in company like BWEL, Muzaffarpur unit, Muzaffarpur. I have also evaluated the various methods of wages and salary administration.

Thus progress is a continuous process. It is relative and absolute. We cannot stop at a certain destination and declare that target has been achieved and we need to go further. One has rightly said the following lines :-

“The woods are lovely dark and deep, but I have promises to keep a mile to go before I sleeps.”

Summer Training Programmes are designed to give the future feel of the corporate happening and work culture. These real life situations are entirely different from the simulated exercise enacted in an artificial environment inside reason that the summer training programmes are designed so that the managers of tomorrow may not feel ill in case when the times come to shoulder responsibility.

That experience that I have gathered over the last sixteen weeks have certainly provided me with orientation which I believe will help me to shoulder any assignment, successfully in near future. I have tried my level best to arrange the work in a systematic and chronological manner.

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We read theoretically the matters noted in the books but are not very much acquainted with the actual working in the organisation. There becomes a lot of difference between the bookish knowledge & the practical Knowledge. To have a practical feelings & go through the working an organisation is very much beneficial for us. The experience gain during these sixteen weeks is of highly importance.

Even though this project report will be helpful for the management of BWEL, to look back at their role and procedures regarding wages and salary activity stake necessary steps to improve it.

The future students of management disciplines who want to know abut the working of BWEL, Muzaffarpur, especially with regard to wage & salary will get a massive help from this project report.

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ACKNOWLEDGEMENT

I have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them.

I am highly indebted to Mr. V.K. Shrivastava for their guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project. I would like to express my gratitude towards my parents & member of Bharat Wagon & Engineering Com. Ltd. (BWEL) Muzaffarpur Unit, for their kind co-operation and encouragement which help me in completion of this project. I would like to express my special gratitude and thanks to industry persons for giving me such attention and time. My thanks and appreciations also go to my colleague in developing the project and people who have willingly helped me out with their abilities.

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CONTENTS

SUMMARY OR ABSTRRACT OF THE REPORT.................................................03

ACKNOWLEDGEMENT.........................................................................................05

COMPANY PROFILE..............................................................................................10

ABOUT BHARAT WAGON....................................................................................11

HISTORICAL BACKGROUND..............................................................................12

REHABILATION OF WAGON...............................................................................16

SELLING WITH INDIAN RAILWAY....................................................................18

MARKETING OF RAW MATERIAL.....................................................................22

ORGANISATIONAL STRUCTURE.......................................................................24

PRESS & SMITHY SHOP........................................................................................44

CUTTING & WELDING SHOP...............................................................................48

DRILLING SHOP.....................................................................................................52

MACHINE SHOP.....................................................................................................54

FOUNDRY SHOP....................................................................................................58

WAGON ASSEMBLY SHOP..................................................................................61

FINISHING SHOP....................................................................................................63

TEMPLATE SHOP....................................................................................................65

SCRAP MEANING & DDEFINATION……...........................................................66

LIST OF SCRAP MATERIALS PRODUCED IN BWEL MUZAFFARPUR.........68

SCRAP MANAGEMENT AND IMPORTANCE.....................................................71

VARIOUS LOCATIONS FOR SCRAP IN SCRAP DEPOT....................................73

TERMS AND CONDITIONS OF AUCTIONS SALE OF SCRAP BWEL MZFF...74

SCRAP MANAGEMENT SYSTEM (SMS)...............................................................78

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TARGET.....................................................................................................................81

CONCLUSION…………………………………………………………..................82

BIBLIOGRAPHY………………………………………..........................................83

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LIST OF FIGURE:- PAGE NO.

Bharat Wagon & Engg. Co. Ltd.(BWEL), Muzaffarpur Unit…………………….10 Organizational structure……………………………………………………………20 Hydraulic press……………………………………………………………………..43 Shearing machine…………………………………………………………………...46 Welding and drilling work………………………………………………………….47 Universal radial drilling machine…………………………………………………...49 Centre lathe machine………………………………………………………………..53 Railway wagon(BOXN-HL)….…………..………………………………………...58 Complete wagon on railway track ………………………………………………….60

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NOMENCLUTRE:-

FWU………..Full Wagon Unit MT………….Metric Tons MM…………Mili Meter Thk………….Thickness Dia…………..Diameter Cwt………….Hundred weight Cfm ………...Cubbic feet/minute Psi………….. Pound/square inch Kva………….kilovolt-ampere Rpm…………Rotation/ miniute Te……………Tone LHB…………..Linke Hofmann Busch

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COMPANY PROFILE

Bharat Wagon is an engineering Industry commanding very good reputation and having decades of experience with two manufacturing units in Mokama & Muzaffarpur in the state of Bihar. Our both units have been accredited with ISO-9001:2000 Quality management System Standards for manufacturing of wagons. The product profile of Bharat Wagons and the enriched experience reveal the credibility of our company and the capability of our skilled personnel that have brought laurels to the organization.

BWEL manufacturers railway wagons, sugar mill machineries & fabrications castings and miscellaneous project equipment. Railway wagons comprise the bulk of the turnover of the company. The company has a wagon manufacturing capacity of 2500 FWU p.a. Railway wagons are produced at the Mokamah and Muzaffarpur units.

The wagons are catered to the Indian Railways and Ministry of Defence. Some special purpose wagons are also produced according to specific customer requirements. The unit at Mokamah s capable of producing only board gauge units while the unit at Muzaffarpur is equipped to produce both Broad gauge and Metre gauge units. In addition to railway wagons the units are capable of producing all relevant wagon components. BWEL diversified into turnkey project o 1979 as part of its diversification strategy and a separate Project Division was set up in 1995. This division has successfully executed a number of turnkey projects.

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ABOUT BHARAT WAGON

Bharat Wagon & Engineering Company Limited (“BWEL” or “the Company”) is a subsidiary of Bharat Bhari Udyog Nigam Limited (BBUNL) and is engaged in the manufacture of Railway Wagons, Sugar Mill Machines & Steel Fabrications and Project Equipment. The entire equity component of BWEL is held by BBUNL and the company is under the administrative control of the Department of Heavy Industries (DHI).

BUNL in consonance with DHI has decided to disinvest up to 74% or 100% of its holding in BWEL in favour of a strategic/joint venture who would provide technological inputs, marketing support, managerial skills and fresh funds and such other assistance to BWEL as may be required to ensure healthy and consistent financial performance. This would complement the existing strengths of WHEL in possessing a team of skilled and highly experienced personnel and a well-respected brand among wagon manufacturers in the country.

The administrative control of M/s BWEL was incorporated in 1978, by an Act of Parliament, through the nationalization and subsequent amalgamation of two erstwhile companies. Arthur Butler & Co. located at Muzaffarpur and Britannia Engineering Works located at Mokamah. The decision of the Government was driven by the industrial sickness in both the companies, which had forced the government to take over their management. Subsequently, in 1983 a third unit was added at Industrial Estate (Bela) Muzaffarpur for manufacturing LPG cylinders. In 1986, BWEL was made a wholly owned subsidiary of Bharat Bhari Udyog Nigam (BBUNL) which is the holding company for 9 nationalized companies in the heavy engineering sector and comes under the auspicec of the Ministry of Heavy Industries.

BWEL is headquartered at Patna and has two regional offices in Delhi and Kolkata. The company has manufacturing unit at Mokamah, Bela and Muzaffarpur. The company is primarily engaged in the manufacturing of Railway Wagons. As a diversification measure the company has also entered into Steel Structures. Bridge Fabrications, Oil Tanks, Sugar Mill Equipment, Canal Gates and other Misc, Project Equipment.

The Units at Mokamah and Muzaffarpur have received the ISO-9002 certification for wagon manufacturing. The company has achieved a number of distinctions in the area of productivity including the Indira Gandhi Memorial Award for Productivity in 1988, Rajeev Gandhi Memorial National Award for productivity in 1990 and National Produtivity Councial Certificate of Merit in 1993.

Bharat Wagon & Engg. Co. Ltd. (BWEL), Patna, a central PSE and subsidiary of Bharat Bhari Udyog Nigam Ltd. (BBUNL) is transferres from the Department of Heavy Industry, Ministry of Heavy Industries and Public Enterprises to the Ministry of Railway w.e.f. 13th August, 2008 (AN).

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Bharat Wagon & Engineering Company Ltd. (BWEL), was incorporated on 8th December 1978 as a Public Sector Unit by take over of two historical wagon manufacturing units of Arther Butler & Co and Britannia Engineering Co, both in Bihar at Muzaffarpur and Mokamah. The third industrial unit was added to the company in 1983-84 at Bela, Muzaffarpur for manufacture of LPG Cylinders. In the year 1986 the company become a subsidiary of BBUNL, Calcutta.

Corporate/Head Office – Bharat Wagon & Engg. Co. Ltd., ‘C’ Block, 5th Floor, Mauryalok Complex, Dak Bungalow Road, Patna – 800001 Regional Offices :

1. Bharat Wagon & Engg. Co. Ltd., 26 A, Barakhamba Road New Delhi – 110001 2. Bharat Wagon & Engg. Co. Ltd., C/O Burn Standard Co. Ltd.,

40, Strand Road, 104, Akashdeep Building, 4th Floor, Room No. – 12, Kolkata – 700001

Factories/Works :

1.Bharat Wagon & Engg. Co. Ltd., Muzaffarpur Unit, Muzaffarpur – 842001

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HISTORICAL BACKGROUND

M/S BHARAT WAGON & ENGINEERING COMPANY LIMITED is a Government of India undertaking under the ministry of Heavy Industry Department of bureau of public Enterprises, Govt. of India. The Govt. of India undertaking was incorporated under the company act, 1956 on the 4th day of December, 1978 with an authorized capital of rupees five crores. Bharat Wagon and Engineering Company Limited comes into being in terms of the Britannia Engineering Company Limited (Mokama unit) and Arthur Butler and Company Limited (Muzaffarpur) under the acquisition and transfer of undertaking of Britannia Engineering Company Limited. Mokama unit & Arthur Butler & Company Limited (Muzaffarpur) with retrospective effect from 1st of April, 1978.

The Britannia Engineering Company Limited Was incorporated in 1917 with its registered office at Calcutta. It owned an engineering unit at Titagarh (where it manufactured road rollers. Jute mills machinery unit and other industrial unit) & also a steel foundation at Titagarh and third unit , which was set in 1960 at Mokama to manufacture railway wagons. The engineering unit at Titagarh closed down in 1970 and on 22nd may, 1976 its management was taken over by the Central Government & interested to M/S Westing House Farmers Limited, Calcutta, a company being managed by the Government has taken complete financial and managerial responsibilities for managing the Titagarh unit. The Wagon unit at Mokama closed down in March 1973. The Central Government took over its management on 10th February 1974 under the Industrial Development and Regulation Act and the unit was reopened on 22nd of February 1974. When it was closed down in March 1973 it employed 888 persons.

This labor was confirmed to then industrial establishment located in North East region of India. It was not like a modern industry as we see understanding about a unit today. It was indigo industry based on agricultural product, which intricate blue colour, a product of indigo cultivation by means of smaller plants. In 2nd district gazetteer of Muzaffarpur district 1958, Much encouraged by the remunerative aspect Mr. Arthur also thought to have his permanent establishment somewhere. The first did setup small shop that sheds with smithy devices something at samastipur, then a central place of communication during those days and then enthusiast Mr. Butler also joined him and began working as two friends doing the same business.

They could pull their resources and began working as partners in course of time, their work expanded and the place proved in sufficient to the requirement. They moved their place of business from samastipur to Muzaffarpur (a place situated in 27’7’ North latitude and 85’24 East longitude is in the central place of north Bihar) a few yards away from present location of the factory. They began doing bigger volume of business and the smaller firms fasts developed into shed. They went yards away from present location of the factory. They began doing bigger

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volume of business and the smaller firms fasts developed into bigger shed. They went on adding to their small unit, different sections and then their industrial venture took a factory form.

Mr.L.S.S.O.Malley I.C.S. mentioned in the first district gazetteer of Muzaffarpur district (1907) M/s Arthur Butler Company as only engineering workshop registered under the factories act having 107 employees on hand already started its industrial activities as the only modern industrial world.

Mr. P.C. Roy writes in the 2nd district gazetteer of Muzaffarpur district (1958) that in the last quarter of the 19th century, the development of the artificial days, which freely imported from abroad, affected the prospect of the indigo industry severally sit lost the ground. But the Arthur Butler venture being in the form of the factory followed. Other industries. One more advantage was with them that they were English people and every industrial activities was being owned and managed by the English people themselves.

Arthur Butler started a new line of business of making screw piles having steel as superstructures there on which could be easily installed, dismantled and shifted was the course changed given by 1910. It expanded as bigger partnership concern.

By 1919, it was registered under joint stock Company Act as a company and also fixed up its workshop at the present site of the factory just adjacent to Muzaffarpur Railway station. Arthur Butler and Company has been also famous for civil works and they were experts in designing screw piles all the fabricated steel bridge in Northern India stand over today as a symbol.

By 1925 when most of the factories used to import machines from England even minor parts of the sugar industries, the efforts of Arthur butler where credit worth of the management development production from repair side of business

It was the year 1938 in which it used to pay heavy dividend to its shareholders. During the 2nd world war it expanded so much so that it could acquire a plant of its own which was used by Mr. H.M. Wealthevall. It also expanded its employment roughly about one thousand persons.

Managing agents changed after 1943, from Balmer Lawrie Co.Ltd. to purchase the company. The English shareholder sold their shares and virtually repatriated from India. The Bihar Motor Service section was also closed and new line of repaint. Railway goods wagon and managing agent.

The Bharat Brothers controlled the management, however, till act for 1954, the management changed hands and Kakrania and sonthalli as purchase the shares and owned the company only small part of the share of the company were in the market and it was easy for them to sell off the ownership. The two groups formed a managing system which was obliged by virtue of amendments to the India Companies Act, 1968. Since them it began to be managed by a Board of 4 Directors consisting of always the family namely Kakranias and Sonthallias.

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During this period the Government decided to stop import of railway goods Wagons and this gave big impetus to Indian factories to develop wagon building. Arthur Butler Company being ideally situated on the meter gauge railways head at Muzaffarpur and doing the repairing railways.

Work till 1954 took advantage of the opportunity and it did expand its workshop to take up the new railway job. In course of time they brought suitable new machines and arranged to build all types of railway wagons.

During the peak period, 1960-1965, it employed even about 1300 persons. In 1967 when the company faced the situation during the general recession.

Bharat Wagon & Engg. Co. Ltd.(BWEL), Muzaffarpur Unit

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REHABILTATION OF WAGONS

We also have experts/engineers with extensive experience in ‘Rehabilitation and Modifications of Wagons’ and can take up rehabilitation of ANY MAKE of railway freight wagons or passenger coaches. We can assist your railways in transfer of technology and imparting training for maintenance. To analyse and review the extent of rehabilitation requirement, we can send a team of expert engineers to customers place. The team will work jointly with customers’ railways for assessment of the work involvement and spares requirement. By investing only one-third of the cost of a new wagon, one gets back a life of round 10 years after the Rehabilitation.

(v) Product profile of the BWEL

At the present time, Bharat Wagon Engineering Company Limited is one of the subsidiary of Bharat Bharti Udyog Limited which has other subsidiary has a good liaison away i.e.

(i) Burn standard company.

(ii) Praith Waite and company limited.

(iii) Bharat Process and Mechanical Engineering Limited.

(iv) Lagan Jute Machinery Company Limited.

At the present time Bharat Wagon and Engineering Company Limited has a target of an average 30 to 35 wagons per month.

It is producing Broad Gauge Freight Wagon. Wagon component pressing, castings and fabrication works are being done here. Casting jobs-grey iron casting up to 12 tonnes capacity.

At Bela works, oil tanks, heavy girdens, Transmission Towers and other heavy fabrications works are being done. But now it is closed.

The production and manufacturing chart of BWEL Muzaffarpur unit are:-

Rolling Stock : Fright Wagon (Open Type) – Box N

Fright Wagon (Covered Type) – MBC

Fright Wagon (Flat type) – BPN

Fright Wagon (Spl Purpose) –BWTA

Casting Jobs : Grey Iron Casting upto 10 tonnes capacity per piece.

Sugar Mill Machineries : Complete Rollers Reselling.

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Filters Press Cystallizers Sulphus.

Furnale Condenser Conveyor Mill

Looping Mollassess and Mama pumpete

Defenale Road Trailer : Defenale Tank Carrier

Trailer upto 20 MT Capacity

Coal Mining Equipment : Coal Tube Mine Cars Rope Way Bulket.

Screw Pile Bridness : Tailer made Bridns with all relevant component to suit the river breadth.

Steel Fabrication Work : Suitable for steel plants. Thermal power plants, Oil Installation, Fertilizer units Railroads, Bridge structure.

Transmission Towers and sub-stations structure :

Manufacturing and exertion of transmission towers and sub-station structure.

Valuable Customer Wagon : Indian Railway, Ministry of Defence

Steel Fabrication : Road Construction Department, Irrigation Department, H.E.C., BCCL, FCI, BHEL, Nagal Paper and Pumps Mill, Eastern Railway.

C.I. Casting : Sugar Mills of U.P., Bihar and Nepal, U.P. State Electricity Board, Road Construction Department.

L.P.G. Cylinders : Indian Oil Corporation Ltd. Hindustan Petroleum Corp. Ltd. Bharat Petroleum Corp. Ltd.

Pontoon Bridges : Naogachhia (Bhagalpur), Kataunjha, Runisaidpur, (Sitamarhi), Bihar Pool Nirman Nigam, Patna (Bihar)

At present Bharat Wagon is only manufacturing rolling stock. In other words, We can tell that the Production of rolling stock is & rest everything has been stopped.

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SELLING WITH INDIAN RAILWAY

Over the years the company has built a broad customer base in almost all product categories. The primary customer for wagons is the Indian Railways and about 98% of the revenue in this area of BWEL’s business accrues from purchase of freight wagons by the Indian Railways. The important customers for the different products are as follows:

Product Important Customers (Procurement) Railway Wagons The Indian Railways

Ministry of Defence Casting Jobs Sugar Mills in Uttar Pradesh, Bihar and Nepal

Uttar Pradesh State Electricity Board Road Construction Department, Govt. of Bihar

Steel Fabrications Road Construction Department, Govt. of Bihar Irrigation Department, Govt. of India Heavy Engineering Corporation, Ranchi BCCL- Western Coal Fields Railway and Road Bridge Structural FCI, Barauni Rampur Engineering Works Bihar State Electricity Board Nagaland Paper & Pulp Mills Eastern Railways

LPG ylinders and Fuel Storage Tanks

Indian Oil Corporation Ltd, Hpcl and Bharat Petroleum Corporation Ltd.

The principal customers by value are the Indian Railways, the predominant customer, Bihar Rajya Pul Nirman Nigam Limited, Numaligarh Refinery Limited, Bihar State Electricity Board and Oil Companies like IOCL, BOCL and HPCL.

The order book position as on 1st September 2001 is given below:

Product Order Book Wagons Physical Order for FWU: 705

Order Value (Rs. Lakh): Rs.3666 New Wagon Order Value (Rs. Lakh): Rs. 111.13 Total Order Book Rs. 3777.13 Lakh

Raw materials in wagon manufacturing can be broadly divided into two categories:

(a) DM components, being components, which are inspected by the RDSO before they are supplied to us and

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(b) Non-DM components, being low value components, which are the procured locally and do not require RDSO inspection.

Common DM components include steel, bogies, coupler sets, air brake equipment, air brake pipe, wheelsets, slack adjuster, nylon bush, door check spring, bearing, twist lock, draw gear (quick draw) and draw bar.

Principal raw materials for our mining machines are flat steel products, such as steel plates. We normally source our entire requirement from suppliers such as SAIL and TISCO. We also require high tensile steel plates, which are sourced from dealers of major companies in India or abroad. We require forgings and castings, which we normally source from locally available forging manufacturers in addition to manufacturing casting at our in-house foundry. We have an arrangement with komatsu Mining Germany (Demag) for supply of components and spares required for heavy earth moving and mining equipment. We import components such as hydraulics and gear boxes for our heavy earth moving mining equipment from komatsu Mining Germany, Rexroth, Carraro and also several other reputed companies in India and abroad. We source our requirements of cylinders and engines for our machines from indigenous sources.

In the Railway Budget for 2008-09, it was announced that Indian Railway will procure around 20,000 wagons. In addition to demand from Indian Railways, demand for wagons from public sector companies such as National Aluminum Company Limited (?NALCO?), National Thermal Power Corporation Limited (?NTPC?), Container Corporation of India Limited (?CONCR?), etc. has also been picking up. Companies such as NALCO, NTPC, etc. Procure wagons for their in-house utilization where as CONCOR procures container flats for container transportation purposes. The demand of wagons has further been bolstered by the wagon Investment Scheme (?WIS?), which was implemented by Indian Railway wef April 1, 2005.

Wheel sets are one of the most critical components in wagon manufacturing and the approximate cost of wheel sets as a percentage of the total selling price of wagon for non Indian Railway customers is almost 30-35%. The prices of wheel sets, are significantly dependent on prices in the international market and their global demand and supply situation. To manage the cyclical fluctuations in the prices of wheelsets, we have developed relationship with a number of RDSO approved vendors in countries such as China, Spain, Brazil and Switzerland. We placed order with such vendors, based on our outstanding order book position and based on the delivery requirements of our customers. Due to significant price fluctuation of wheelsets in the global markets and current global shortage, we endeavour that our non-Indian Railway customers? Open letters of credit against our purchase orders with our approved vendors directly. In order to reduce the risk of price fluctuation of wheelsets and to ensure continuous supply of wheelsets for our production, we are planning to setup an axle machining and wheelset assembly plant at an estimated cost of Rs 129.33 mn. The assembly plant will have an assembly capacity of 10,000-12,000 wheelsets per annum. We believe an axle machining and wheelset assembly shop would

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give us a cost advantage with respect to savings in freight charges and would also give us greater operational continuity.

Non-DM components such as horizontal levers and safety plates, being low value components, are procured locally and require no RDSO inspection. Suppliers of Non-DM components are approved as per guidelines specified in our quality assurance manual and in accordance with the requirements.

Railway Rolling Stocks, Components & Track Materials

BWEL is the largest Rolling Stock manufacturer in India. With an annual production capacity of over 8600 Vehicular Units, BSCL offers the following range of Railway Wagons.

Open Type Freight Wagons for transportation of Coal, Ores, Minerals etc.

Closed Type Freight Wagons for transportation of all classes of General Goods, Food Grains, Bagged Cement etc.

Bottom Discharge Open Ballast Hopper Wagon with automatic unloading facility (suitable for bulk goods)

Special Leak Proof Wagon for Alumina & Cement (with pneumatic discharge system direct from wagon to the unloading point)

Milk Tank Wagon

Special Wagon for Liquefied Petroleum Gas (LPG)

Flat Wagon for Transportation of steels.

Crop Wagon for Transportation of scraps.

BSCL’s foundry practice dates to the 18th century and today with its modernised Steel Plant, Moulding Equipment, Electric Arc Furnaces, Heat-treatment and Shot Blasting facilities, the annual production of 15,000 MT covers finished Alloy Steel Castings, Heavy Nihard and Mn Steel Casting and Crossing. Maximum weight of castings that can be made is 4 MT.

The battery of Drop Stamping Hammers and Hydraulic Presses with supporting machinery’s including heavy die machining facilities have enabled the Forge Division to produce customer need based forging and pressings.

Maximum dimensions – 450/R Bloom.

Maximum weight – Drop Stamping: 40 Kg,

Plain Forging: 2.5 Tons

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Starting from the raw mining to the finished product BSCL,s Refractory Unit offers a one window solution for a wide range of products basic bricks e.g. Mag. Chrome, Chrome Mag, Magnetite, Chemically Bonded (Unburnt), Direct Bonded, Mag. Carbon, Refractories for Copper, Cement & Glass and many other Varieties.

BSCL is the “preferred supplier” for Steel Structurals for major Rail and Road Bridges in India. Supplies have included structural work for bridges over India’s widest Rivers: Ganga, Krishna, Godavari, Hooghly and Bramhaputra to name a few.

Steel Frame Building Structures

Steel Plant Structural Work

Steel Plant Equipment

FACILITY PROVIDED BY INDIAN RAILWAY

New Delhi During 2009-10, the Indian Railway plan to acquire 18,000 new wagons against 11,000 in 2008-09. Announcing this in Parliament today, the Minister of Railways, Mamata Banerjee, said that there was a growing demand for wagons in Indian Railways.

The ministry also proposes to take over the wagon units of Burn Standard Co. Ltd. (BSCL) and Braithwaite & Co. Ltd. (BCL), under the Ministry of Heavy Industries. During the year 2008-09, the Government released Rs 8-38 crore to BSCL, Rs 3.76 crore to BCL for modernization and production facilities.

During 2008-09, BSCL has registered a net loss of 199.92 crore INR (Prov.) and a loss of 151-29 crore INR during 2007-08 (Actual). During 2008-09, BC has registered a net profit of 1.42 crore INR (Prov.) and a profit of 0.55 crore INR during 2007-08 (Actual).

The proposal to acquire 18,000 new wagon is good news for the domestic wagon manufacturing firms.

VRS Natarajan, CMD, BEML felt that the budget was very encouraging and would increase the business of coach builders and manufacturers.

The minister also proposed premium freight service for container movement with assured transit time and a mega logistic hub alongside eastern and western dedicated freight corridors.

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MARKETING OF RAW MATERIAL

The wagon manufacturers are not unduly worried over supply of raw materials such as steel and wheels by the Railways. Some of the wagon manufacturers express their reservation about the Railways plans to acquire the wagon units of Burn Standards and to set up a new coach factory in Kanchrapara (West Bengal).

The two wagon units of Burn Standards employ about 1,000 people – 700 in Burnpur Factory and 300 in Howrah factory. Together the units produce about 1,000 wagons a year. In 2008-2009, the company posted a cash profit of a little over Rs 5 crore (unaudited) on a turnover of about Rs 175 crore, of which the share of the wagon units will be about Rs 80 crore.

Meanwhile, Mr. Pawan K. Rui, Chairman, Jessop & Company, in a statement said, Jessop being a manufacture of EMU coaches for several years would not only welcome the proposed an EMU coach factory at Kanchrapara but would also be keen to share the experience in this regard.

More than 60 par cent jump in the wagon procurement target would also a boon to Jessop, now ready with improved designs of wagons and aluminium wagons. According to Mr Umesh Choudhary, Managing Director, Titagarh Wagons, the dedicated railway freight corridor project would be a game changer for the logistics industry and the economy.

The project’s emphasis on light-weight specialized wagons is important for Titagarh Wagons set to enter the manufacture of aluminium wagons manufacturing.”

Titagarh Wagons, in collaboration with Freightcar America, is designing a prototype for aluminium wagons in the country. It is expected to be ready by December.

In case of EMU coaches, the company has bagged its first set of orders for six rakes from the Railways and expects order flow to increase in view of the Minister’s proposal to increase frequency of local and short-distance EMU trains.

After the heightened expectations in the run up to the Railway Budget, the announcements made on Friday may have come as a dampener. With no roll back of the increase in freight charges, the Budget did not provide much of an impetus, on the lines expected by Corporate India. But it does spell positively on companies associated in the business of making railway related goods.

Companies such as BEML, Texmaco and Titagarh Wagons that are in the business of making wagons, EMU and metro coaches stand to benefit from the announced addition of 18,000 wagons (as against 11,000 in FY09) to Indian Railways fleet in the current year.

The announcement of new train services, refurbishment of older coaches and the intended introduction of high-capacity air-conditioned double-decker trains will also bode well for these wagon manufactures. The setting up of a new coach factory for manufacturing 500 coaches a year in Kanchrapara in West Bengal may not pose significant competition to the players as the

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Railways (according to industry estimates) is expected to acquire 1,00,000 wagon units in the 11th Five year Plan.

Such a high wagon procurement target may result in all the players getting meaty orders.

That the planned investment outlay by the Railways has been increased to Rs 40,745 crore is also a positive for other railway-related stocks. The budget has increased its allocation (compared with the one made in the interim budget) for new lines from Rs 1,100 crore to Rs 2,921 crore.

In addition, even though the budget did not spell out definitive plans for taking the dedicated freight corridors forward, that the Ministry continues to focus on it also reflects well for these container operators. Players such as Concor and Gateway distriparks, give their cold chain initiatives may also benefit from the proposed development of cold storage facilities for farmers to store vegetables and fruits.

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ORGANIZATIONAL STRUCTURE

Bharat Wagon and Engineering Company Limited is divided into following department :-

(i) Personnel Department - The personnel department is hereby in charged (Personel and Administration) assistant who is also looking after the job of welfare officer.

(ii) Finance Department – Finance department is headed by a Manager (finance). The work of finance department is to fix the price of the product by costing methods and other allied works related to the employees for which they are entitled.

(iii) Stores and Purchase Department - Stores and purchase department is headed by Material Manager. The department conducts the supplies and purchase of all materials and products. This department receives the order for the supply of products.

(iv) Work Department – Work department is headed by Deputy Manager (Works). The main function is to take care about wagon assembly, cutting and welding, Pross and smithy, machine shop, finishing and painting shop.

(v) Planning and Civil Department – Deputy Manager (planning and inspection) headed this department. The main function of the department is to get the civil work done and capital budgets etc.

The structure at Bharat Wagon and Engineering Limited Company is shown in adjacent page :-

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26

FUNCTIONS OF VARIOUS DEPARTMENT AT BWEL

PERSONNEL DEPARTMENT

Employment Administration :-

Cultivation of specific sources of manpower.

Selection process including test, interview, examination etc.

Placement, induction.

Maintenance of employees records.

Transfer, promotion, demotion, disciplinary action, grievances etc.

Manpower planning.

Wages rates clearance allowance and other monetary allowances.

Cost of living incise.

Administration of employees appraisal plan.

INDUSTRIAL RELATIONS :-

Settlement of grievances.

Negotiation and dealing with trade union and labour department.

Interpretation and dissemination of company’s personnel policies.

Legal matters concerning employees.

Employment moral.

Communication

WELFARE ADMINISTRATION :-

Canteen and cafeteria

Workmen compensation.

Educational, recreational and cultural activities.

Co-operative activities.

Transport.

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Personnel guidance and counseling.

MANAGEMENT DEPARTMENT :-

To provide training facility to improve skills of the employees.

To facilitate them on the job training and off the job training.

Arranging seminars and conferences.

Providing educational and vocational counseling.

Execute the performance appraisal of the employees potential and capability.

MANPOWER PLAINNING :-

RECRUITMENT AND SELECTION

REPRESENTATION OF COMPANY IN LABOUR COURT

ISSUING CHARGE SHEET AND CONDUCTING DOMESTIC INQUIRY

FURNISHING VARIOUS STATUTORY RETURN TO HEAD-OFFICE AS WEL AS DIFFERENT AGENCIES ETC.

LIASIONING WITH THE TRAINING OF AGENCIES :

MOTIVATING AND PRACTICAL TRAINING OF EMPLOYEE FOR PRODUCTIV.

2. Finance Department

The work of the finance department is to find the price of the product by costing method and other allied workers related to the monetary payments of all sorts of the employees for which they are entitled.

The main functions of finance department

a. Maintenance of books of accounts related to purchase sale, stores establishment and salary v and wages payment etc.

b. Preparation and submission of various management reports on productions, cost control, cash flow stock, sales etc.

c. Statutory compliance under excise, income tax, provident funds, E.S.I. etc.

d. Handling matters related to statutory internal C.A.G. commercial and tax audits.

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e. Analysis of accounting: data for decision-making purposes.

f. Financial concurrence to different proposal including capital investment decision.

g. Cash management and handling banking matters.

3. Works Production Department

1. Fabrication and assembling of railway goods.

2. Manufacturing of wagon components. Fabrication of component of railway bridges/ road bridges.

Safety Officers have been appointed in this company to render the following function :-

a. To act as an expert and safety and pollution control.

b. To provide preventive measures against occupational diseases so as to product. The health of the workers and promote better hygienic atmosphere through the co-operation of the medical officers of the factory.

c. To implement the safety provisions under the factories act, 1948.

d. To ensure accident free atmosphere and to check operations and issue work permits after the hazards having removed and repair made.

e. To check from time to time water and air pollution.

f. To check noise hazards through appropriate means and to reduce them to the appropriate means and to reduce them to the appropriate sound levels.

g. To prevent the loss of the property of the organization due to accidents and mishandling o the tools and materials of the company.

h. To procure safety equipment and prepare for safety budgets and also to see that those safety aids are properly utilized by the workmen.

(ix) To promote safety education and training for th workmen and also motivate them through safety campaign and rewards.

(x) To make safety amidst, appraisal and review to ensure against recurrence of accidents.

(xi) To laise with the Factory Inspector as and recognized training institute like Central Labour Institutes (CLI), Regional Labour Institutes (RLI).

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(xii) To prepare accident reports and analysis for submission to organize works department is divided into different sections & sub sections for better and systematic production as follows:-

Department / Sections Department Code No. Personnel 200 Canteen 203 Store 401 Loading 403 Press and Smithy 501 Cutting and Welding 502 Drilling 503 Wagon Assembly 504 Wagon Finishing 505 Foundary 506 Machine-shop 507 Sub-Assembly/Shot Blast 508 Progress 509 Template 510 Inspection 511 Mechanical and Electrical Maintenance 512 Safety 516

4. Maintenance Department

The Function of the maintenance Dept. is as follow:

Mechanical Maintenance of all machineries and equipments.

Electrical maintenance of all machineries and equipments.

Vehicle maintenance.

Generator operations and maintenance.

Erection and commissioning of equipments.

5. Planning and Inspection Department:

The main functions of Planning and Inspection Department are:-

Total planning of the unit in respect of the requirements of materials for wagon production.

Liaison with railways and other officers for better output in the line of demand.

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Inspection of all incoming material for wagon production and other items.

Audit check of different stages of production of as per the manufacturing standards of railway

C-72 for better quality assurance and do the satisfaction of RDSO (Railway design & standard organization).

Liaison with mounting team for mounting of wheel set.

Security Department

The main functions of the Security Department are

To supervise the factory from any pilferage, damage, fire hazards as well as security of plant & machineries.

To maintain the records of incoming and outgoing materials, persons etc.

Medical Section

B.W.E.L., Muzaffarpur having a full fledged medical provide first aid to the employees.

8. Computer Science

This department is completely meant for Management Information system (MIS) and co-ordination with all the concerned departments and render the following functions.

(a) To keep proper records of employees, their identification no. and relevant details.

(b) To keep records of accounts of production.

(c) To maintain the database management of the company to coordinate with all the departments in keeping information up to date.

(d) To make pay – roll of the employees.

(e) To keep records of accounts of production.

(f) To assist the finance department in preparing the balance sheet, sundry debtors, cash

Bank, GV. (General Voucher) etc.

(g) To prepare Goods Receipts Note (GRN), B.H.W.R. (Bolt, Nut, Washer & Riveties)

Bought out components, Issue, Vouchers etc. records for stores department.

(h) To prepare data entry of variable earning & deduction (monthly overtime, attendance,

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leave etc.

(i) To prepare monthly D.O. value position

9. Material Department

Material Department of Bharat Wagon & Engineering Company Limited, Muzaffarpur is very important as it is primarily intended to assist in the production, maintenance and other allied function of all departments in respect of

To make available balance flow of raw materials components, equipments and other materials necessary to meet operational requirements.

To provide maintenance of materials, spare parts and general stores as required.

Material Department has been sub divided into major sections.

Purchase section is mainly engaged for procurement of all materials required for the company’s business e.g. from paper pin to C.S. Bogie from calculator to shot blasting equipment.

Store section is mainly to engaged for receiving, storing issuance with all case of inventory

control and plays a vital role to achieve the targeted production with all possibilities of cost reductions and make the company in profit. As because Bharat Wagon and Engineering Company Limited is an engineering company and where the cost of raw materials for production is 50-60% of the total cost incurred.

The unit wise manpower break-up is given below:

Unit As on 31st March 2001 As on 1st September 2001

Muzzafarpur Unit 771 743

Mokama Unit 741 707

Bela Works 110 101

Head office, Patna 105 113

Regional office, Kolkata 16 12

Regional office, New Delhi 06 06

Total 1749 1682

Strength and Opportunity Analysis

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Strengths

Established brand name

ISO-9002 certified factories for wagon manufacturing

Location well connected by rail & road

Ample space available for future expansion at Mokamah & Bela

Skilled workforce with rich experience in steel erection & fabrication

Good track record

Opportunities

Moving into value added wagons-

Increase thrust in the area of pontoon Bridges and Screw pile bridges

Focusing on oil companies for building overhead/underground fuel storage tanks.

Utilisation of the excess space in the units at Mokamah and Bela for expansion

Tapping export market for wagons

INDUSTRIAL MARKETING POLICIES

Powers are delegated to various agencies namely Board, Managing Director, General Managers and other Officers depending upon the nature of issue. Some of the important Policies delegated are mentioned below –

Board:

Policy matters relating to service conditions, wages and salary structures including allowances, bonus, retirement benefits, not requiring Government’s approval.

Contracts (above rupees one crore). Write of bad Debts ( over Rs. 25000/-), Sanctioning above 20% excess over senctioned estimate in a project/item.

Ex-gratia payment above Rs. 10000/- in case of death / injury of company employees. Appointment of officer above Dy. Manager

Manager post, scale- Rs. 5400-225-6300-250-9050/- (1995 Revision), and below Board Level.

Norms set by the BWEL for discharge of its functions:

The company has well defined procedures and guidelines for discharge of various functions. These are highlighted below –

Manuals

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BWEL has procedural manuals covering important activities viz Purchase Manual, Works Manual. These manuals ensure carrying of activities in a systematic and standardised manner and eliminate the scope of exercise of discretion. While discharging the functions covered by these manuals, the employees follow the provisions of these manuals.

Guidelines of Department of Public Enterprises

BWEL being a public Sector Enterprise follows the guidelines of Department of Oublic Enterprises and directives of Government of India issued from time to time.

Burn standard Co Ltd

Braithwaite & Co Ltd

Bharat Wagon & Engg Co Ltd

The group companies have supplied various types of wagons with different capacities, both in eight wheeler (Bogie type) and four wheelers to Indian Railways and many overseas Railways. The group companies have also received ISO 9002 Certificates for manufacturing Wagons and wagon components.

Railway Wagons Type of wagon manufactured:

Open Type Freight Wagon (BOXN)

Covered Type Freight Wagon (BCNA)

Flat Type Freight Wagon (BRNA)

Casting Jobs Grey Iron Casting including wagon components, bevel gear box, screws and other components.

Sugar Mill machineries Complete Rollers, Roller Reshelling, Filter press, Crystallizers, Sulphur furnance, Condensers, Conveyor Mill Coupling, Molasses pumps and other allied equipment.

Steel Fabrications Fabrications suitable for the following:

Steel Plants

Thermal Power plants

Oil Installations

Fertilizer Units

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Railway and Road Bridge Structural

Screw Pile Bridge Designing and manufacture of components for screw pile bridges with all relevant components to suit river width.

Coal Minning Equipment Coal Tubs, Mine Cars, Ropeway Buckets

LPG Cylinders Manufacturing LPG Cylinder for domestic use

Projects Defence Road Trailers, Transmission Towers and Sub-Station Structural

Product Range With Description

Product Category Description

Railway Freight Wagons

BOXN – 8 Wheeler Broad Gauge Bogie Open Type Wagons fitted with Cast Steel Casnub Bogies, High Tensile Centre Buffer Couplers (NT) with single air brake system, Tare Wt. 22.47 MT,Pay Load – 58.81 MT and Gross Load – 81.28 MT.

BRNA – 8 Wheeler Broad Gauge Flat Wagons with fixed ends but fitted with single air brake, Casnub bogies and HT CBC coupler

BCNA – 8 Wheeler Broad Gauge Bogie covered wagons fitted with cast Steel Casnub Bogie with Air Brake and CNC(NT) couplers

Structural MS Trough plates – 8 mm thick MS double troughs used in screw pile road bridges of width 0.76 m, length 4.27 m and 10 mm thick double steel trough used in railway tracks on bridges.

Fender plates – 8 mm thick fender plates used in screw pile briges.

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Underground Mild Steel Tanks – 15KL, 20 KL, 45 KL and 70 KL tanks

Grinders – Grinders for screw pile bridges

Wagon Components – Forged, Pressed and Fabricated components for various types of wagons.

CI Castings Wagon Components, Bevel Gear Box, Standard plates & Various components

Sugar Mill Items Rollers – New rollers and Reshelling of rollers

Tail Bar Couplings

Scraper Plates and Sulphur Burner

Machine Parts for Jute Mills

Other Miscellaneous Items

Heavy Media Sump

Hopper used in coal washery units.

Coal tubs and Mines car

High Pressure Heat Exchanger Pipe for oil refinery

Coal handling plant equipment for power plant

I.D. Fan impeller

I.D. and F.D. fan shafts

Crush shafts

Steel Brake Drum

List of Major Plant & machineries for production of wagons at Muzaffarpur

S.No. Description Capacity Nos.

1. Brake Press M/C 315 T 1

2. Brake Press M/C 135 T 1`

3. Hyd. Press m/c 400 MT 2

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4. Hyd. Press m/c 250 MT 1

5. Profile gas Cutting m/c pug 1/8” to 6” thk 6

Straightline gas

6. Cutting m/c 50 MM thk 7

7. Profile Kangaroo gas cutting 38 mm thk 1

8. Pillar Drilling M/C 40 MM & 50 MM dia 2

9. Radial Drilling M/C 50 MM to 65 MM dia 5

10. Girder Drilling m/c 52 mm to 56 mm dia 1

11. Shearing m/c 10 mm to 16 mm thk 4

12. 3-Roll plate bending m/c 16 x 2500 mm 1

13. Power hammer (pneumatic) 5 cwt 2

14. Rivetting hammer 5 cwt 1

15. Cropping Machine up to isa150 x 150 x 12 2

16. Co2 mig welding m/c 450 amp 7

17. Welding transformer 450 amp 60

18. Welding transformer 350 amp 10

19. Submerged auto welding set 750 amp 2

20. Shaper Stroke-24” 2

21. Universal Milling M/c 400 x 1650 mm 2

22. Central Lathe 1.5 to 2 m centre dist & SP 2

bore 53 to 80 mm

23. Central Lathe SW-370 to 390 mm 2

24. Engine Lathe SW-870 mm 1

25. Turret Lathe SW-550 mm 1

26. Capstan Lathe SW-450 mm 1

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27. Horizontal Beam bending m/c 315 mt 1

28. Power Hacksaw 18” 1

29. Circular Sawing m/c Round 9” dia, SQ-8” 2

30. EOT Crane 5 T 5

31. EOT Crane 10 T 2

32. EOT Crane 15 T 3

33. Mobile Crane 10 T 1

34. Vacuum Tester 41 CFT / MM 1

35. Wagon Weighment machine 40 T 3

36. Platform Weighing Machine 30 T 1

37. Oil Fired Heating Furnace - 1

38. Power Winch 5, 10 T 2

39. Shot Blasting Plant 3-4 wagons 1

Machineries for Utility service

1. D.G. Set 250 KVA 4

2. D.G. Set 500 KVA 1

3. Air Compressor 400 CFM at 100 PSI 1

4. Air Compressor 535 CFM at 100 PSI 1

5. Air Compressor 547 CFM at 8 ATM(G) 1

6. Mobile Air Compressor 400 CFM 1

7. Fork Lifter 3 Ton 3

List of major plant and machineries in respect of structural fabrication

Sr.no. Description Capacity Nos.

1. Three roll bending m/c 16 x 2500 mm 1

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2. Shearing m/c 10 mm to 16 mm 4

3. CROPPING M/C IP TO ISA 150 X 150 X 12

4. PUG STRAIGHT LINE 50 MM THIK 7

CURRING M/C

5. PROFILE GAS 1/8 TO 6 THK 6

6. CUTTING M/C

7. PILLAR DRILLING 40 MM & 50 MM dia 2

M/C

8. Radial drilling m/c 50 mm to 63 mm dia 5

9. Brake press m/c 315 T 1

10. Ecentric press m/c 135 T 1

11. Shaper m/c stroke-24 2

12. Co2 mig welding m/c 450 amp 7

13. Welding transformer 450 amp 60

14. Power hacksaw 18 1

15. Centre lathe sw 370-390 mm 2

16. Mobile crane 10 t 1

17. Air Compressor 400 cfm at 100 psi 3

18. D.g. set 250 kva, 500 kva 5

19. Fork lifter 3 t 2

20. Mobile air compressor 400 cfm 2

21. Circular sawing Machine 9 dia & 8 SQ 1

22. Power winch 5, 10 t 2

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S. No. Description Capacity Nos.

1. Power source

a. Step down transformer 500 KVA 2(11kv-440 v)

2. Capacity power source

(a) Diesel Generator 250 Kva 1

(b) Diesel Generator 500 Kva 2

(c) Diesel Generator 20 Kva 1

3. Air compressor

Compressor (elect) 240 CFM 3

Compressor (elect) 565 CFM 1

Portable Compressor (diesel) 400 CFM 2

4. Cranes & Hoist

(a) EOT Crane 15 T 2

(b) EOT Crane 12 T 1

(c) EOT Crane 10 T 2

(d) Hot Crane 10 T 2

(e) Hot Crane 5 T 2

(f) Jib Crane 2 T 2

(g) Jib Crane 1 T 1

5. Mobile Cranes & Materials Handling Equipment

(a) MOBILE CRANE 7.5 T 1

(b) MOBILE CRANE 8 T 2

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(c) MOBILE CRANE 10 T 1

(d) FORK LIFTER 2.5 T 1

(e) LOCO PULSER (WAGON - 2

SHUNTER)

(f) DIESEL LORRY TRUCK 10 T 2

6. Shearing/Cropping/Punching/Shaw machines

A Shearing Machine 10 mm x 2500 mm 1

B Shearing Machine 16 mm x 2500 mm 1

C Shearing Machine 7mm x 3200 mm 1

D Cropping Machine angle upto 150x150X10 1

E Cropping Machine angle upto 150x150X10 1

F Punching Machine upto 7/16” thickness 1

G Circular saw machine upto 150 mm 1

H Power Hackshaw upto 150 mm 1

a) Profile Cutting machines 1.5 m x 150 mm thk 3

b) Profile cutting machines 1.5mx3.0mx150mm thk 1

c) Pug Straogjt edge cutting m/c 50 mm thk 3

7. Power Press & Hammers

a) Hydraulic Press 250 mt 2

b) Pillar type hydraulic press 600 T/400 T 2

c) Ecentric Electro mech. Press 80 T 1

d) Pneumatic Hammer 400, 250, 200 & 100 kg 4

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e) Pneumatic Chipping Hammer 10 mm x 180 mm 5

8. Power Press & Hammers

a) Hydraulic press 250 MT 2

b) Pillar Type Hydraulic Press 600 T/400 T 2

c) Eccentric Electro mech. Press 80 T 1

d) Pneumatic Hammer 400, 250, 200 & 100 kg 4

e) Pneumatic Chipping Hammer 10 mm x 180 mm 5

9. Welding Equipment

a) Arc welding transformer 400/450 38

b) Mig/Mag Welding Machine 400 A 9

c) Submerged Arc Welding Machine 600 A 1

10. penumatic rivetting hammer upto 20/22 mm 14

11. machine/drills

A Heavy Duty Lathe cht 500 mm x 5.5 m bl 2

B Heavy Duty Lathe cht 350 mm x 4.6 m bl 1

C Centre Lathe cht 125 mm x 2.0 m bl 3

D Centre Lathe cht 200 mm x 1.5 m bl 1

E Capstan Lathe collet dia 40 mm x350 m 2

F Shaper Double Arm Stroke 26” 1

G Shaper Single Arm Stroke 20” 1

H Planer Heavy Duty bed 3 x 1.5 m, HT 1.2 M 1

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I Planer Light Duty bed 1/45 x 0.5 m, HT 0.45 M 1

J Slotter Heavy Duty Stroke 500 mm bed dia 1 m 1

K Plain Milling Machine -

L Universal Milling Machine bed 1.25m, ht 0.4 m 1

M Boring Machine (Horizontal) d 1.0 m x 12 m 1

N Boring m/c (Vertical) double Head900mm od*500 mm id*2M10Lg 2

O Shell Boring m/c double head Sugar Mill roller Boring 2

P Gang Drilling m/c double head 1.25” , BL 13 M 1

Q Universal Drilling m/c size 1.5” 1

R Radial Drilling Machine size 1/25”/1.5”/2” 3

S Surface Grinding m/c 8” x 5.5” x 2” 1

T Pedestal Grinding m/c 16” x 5” x 1.5” 1

U Pedestal Grinding m/c 18” x 2.5” x 2.5” 1

V Portable Drilling m/c 20 M 2

12. foundry equipment

a) Cupola 5t. 2t 3

b) Oil Fire Melting Furnace 0.5 t 1

c) Hot Metal Ladles 8t, 4t, 2t 1

d) Coal fired Core Drying Oven 250-300 degree c 2

e) Sand Muller Machine 5 cft/hrs 1

f) Jolt Squeeze Moulding Machine 340 kg 1

g) Wood Planner Machine 18” Cutter Length 1

h) Band Saw Machine 5 hp 1

13. Air Brake Testing Rig 6 kg/CM.SQ 2

14. Vacuum Brake testing machine -

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15. wagon weighment machine 40 T 2

16. Shot Blasting Plant 3-4 wagon/day 1

17. Power winches 15 hp 2

18. Three Roller Type Plate Bending m/c 16 mm tjocl x 2500 mm wide 1

Technical Parameters of Meter Gauge Coach for Indian and Vietnam Railways

Description Indian Railways Vietnam Railways

Track Gauge 1000 mm 1000 mm

Length over Bodyend Pannel 19500 mm 19000 mm

Length over Centre Buffer Couplers 20184 mm 20184 mm

Distance between Bogie Centres 13715 mm 13300 mm

Bogie Wheel Base 1980 mm 1980 mm

Max. Load per Axle 10 Te 10 Te

Width over Bodyside Pannel 2740 mm 2740 mm

Height of Roof from Rail Level under Tare Condition

3355 mm 3700 mm

Height of Centre Buffer Coupler from Rail under Tare Condition

825 mm 825 mm

Max. Service Speed 90 Kmph 100 Kmph

Wheel Dia. On Tread 952 mm 780 mm

Brake system Vacuum/Air Brake Air Brake

Max. Radius of Curvature 90 m 90 m

Coupler Type High Tensile C.B.C type of IR Standard

High Tensile C.B.C type AAR 10 A Contour

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PRESS & SMITHY SHOP

In this press and smithy shop there are seven open nearth furnances where coal burns on the bed. On these famous various of parts are heated. The heated part is kept on the anvil with the help of hammer the required shape is formed. In this shop more than 50 components are :-

Head Stock pressing

Anchor plate pressing

Anchor support pressing

Foot Step

Pull Road

Head Stock

Hand Wheel

Bolster

List & Numbering of machine :-

1. Hydraulic Press (400 T) -----

2. Hydraulic Press (250 T) -----

3. Press Machine (600 T) -----

4. Power Hammer (400 Kg) -----

5. Power Hammer (250 Kg) -----

6. Power Hammer (100 Kg) -----

7. Power Hammer (80 Kg) -----

8. Coal Fired Forge -----

9. Oil Fired Furnance -----

10. Blower -----

(1) Press & Press Work :-

The press is metal forming machine tool designed to shape of cut metal tool by applying mechanical force or pressure. The metal is formed the desired shape without removal of clops.

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The presses are exclusively intended for mass production work and they present the fastest and most efficient way to form a sheet metal in a finishing products.

(2) Power Press

The constructional feather of a power press is almost similar to the hand press the only difference being, the ram instead of driven by hand is drives by power. The power press may be designated as mechanical or hydraulic according to the type of working mechanism used to transmit power to the ram. In a mechanical press, the rotary motion obtain from an electric motor is converted into reverted into reciprocating movement of the ram by using different mechanical device. In a hydraulic press, the fluid under high pressure is pumped on one side of the piston and then on the other in a hydraulic cylinder to derive the reciprocating movement. A power press has driven by crank and connecting road mechanism. The working of the press is similar to that of a hand press. The punch is fitted on the end of the die is attached on the bolster plate. The fly wheel mounted at the crank shaft stores up sheet metal is pressed between the punch and the die.

Power Press Parts :-

The different parts of a power press are described below :-

Base

Frame

Bolster Plate

Ram or slide

Pitman

Crank shaft or eccentric

Fly Wheel

Clutch

Brake

1. Base :-The base is the supporting member of the press and provides arrangement for tilting and clamping the frame in an inclined press.

2. Frame :-All presses except the straight side type have “C” shaped frame to take up the vertical thrust of the ram.

3. Bolster Plate :-The Bolster plate is a flat plate fetted on the base for supporting the die block and other accessories of the press.

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4. Ram :-The ram is the reciprocating member of the press that slides with in the press and guides and supports the punch at its bottom end.

5. Pitman :-The pitman is the connecting rod in a crank or eccentric driven press. The position of the stroke of the ram can be changed by altering the length of the connecting rod.

6. Crank shaft of eccentric :-The rotary movement of the motor is motor is converted into the reciprocating movement of the ram by crank and connecting rod, eccentric and connecting rod, or many other mechanisms.

7. Fly Wheel :-The fly wheel is mounted at the end of the driving shaft and is connected to it through clutch. The energy is stored up in the flywheel during idle periods and it is expand to maintain the constant sped of the ram when the punch is pressed into the work. The fly wheel is directly coupled with the electric motor.

8. Clutch :-The clutch is used for connecting and disconnecting the driving shaft with the fly wheel when it is necessary to start or stop the movement of the ram.

9. Brake :-

The brakes are used to stop the movement of the driving shaft immediately after it is disconnected from the fly wheel.

Hydraulic Press :-The hydraulic press is used to manufacture anchor plate. For this plate in the oil furnance. The heated plates is kept horizontally on the machine table and ram is allowed to press the plate due to downward movement the U-shaped anchor plate is manufactured.

The specification of this machine is as :-

Nominal Pressure ----- 250 Tons

Working Pressure ----- 200 atms.

Speed ----- 0.20 m/Sec.

Pressure exerted by Slide ----- 80 Tons

Stroke of slide ----- 500 mm

Maximum distance in table & slide ----- 630 mm

PNEUMATIC HAMMER :-On this machine the part which is to be manufactured is kept on the after heating on the furnance and the ram is allowed to strike the component on the die. Due to the strike of ram the component takes the shape that of the die. The machines have following specifications :-

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Falling weight of ram ----- 400 Kg.

Maximum stroke of ram ----- 700 mm.

No. of blows per minute ----- 130 blows/mln.

Working Space ----- 530 mm.

Distance from centre of ram to housing ----- 520 mm.

Hydraulic press

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CUTTING AND WELDING SHOP

Introduction :-

This shop works under the Supervision of Mr. Taukir Ahmad this is one of the shops in which the basic work is performed. As the name indicates this shop is mainly involved in cutting the plates of different thickness in the desired shape & size and in the profile cutting.

In the metal-working work pieces of most difference shapes and dimensions and of different materials are worked. The various working processes fall into the two groups, the of non-cutting shaping, e.g. forging pressing, drawing, etc. and that of cutting shaping by which finish surface of desired shape and dimensions is obtained by separating a layer from the parent work piece in the form of chips e.g. turning, drilling milling etc.

List of no. of machine :-

1. Shearing Machine ---- 1

2. Cropping Shearing Machine ---- 2

3. Chipping Machine ---- 1

4. Profile Cutting Machine ---- 3

5. Kangaroo Machine ---- 1

Shearing Machine :-On the shearing machine the to be cut should be flat & the thickness should not be more than 8 min. For cutting the flat plate is kept on the bed of the held of crane. The machine consists of a cutting blade & no. of pressing bolts press the plate and keep it rigidly fixed the downward movement of the cutting plate.

Cropping Machine :-On the cropping machine number of works are performed. This machine can cut the flat plate of small sizes, angles, plates, square hollow rod & circular hollow rod. Also this machine can be used as punching machine.

Chipping Machine :-This machine is use to produce an inclined shaped at end of plate which is necessary in the end to end welding. This machine has a gun through which high pressure air comes. This machine holds a chisel. The high-pressure air pushes the chisel. Which causes to cut the plate?

Profile Cutting Machine :-This machine consists of a vertical column and two horizontal arms. The one arm consists of the template and another arm consists of the welding torch and the small driving motor. This machine can cut the plate of thickness of 35 to 40 mm. Through the welding torch acetylene and oxygen gas is supplied. This machine requires extra amount of oxygen gas. So two oxygen pipes are connected to the torch. To cut the plate in the desired shape. The same

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shape template is fitted to the upper arm and the magnetic roller of the second i.e. lower arm is toughed to the template. The driving motor drives the torch. The torch moves through the profile of the template and plate cut in the desired shape.

Kangaroo Machine :-One another plate cutting machine in this shop is Kangaroo Machine. This is the biggest cutting machine. This machine consists of two welding torch. The torch can move in all the three coordinate axis i.e. X,Y and Z axis. This is fully electronic controlled machine. This machine consists of an electronic sensor and a horizontal plate. The drawing of the required shape is kept on the horizontal plate and the sensor moves through the black lines of the drawing this machine can be moved manually. The amount of acetylene and oxygen gas can be controlled with the knobs.

In the welding section mainly bolster and cross bars are manufactured.

The Process of metal cutting in which chip is formed is affected by a relative motion between the work piece and the hard edge of a cutting tool held against the work piece. Such relative motion is produced by a combination or rotary and translating movements either of the work piece or of the cutting toll or of both. Depending of the nature of his relating motion, metal cutting processors are called by names example :- Turning, Planning, Boring etc.

A cutting tool may be used for cutting apart, as with a knife, or for removing chips. Parts are produced by removing metal mostly in the form of small chips.

Chips :-The form and dimension of a chip metal machining indicates the nature and quality of a particular machining process but the types of chip formed in influenced by the properties of the material cut and various cutting conditions.

In engineering manufacturer particularly in metal machining process hard brittle metals have a very limited use, and dutile metals are mostly used.

Chips of ductile metals are removed by varying proportions of shear flow. This results in general type of shapes.

1. The discontinuous or segmental form.

2. The continuous or ribbon type.

Discontinuous or Segmental Chip :-

It consists of elements fractured into fairly small pieces ahead of cutting tool. This type of chip is obtained in machining most brittle materials such as cast iron bronze. These materials rupture during plastic deformation and form chip as separate small pipes. As these chips are produced, the cutting edge smoothes over the irregularities and a fairly good finish is obtained. Tool life is

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also reasonably good, and the power consumptions low. Discontinuous chip can also be formed on some ductile metals only under certain conditions particularly at very low speeds and if the coefficient of friction is low with ductile metals, however the surface finish is bad and the tool life is short.

Conditions :- Ending to promote its formation brittle metals, greater depth of cut, low cutting speed and small rake angle.

Continuous chip :- It consists of elements bonded firmly together without being fractured. Under the best conditions ribbon of metal which, under the microscope shows no sings of tear or discontinuous. The upper side of a continuous chip has a small notch while the lower side, which slides over the tool face, is smooth and shiny. The continuous form is considered most desirable for low friction at the tool- chip interface lower power consumption long tool life and good surface finish.

Shearing machine

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Welding and drilling work

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DRILLING SHOP.

INTRODCUTION :-

The drilling machine is one of the most important machine tools in a workshop . As regards its importance it is second only to the lathe. Although it was primarily designed to originate a hole, it can perform a number of similar operations. In drilling machines holes may be drilled quickly and at a low cost. The hole is generated by the rotating edge of a cutting tool known as the drill which exerts a large force on the work clamped on the table. As the machine tool exerts vertical pressure to originate a hole it is loosely called a “drill press”.

Holes were drilled by the Egyptians in 1200 B.C. about 3000 years ago by how drills. The bow drill is the mother of the present day metal cutting drilling machine.

In the drilling shop there are different types of drilling machines such as radial drilling machine.

RADIAL DRILLIGN MACHINE :-The radial drilling machine is indented for drilling medium to large and heavy work pieces. The machine consists of a heavy, round, vertical coulomb mounted on a large base. The column supports a radial arm which can be raised and lowered to accommodate work piece of different bights. The arm may be swung around to any position over the work bed. The drill head containing mechanism for rotating and feeding the drill is mounted on a radial arm and can be moved horizontally on the guide ways and clamped at any desired position. These three movements in a radial drilling machine when combined together permit the drill to be located at any desired point on large work piece for drilling the hole. When several holes are drilled on a drilled on provide guide ways on which the drill head may be made to slide. The arm may be swage bound the column. In some machine this movement is controlled by separates motor.

Drill head :- The drill head mounted on the radial arm and drives the drill spindle . It encloses an the mechanism for driving the drill at multiple speeds and at different feed. At the mechanisms and control are may be made to slide on the guide ways of the arm for adjusting the position of drill spindle with respect to the work. After the spindle has been properly adjusted in position the drill head is clamped on the radial arm.

Universal Drilling Machine :- It is one of the important drilling machine. This drilling machine can produce a hole any direction at any angle. The universal drilling machine consists of a vertical i.e. horizontally, vertically and at any inclination. The drilling can be done by automatic feed mechanism and by manual operation.

Semi Universal radial drilling machine :- It is same as universal radial drilling machine except this drilling machine cannot produce a hole in inclined direction. This machine consists of two electrical motors. One is used for the operation of drilling and the another is used for the vertical

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movement of horizontal arm is the feed. In these machine water is used as a coolant the chip which comes out from the operation is continues chip.

Sensitive drilling machine :- On the machine small sized hole is drilled usually a drill of 5 mm and 6 mm is used for the machine has a very long bed and a gang of three drilling machine. This machine is used to produce a hole in the very long channel. For operation the channel is kept on the bed the jig is fitted to the channel and with the help jig bush the hole is produced at desired position.

Drilling of Job :- In the shop drilling is done by two methods, i.e. by marking and by jig. The following are the drill size & which are used for drilling in this shop are 5 mm, 6 mm, 11 mm, 13.5mm 17.5mm 21.5 mm and 23.5 mm. These are the drill size which is used here for drilling marking takes a lot of time and it requires more skilled person for marking . so drilling of component by marking is used fro a few, components where it is different to set a jig. For mass production of components jig is used for drilling. The thickness of the jig plate, which is in practice, is 12 mm. To manufacture jig a hole greater die is done in the jig plate and bush of required drill size is filled in the hole, The material of the jig bush is called IV and IS: 1875. In this drilling shop there is one universal radial machine, two semi universal radial drilling machine and a few ordinary machines. There is one gang drilling machine and one sensitive drilling machine.

Universal radial drilling machine

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MACHINE SHOP

INTRODUCTION :-

The shop works under the supervision of Mr. S.B.P. Shirivastva . This is the biggest shop of this organization . In this shop there are various type of machines. :-

Such as :-

1. Lathe - 11

2. Drilling M/c - 2

3. Shaper - 2

4. Slotter milling m/c grinder - 3

5. Planed - 2

6. Etc. - 2

The Lathe :-In the year 1797Henry Maudslay and Englishman, designed the first screw cutting

lathe which is forerun C of the present day.

Function of Lathe :- The main function of lathe is to remove metal from a piece off work to

give if the required shape and size. This is accomplished by holding the work securely and

rigidity an the machine and then remove metal from the work in the form of chips. To cut the

material properly the tool should be harder than the material of the work piece. Should be rigidly

help on the machine and should be fed or progressed in a definite way relative to the work.

Lathe Parts :

1. Bed

2. Head Stock

3. Tail Stock

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4. Carriage

5. Feed Mechanism

6. Screw Cutting Mechanism

Description and Foundation of Lathe Parts :-

1. The Bed :-The Lathe bed forms the machine . The head stock and tail stock are located at

either end of the bed and the carriage rest over the lathe bed and slides on it. The lathe bed being

the main guiding member of the tool for accurate machining work.

2. The head Stock :-The head stock is secured permanently on the inner ways at the left

hand end

of the lathe bed it provides mechanical of rotating the work at multiple speeds.

3. Tail Stock or Loose Headstock :-The tail stock is located on the inner ways at he right

hand end of the bed. This has two main uses.

(a) It supports the other end of the work when it is being machined between centrs.

(b) It hole a tool par per forming operations such as drilling remaining tapping etc.

4. Carriage :-

The carriage of a lathe has several parts that serve to support, move and control the

cutting. It consists of toll parts :-

(a) Saddle

(b) Cross-slide

(c) Compound slide or compound rest

(d) Tool past and

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(e) Apron.

5. Feed Mechanism :The movement of the tool relates to work is lumed as “feed” . A lathe

tool may have three types of the lathe axis; the movement is termed as longitudinal fed and is

effected by the movement of carriage.

6. HEAVY DUTY LATHE

The heavy duty lathe 4 jaws chuck and can hold a job of India .. can rotate up to a mix . Speed of

315 rpm.

The motor, which is required to rotate the chuck, has the following specification. This is 3 phase

induction motor and required 415 volts . It s dello connection the horsepower of the motor is 50

H.P. and the out put shaft of this motor can rotate speed of 1460 rpm. The tail stock of the lathe

consists of separate electric motor to move to move it self on the lathe bed.

HORIZENTAL BORING MACHINE

This machine is used for the boring purpose of big components. This machine is driven by

electric motor & with the help of gear mechanism and main shaft is rotated. The sail, which is to

be mechanized, is kept on the bed. Before it, a ring is inserted over the sail to rigidly damp it.

The main shaft consists of to heads, which has groove in which cutting tool is fitted & frightened

with the bolts. The cutting head starts cutting from opposite sides both the cutting tools rotate in

opposite direction.

SHAPPER MACHINE

This machine which is used here is known as Double sharper machine . As the name itself the

machine has two ram & one long table. Both ram on the table and as per the requirement on or

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both machine is used to produce good surface on rough work place. Also it can be used to cut a

key way & for many other operations too.

Centre lathe machine

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FOUNDARY SHOP

Mr. S.B.P. Srivastava supervises the work of this shop. This is also very important shop of this

plant. In this shop casting is done. The various parts on the wagon

are manufactured in this shop.This casting is divided into three groups Low & Medium casting

are again divided in to sub group Green and dry and loam casting of sweep moulding. For

moulding clay is mixed with send to improve binding strength. Normally Bentonite & cow dung

improved the porous nature of sand. Normally 3% clay is mixes with sand. For casting first

mould is prepared with help of moulding box.

As per the requirement core is used in moulding . Fro preparing core reinforcement is used

which supports. The pressure of the molten metal.

Green casting is used for mass production. For dry casting, the core and the prepared mould is

hearted from inside the coal oven to reduce the moisture & to improve the strength & reduce the

shrinkage allowance.

CUPOLA FURNACE :-This is very important type furnace. It has the bottom bed & air

chamber. During operation the bottom bed is closed & the inclined sand bed is prepared on the

bottom bed. The air chamber which is connected with the outlet of bower which supplies air to

the coke is 12 to 36 inches above the air chambers. Improve the firing . The coke is fired air

blown. As the coke produce heat nearly equal to 22000 C the ferrous metal starts melting.

After melting the metal flows downward and get stored on the sand bed. Due to its high density

the coke starts flowing. As the slag starts flowing outside it is confirmed that the metal is in the

fully molten state condition the gate is opened and the molten metal is allowed , to blow in the

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ladle. In this system the hot air which tends to pass from top is recycled and again supplied to

the air chamber. This reduces the cost of production.

ZONES CUPOLA:-The Cupola furnace is divided in various Zones. A number of chemical

reactions take place in this Zone, which are as follow as :-

1. Well :-It is the space between the bottom of tuyers and the sand bed. The metals are

trickles down after melting and collects in this space before it is tapped out.

2. Combustion Zone :-It is also known oxidizing zone. It is located between top of the

tuyers and theoretical level above it. The actual combustion takes place in this zone. More heat is

evolved due to silicon & manganese. A Temperature about 15400 C to 18700 C is produced. The

exothermic reaction taking place in this zone.

C+O2 ……………………………. CO2 – Heat

Si+O2 ……………………………. SiO2 – Heat

2 Mn + O2 ………………………… 2MnO2 + Heat

3. Reducing zone:-It is also known as productive zone. It is located between the top of the

combustion zone and the top lave of the coke bed. Co is reduced in co in this zone through an

endothermic reaction, as a result of which the temperature falls from combustion zone.

Temperature is about 12000 C of this zone.

CO2 – C (of coke) ……………………. 2CO + HEAT

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4. Melting zone :-The first layer of metal charge above the coke bed. This solid metal changes

to state in this zone.

3 Fe + 2 CO ---------------------------------- Fe3C + Co2

5. Preheating Zone :-It extends from above the melting zone to the bottom level of the charging

door and contains a number of alternate layers of coke and metal charges. The function of this

zone is to about 1093 C before the downward to enter the melting zone. This preheating takes

place due to the upward advancing hot gasses.

6. Stack Zone :-The empty portion of cupola the preheating zone. Which provides the passage

to hot gasses to go to atmosphere ,is known as stack zone.

Cupola Efficiency :- The thermal efficiency of cupola is given by the ratio of heat actually

utilized in melting zone and superheating the metal to the involved in through various means.

The ratio can mathematically :-

Percent Cupola :- Heat utilize in melting and super heating x 100

Calerific value of coke – heat involved due to

oxidation of iron , si and Mn

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WAGON ASSEMBLY SHOP

In this shop the various components which are manufactured in the different shops are assembled

and the completed and then set to the finishing shop. First of the assembly of wagon, the centre

sill is kept on the fixture.

Centre Sill -This is manufactured in the sub assembly shop. To manufacture two Z channels are

welder after welding the supporting plate is welded to require position and then it is sent for

marking . After marking drilling is done by the air gun. Lastly it is checked whether it is true

size or not. If not the length is reduced by gas cutting.

The length of the centre sill should be 9784 mm and width should 2960 mm. The centre sill is

placed in the fixture and cross bar bolster welder to it. After welding these two seal are attached

and is welder.

Now this knows “Under frame”, now riveting is done . The head stock also welded to the centre

still at the ends. The gusset plate and the cross bottom plate is welded to bolster and cross bar

respectively . The stranger welded to the under frame through out the length. The under frame is

placed on the manipulator for welding at the bottom side. Now the air brake cylinder and the

pipe line is fitted and clamped . The side body and end body is attached and riverted and welded

to the frame . This complete box is kept on the wheel .

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Railway wagon(BOXN-HL)

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FINISHING SHOP

After assembling the wagon is sent to the finishing shop. In this the wagon is brought to the shot

blaster chamber. In this chamber small iron particle is allowed to strike on the wagon to remove

the extra welding deposit and the rust formed on it. The high pressure air helps the iron particle

to come out from the gun and to strike rapidly. In this chamber the working condition are very

hazardous. So the worker wears oxygen mask before doing work inside the chamber. After this

the wagon is painted and the specification are written on the wagon is painted and the

specifications are written on the wagon and then dispatched to Indian railway.

10. SUPPLIER OF MAIN WAGON COMPONENTS

Components Suppliers

1. Wheel W.A.P. Banglore

2. Bogie BESCO Kolkata

3. High Tension Couler H.D.C. Kolkata

4. Air Brake Equipment 1. Escort Ltd. Faridabad

2. Stone India Ltd. Delhi

3. Bharat Braks & Value Ltd. Kolkata

5. Steel 1. Bokaro Steel Plant

6. Bearign 2. Tisco Indi Thmken India Jamshedpur

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Complete wagon on railway track

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TEMPLATE SHOP

Before describing the template t is worth while to elaborate the word “template”. This is a

pattern or gauge a time in mass scale. This saves a lot of time, as no marking is necessary when

using template . Basically templates are of two types :

1. Marking Template

2. Checking Template

The main objective of this shop is making templates of all the consigned wagon components

where a certain profile cutting is necessary.

The manufacturing of template is done with the help of the design and drawing provided by

R.D.S.O. Lucknow . Also the allowances for different tools are taken into consideration during

marketing the template. The varies machine to machine. The templates here are usually made of

mild steel . They are of small thicknesses.Working in this shop needs greatest accuracy because

shapes all the components made with the help of template depends upon the template. Thus a

minor fault cans a great fault in the production.

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SCRAP :MEANING AND DEFINATION

Scrap has various definitions and meaning in different contexts. Broadly scrap is materials.

Discarded from manufacturing operations that may be suitable for re processing. Scrap is a term

used to describe the recycling of metal. Old unwanted metal such as left out iron sheets, building

supplies, surplus materials, useless equipment, safety appliances, wornout tools machine part etc.

Sometimes some raw material which is basically to be used for some special purpose but on due

inspection it is observed that material does not meet required specifications, or is of of poor

quality and is not suitable for the purpose, such material is also considered as scrap. Scrap is

material that has been found to be unfit for further processing. Here in BWEL muzaffarpur

various type of scrap is produced . Broadly various types of scrap produced in BWEL

muzaffarpur can be classified as follows:

1. scrap from wagons shop :

Left out metal sheets after cutting out of required shapes of sheets used in production of LHB FIAT wagons.

Sheet portions left out after cutting by laser cutting machine. Iron pieces and bits that are of not suitable to be welded with wagons frame. Metal fillings and residue left out during machining of LHB wagons.

2. Scrap from shell shop :

Left out metal sheets during cutting out upper and side frames.

3. Scrap from sheet metal shop :

Damaged or mutilated iron or steel sheet which are not suitable for further use.

4. Scrap from furnishing shops :

Various types unused material like foams, leather, unused wooden parts etc…

5. Miscellaneous scrap :

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Wooden scrap from carpentry shop. Empty paint BOXES AND TUBES.

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LIST OF SCRAP MATERIALS PRODUCED IN BWEL MUZAFFARPUR

1. punching, sheet cutting etc of various sizes. shapes and thickness, etc.

2. scrap of ms skeleton and its cuttings of varous sizes. shapes and thickness upto 10 mm.

3. scraps of cuttings of ms plate skeleton, bar, rods, strips etcof various sizes. shapes and

thickness.

4. scrap of ms plate skeleton and its cuttings of various sizes. shapes and thickness 10 mm

and above (cutting allowed for loading purpose only)

5. scrap of pcv insulated copper cable and wire of different sizes, shapes, thickness and

length including leads of welding torcheswith or without attachements.

6. scrap of empty iron drums cap 200 kg released from bitumen compound broken/unbroken

with or without lid and residue.

7. misc. scrap of ms and cr consisting of cuttings, punchings, angels, channels, circles, fine

melting and other small manufacturing scrap of shop, scrapped window blanks etc of

various sizes, shapes and thickness etc. aluminium scrap consisting of sheet cuttings,

skeleton cuttings, off cuts cuttings, punchings, angels, channels, mouldings, extrusions,

pipes, conduit, chequred sheet cuttings, rejected and condemned components of

aluminium, etc.

8. aluminum scrap consisting of sheet cuttings skelton cuttings, off cuts, cuttings,

punchings, angels, channels,moulding extrusions, pipes, conduit, chequred sheet cuttings,

rejected and condemned components of aluminum, etc.

9. scrap of cr off cut and its cuttings of various sizes, shapes and thickness upto 4 mm. scrap

of cr skelton carline type and its cuttings of sizes, shapes and thickness upto 4 mm.

10. scrap of cr off cuts and its cuttings of various sizes, shapes and thickness mainly 4-6 mm

including chequred plate off cuts.

11. scrap of cr skelteon and its cuttings of various sizes, shapes and thickness 4 to 6 mm.

12. scrap of pvc flooring off cuts of various sizes, shapes, grades and shades with or without

glue etc.

13. scrap of used and condemned ferrous spare parts of various types of machines, vehicles,

eot cranes etc. like silencer flexible connection, torque convector, clutch plates, brake

shoes, connecting rod, gear leaver, axle shaft, the rod, fan blades, shockers, cylinder

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head, roller, chain, hub, master cylinder, roller bearings, eot crane wheels, diplory wheels

etc. and other ferrous scrap of spare parts with or without non ferrous attachements.

14. scrap of ms and cr rejected and condemned wagon components released during

manufacturing like cantrail, sole bar, side frame, end extension etc, cuttings, angels,

channels.

15. scrap of ms skeleton and its cuttings of various sizes. shapes and thickness upto 10 mm.

16. scrap off cr off cut and its cuttings of various sizes, shapes and thickness upto 4mm. misc

scrap of stainless steel of various grades mainly ferretic and consisting of sheet cuttings,

skeleton cuttings, off cuts, angles, channels, cuttings, punching moldings, shop made

rejected wagon components and other manufacturing scrap of various types, grades and

shapes. scrap of cr skeleton and its cuttings of various sizes.

shapes and thickness upto 4 mm.

17. scrap of cr slitting trim cut end waste in coil shape of various sizes, width upto 65 mm.

18. scrap of ms skeleton and its cuttings of various sizes. shapes and thickness upto 10 mm.

19. scrap of ms skeleton and its cuttings of various sizes. shapes and thickness upto 10 mm

and above.

20. scrap of cr skeleton and its cuttings of various sizes. shapes and thickness upto 4 mm.

21. scrap of cr trim cut end waste slitting in coil shape max. width upto 140 mm and

thickness upto 6 mm.

22. scrap of ms off cuts and its cuttings of various sizes. shapes and thickness mainly 6 mm

and above and width mainly upto 200 mm including chequred plate off cuts if any.

23. scrap of stainless steel trim cut end waste slitting in shape of various grades mainly non

ferratic, and of various shapes, sizes, thickness etc. misc mixed scrap of ms and cr

consisting of angels, channels, small off cuts, sheet cuts rejected and condemned small

wagon components cuttings, manufacturing scrap, molding, pipes, square tubes, mesh

etc.

24. scrap of codemnned floor griding machines with or without accessories.

25. scrap of limpet/nftc sheet cuttings of various sizes and grades and shades.

26. scrap of limpet/nftc sheet cuttings of various sizes, shapes, thickness, grades and shades.

27. scrap of lp sheet (sunmica) of various shapes, sizes, and thickness with or without pasting

of plywood including kachra type small strips etc.

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28. scrap of wooden sleepers cut pieces of different shape & sizes.

29. scrap of rejected & condemned stainless steel water tank modules with or without ferrous

attachments etc.(9 nos)

30. scrap of limpet/nftc sheet cuttings of various sizes, shapes, thickness, grades and shades

etc.

31. scrap of condemned fire extnguishers of foam types.

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SCRAP MANAGEMENT AND IMPORTANCE

Such a large quantity of scrap needs a proper way of management and disposal. Otherwise it would create wastage and environmental hazards.

The proper utilization, processing, disposal and other type of related maintainance of various types of scraps is broadly termed as scrap management.

Scrap management process differs from industry to industry. Scrap from large and big industry usually serves as raw materials for small scale industries and factories .

In case of small industries like in case iron or sheet metal industry scrap management simply consists of activity in which scrap material is taken from workshop to a scrap yard, where they are processed for later melting into new products.

But in case of a large industry where different types of raw material is used and different processes and operations are carried out a very comprehensive method of scrap management is necessary for the betterment of industry.

Thus we see that scrap management plays an indispensable role in upliftment of the industry. Now we are going discuss the scrap management in context of BWEL MUZAFFARPUR. SCRAP MANAGEMENT IN BWEL MUZAFFARPUR

Scrap production in BWEL MUZAFFARPUR is one of largest in the North India. Every year crores of scrap is produced in various workshops of BWEL MUZAFFARPUR, whose proper management and disposal is very necessary. That’s why scrap Management is very important aspect in proper functioning of BWEL MUZAFFARPUR.

Specially for this purpose there is a scrap depot in the factory campus where all the scrap and waste material is dumped and whole process of scrap management is carried out from there.

Various poles and bins are designated and number for arranging different types of scrap. Different type of scrap is distributed at different places in scrap yard according to the

requirement and auction requirement. Dy. CMM of scrap Depot is incharge of all the proceedings carried out related to scrap in

the factory. Now the management of scrap starts right from the workshops. In each and every workshop scrap bins are suitably placed where different types of scrap

is placed. This scrap is before hand distributed according to its type, such that there is no need of differentiating scrap after it reaches the scrap depot. These bins are actually large containers which can be suitably installed on truck.

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A large crane picks up these containers and puts it upon the trucks which carries these scrap upto the scrap depot and unload them in the scrap depot according to the designated place.

These places are actually designated according to the pole number or heap number. Now there is form known as Advise Note on which all the paper work related to the

transportation of scrap from the workshop to the scrap depot takes place. Person concerned in workshop fills the advice note and sends it along with the scrap to

the scrap depot. In scrap depot the concerned official receives the scrap truck and further fills the advice note.

Pole number or heap number where scrap is unlocated is noted down. Advise note is kept in records.

The size of scrap heap in depot is kept, keeping in mind various factors. When the amoumt of scrap is large enough auction of this scrap is done. Before auction various beforehead preparation are done. Size of scrap heap is kept such that it is easier for the trader to carry the scrap easily. If

the scrap heap is smaller it will be easier for the trader or the dealer carried to desired position, moreover less scrap heap means less weight and less transportation costs for the trader and he will be more encouraged to buy the scrap.

Certain minimum price is selected beforehand by the depot officials by reviewing the present market prices of iron and other such kind of scrap.

Sometime special scrap such scrap of Mynmar wagons, include the taxes also. Various traders or dealers are informed beforehand by various means.

A special catalogue of scrap available is distributed among these traders and dealers. This catalogue tells aqbout the different types of scraps available, their weight, minimum

piece before auction and position where they are placed in the scrap depot. These traders are either from some small scale industries or just moderators who further

sell these scrap to other people. The highest bidder or particular scrap gets to have that scrap. This scraps serves as raw materials for these small factories. Some scrap such that of iron and other metallic scrap is often remelted and cast into other

useful products. Other miscellaneous scrap such as tubes, plastic, etc are also useful for some small scale.

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VARIOUS LOCATIONS FOR SCRAP IN SCRAP DEPOT

In scrap Depot large amount of scrap is to placed in distributed manner so that it is easy to distinguish various types of scrap and other information related with it.

For this purpose scrap depot following type of division are done : A) Sectors B) Poles C) Bins

Sectors: These are the broad classification of a certain area that has certain amount and certain type of scrap lying there. These are alphabetically numbered. There are sectors numbered from sector A to sector H in scrap depot.

Poles: There are many poles which are numerically numbered. Below these poles heaps and lots of scrap are placed.

Bins: These are cemented scrap bines where whole of scrap is dumped. These again are numbered.

All of these are simply identification to know where and what type of scrap is placed in the scrap depot.

In the catalogue also it is given that so much kg of scrap placed in given secto or near the given pole or in certain beam.

This also helps the bidders and purchasers during the auction to easily and properly identify and inspect the scrap.

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TERMS AND CONDITIONS OF AUCTION SALE OF SCRAP IN BWEL MUZAFFARPUR

1. ENTRY :

Its welcome for participating in auction to all bidders who accept and abide by the terms and conditions of auction sale given here under.

All bidders intending to participate in the auction shall be charged Rs 15/- each as entrance fee which is non returnable and every participating bidder has to submit a demand draft of Rs 10,000/- each in favour of FA and COAO/BWEL/MFZ payable at New Delhi issued by any nationalized bank which ahall be normally returned after the auction is over.

Any bidder who has deposited demand draft of Rs 10,000/- as entry fee can participate in the bidding. If it found at any stage that bidder has not deposited the entry fees, then the bids of such a bidder may be cancelled.

The lots put up for auction, can be inspected at any working day prior to the auction. The bidder can enter the scrap yard one hour before the commencement of the auction. The intended bidders who wish to participate in the auction should bring authority letters

on letter pad of the firm with name and address to whom he represents. They should produce Trade license ST/CST/No. on their letterhead to participate in the

auction at the Depot gate before commencement of the auction, the demand draft and a copy of letter shall be kept at gate and receipt will be issued to them.

Participants taking part in the auction have to mention reference of Sales Tax Registration No. if there is any, at the time of entrance to the auction.

2. BIDDING:

It must be clearly understood by the bidder that auction document have been issued to bim and he is permitted to bid in consideration of his agreement to the condition here in after.

The highest bid given by the bidder for a particular lot will irrevocable till final decision by the auction conducting officer.

The quantity declared against each lot/item is approximate. Mere acceptance of bid by the auction conducting officer and deposition of the cost by the purchaser shall not transfer the property in goods to purchaser unless the lot/item is weighed, measured or tested as the case may be warrant by the Depot Officer incharge of material on production of delivery cost.

In event of any dispute arising out of or relating any bid, the item/lot in respect of which the dispute arises shall be immediately put up for sale against the last undisputed bidding.

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The intending buyers must satisfy themselves on all points before bidding goods I each lot of sold on “As is where is basis” and no warrenty is given as regards size, quality, weight, description and the like. No sale shall be invalidated by reason of any of the item or the items or the lots being incorrectly described as regards the nature, quantity or quality or in any other respect and no compensation shall be paid or allowed in respect of any such fault or error of description.

Sale shall only be made to a single person/firm and not to combination of two or more persons/firms as cosharer.

The auction conducting officer may at his discretion, without assigning ay region, refuse to accept the bid of any bidder or demand a higher percentage of amount of the bid as earnest money or the full amount immediately after the fall of hammer.

The purchase shall sign the bid sheet prescribed by the Railway Administration. No re-sale by the purchaser shall be permitted in railway premises. Bid not in accordance with the standard terms and conditions shall not be entertained

unless made in writing by the bidder and recorded in writing on the spot by Auction Conducting Officer.

The Auction conducting Officer shall have power to ask any bidder to leave the premises if he found to be obstructing or conducting hindrance to smooth conduct of auction.

Auction Supervising Officer is not bound to put the lots serially and reserve the right to put any lot at any time during the commencement of auction in interest of Railways.

Auction Supervising Officer can continue the auction till next day if found necessary by the Railway Administration. Auction conducting Officer can withdraw any lot from auction during or before the auction without assigning any reason.

The Auction conducting Officer reserves the right to depart from the program of the auction, if found necessary without assigning any reason or giving any notice other than that verbally announced to the bidders, present at the site of sale and to refuse to accept any other or to stop the auction in the event of offer not being considered satisfactory.

The controller of stores may at his discretion make any changes or departure, which he deems necessary from the forging standard of auction sale of Railway stores before auction takes place.

3. Payments :

The purchaser of each item or lot shall give his name and full address on the fall of the hammer and deposit with Railway Administration, the fixed percentage or fixed amount whichever is more, of the purchase price in cash/demand draft of any nationalized bank as earnest money vide clause 2.2. If any purchaser fails to comply with any of these conditions, the lot or the lots in respect of which such failure occurs may, if the railway officer supervising the sale considers fit be put again and resold treating the previous bid as cancelled.

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Subject to the clause 2.7, the purchaser has to deposit the earnest money to the cashier immediately on the fall of the hammer as per the following scale: 100% for sale value and including Rs 10,000/-, .25% for sale value 10,001/- to 1,00,000/- subject to minimum Rs 10,000/- .10% for sale value exceeding Rs 1,00,000/- subject to minimum of Rs 25,000/-

Time limit for deposit of balance money: a) Lots having sale value upto 5 lacs- within 10 days b) Lots having sale value above 1 lac-wiyhin 29 days

The earnest money will be forfeited in case balance payment is not deposited in 50 days. The balance amount to be deposed in the accounts department in the form of demand

draft or cash. The material will be delivered only after actual realization o amount of demand draft.

4. DELIVERY:

Free delivery period for lifting up of sold matrial: a) Misc. ferrous and non ferrous scrap upto 5 lac-40 days. b) Misc. ferrous and non ferrous material above 5 lacs-50 days.

Delivery order will be issued at the address mentioned in the bid sheet. If the bidder does not want to lift the material himself and desires to authorize to some

body else, in such case he has to submit authority letter on stamped paper duly tested by notary public.

The quantity of lot mentioned in auction catalogue is approximate. Actual quantity may differ at the time of delivery of the material.

When material are weighed, if any shortage, which may occur between the actual estimated weight of lot or group of lots sold to the purchaser, shall not be made good from any other material I the depot elsewhere.

The excess material shall only be delivered subject to the direction of the railway administration who may refuse delivery of the excess material or any quantity there of without assigning any reason whatsoever.

During the course if delivery if any material is found from the lot which is different from as mentioned in the description, the railway administration reserves the right to take out that material from the lot.

Delivery of material will not be given on gazette holidays/Sundays observed at BWEL/MFZ. Normally material will be delivered on all working days except Sunday between 09.00 to 17.00 hrs.

Unless otherwise specified picking, sorting, cutting or breaking of the lot will not be allowed in Railway Premises. Delivery must be taken as the material came to hand.

Unless specifically mentioned Railway Administration will not help in loading of the material.

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Purchaser shall make his own arrangements for removal of materials. The purchaser shall have to make good any loss or damage caused to the railway.

Lots of ferrous material weighing upto 5 MT, the purchaser will have to take the delivery at one time(the delivery not to be given in part)

The weight of the lorries will be done by the authorized witness team. No delivery order will be issued without sales tax form or without depositing the sales

tax and if the purchaser does not comply with, he will deposit the amount of sales tax first otherwise The Railway Administration may refuse to deliver the material.

The lots of two or more purchasers shall not be delivered in same lorry. The Railway Administration shall not be responsible for death injury, incident to

purchaser or any of the representative or any of the labourer arising out of sale and delivery.

5. GENERAL :

As Per Railway Boards hazards waste rules 1989 dated 30/06/1999 letter no/85/RSS7092/OILS, the non ferrous metal waste and scrap like lead, copper and zinc waste, waste oil and used batteries are to be sold only to actual reprocessor. The bidder has to submit the required certificates at the time of auction itself.

In the event of any question/dispute of difference arising under these conditions or any in connection with, the contract the same shall be referred to the sole arbitrator appointed by the General Manger of BWEL MUZAFFARPUR.

It is a term of this contract that no person other than the person appointed by the General Manager of BWEL, MUZAFFARPUR as aforesaid should act as arbitrator and if for any reason that is not possible, the matter is not to reffered to the arbitration at all. The arbitrator may, from time to time with the consent of all its parties to the contractor enlarge the time of making award. The venue of arbitration shall be decided by the arbitrator. Subject as aforesaid, the Arbitration and Concilliation Act 1996 and the rules the reunder and any statutory modification thereof shall apply to the arbitration proceeding in this clause.

It is understood that all the participationg bidders have duly inspected all the lots put up for auction and understood all above terms and conditions before participating in the auction and these are acceptable to them Railway Administration will not be responsible for any ignorance or misunderstanding.

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SCRAP MANAGEMENT SYSTEM (S.M.S.)

Scrap management system (S.M.S.) is specially designed computer software that is used for almost full management of scrap in scrap depot of BWEL Muzaffarpur.

Almost all the operations from making of advicer not to keeping auction records is vdone through S.M.S.

It has simplified the process of scrap management by decreasing the manual labour. It is better way of keeping records safe and easily approachable then through files etc. All the information regarding the scrap lot like weight, type, quantity, location etc is

feeded into the S.M.S. for further processing. S.M.S. is password protected, so only the incharge of scrap depot or some designated

person can operate this program. So no body else can temper with the records. Thus it is good system with the respect to the security also.

A printer has been attached to the computer. Thus we can easily print out details and reports from the S.M.S.

Although there are numerous operations that are performed through the S.M.S., few of the important one are as follows:

A. Preparing the advise note B. Preparing staff gate pass C. Preparing Bidder Gate Pass during auction D. Preparation of auction catalogue E. Various types of reports F. Keeping record of payments and balance records during auction.

Main Menu of S.M.S. consists of following sub-menus : A. Master B. Despatch C. Lot D. Auction E. Delivery F. Reports G. Exit Master has been sub divided into following parts : 1. Codes 2. PL Master Dispatch has following sub menus : 1. Dispatch 2. Bin Detail

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3. Bin Transfer 4. Weigment Detail 5. Club Weigment detail 6. Receipt Order Detail 7. Stock Verification 8. Dispatch Reports Advice Note Dispatch Register Weigment Register Weigment register with RO Receipt Order Register Receipt Order Register with Lot Shop Wise Receipt PL wise Receipt PL wise Transaction PL wise Book Average Rate Bin Transaction Balance Detail of an Item

Lot has following sub-menus 1. Lot Formation 2. Lot Survey 3. Serveying Team 4. Survey Feedback 5. Release Lot 6. Lot Reports Survey Report Lot Status Register Vie Lot History PL wise Transaction PL wise Book Average Rate Bin Transaction Balance Detail of an Item

Auction has following sub-menus : 1) Auction Detail 2) Auction Catalogue 3) Bidder registeration 4) Bid Lot 5) Entry Free Return 6) EMD CR Entry 7) Auction Reports

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Auction Catalogue Report EMD Deposit Slip Bid Sheet Report

Delivery has following sub-menus : 1) Delivery Order Detail 2) Staff Issue 3) Staff Gate Pass 4) Shop Issue 5) Shop Gate Pass 6) Sale Issue 7) Bidder Gate Pass 8) Do/ Issue Reports Reports has many submenus but these are also approachable through previously

discussed menus. Here all the reports are grouped together for easy approach. Exit is used to exit SMS

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TARGETS

Every Year BWEL, MUZAFFARPUR decides certain target for scrap sale. His helps in performing more efficiently in Scrap Mangement. This year target for scrap sale is Rs 16 crores.

CONCLUSION

Even though the scrap management in BWEL MUZAFFARPUR is fully efficient and capable in itself, that it needs no more alterations. I think few minor improvement in its functioning may slightly help in better management of scrap.

Better communication link between the workshops and the scrap depot can be developed for faster and efficient transportation of scrap. Copmputors at workshop and the scrap depot should be linked through networking such that there is no need of advice note and all formalities could be done on computer only. This surely will result in faster scrap management.

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BIBLIOGRAPHY

LIBRARY OF B.W.E.C.L

INTERNAL RECORDS OF B.W.E.L.

JOURNALS OF B.W.E.C.L

INFOMATION FROM EMPLOYEES OF B.W.E.C.L.

WWW.GOOGLE.COM

WWW.WIKIPEDIA.COM

WWW.YAHOO.COM

THE END

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