Swachh Bharat Abhiyan

18.02.2015

TTC Auditorium

Integral Coach Factory, Indian Railways

Organised by

Indian Railways Technical Supervisors Association

(IRTSA)

Chief Mechanical Engineer Chief Project ManagerController of StoresChief Mechanical Engineer / QAChief Workshop Engineer/ShellChief Design EngineerChief Workshop Engineer / FurChief Material Manager /ShellDy. HODs, OfficersUnion Office bearers &Technical Supervisors / Supervising Engineers

Presentation byK.V.RAMESH

Senior JGS/IRTSA

Father of Nation

“Your beliefs become your thoughts,

Your thoughts become your words,

Your words become your actions,

Your actions become your habits,

Your habits become your values,

Your values become your destiny.”

I Pledge• “I take this pledge that I will remain

committed towards cleanliness and devote time for this. I will devote 100 hours per year — that is two hours per week — to voluntary work for cleanliness. I will neither litter nor let others litter.

• I will initiate the quest for cleanliness with myself, my family, my locality, my village and my work place. I believe that the countries of the world that appear clean are so because their citizens don’t indulge in littering nor do they allow it to happen.

.....Continued • With this firm belief, I will propagate the

message of Swachh Bharat Mission in villages and towns. I will encourage 100 other persons to take this pledge which I am taking today. I will endeavour to make them devote their 100 hours for cleanliness. I am confident that every step I take towards cleanliness will help in making my country clean.”

- Narendra Modi

WITH THE WORDS OF FATHER OF NATION

& THE PLEDGE OF THE PRIME

MINISTERIRTSA PROPOSES FOLLOWING

SUGGESTIONS

Scrap Disposal Schedule (SDS) along with material procurement

• ICF is having well laid procedure & schedules for procurement of RM, semi finished & finished products.

• Even though procedures are available for reclamation & scrap disposal – they are inadequate.

• Scrap disposal schedule, procedure & responsibility have to be made in accordance to present day requirements.

• Sheet metal scarp, packing materials for outsoared items like trough floor, paint drum, e-waste can be included in scrap disposal schedule (SDS)

SDS for heavy items purchased for under frame assembly

Name Coach sets / pack

No. of packs for the outturn

of 150 coaches /

month

Size of packing

channels that have to be

disposed as scrap

Trough Floor 5 30 900 X 9500

Sole Bar 5 30 500 X 11000

Head Stock 1 150 600 X 1100

Body Bolster 2 75 1600 x 2600

Considering the usefulness of these packing materials for general engineering purpose, ICF can earn from theses scrap disposals without utilising its man power.

Long Term Plan for SDS

• Tender condition – Supplier of these materials should take back the packing materials as per Daily or Weekly schedule.

• As like flow of information / Documents from Material Planning to Shop floor for every purchase of RM, Flow of information / Documents (in e-form) on SDS should happen from shop floor to accounts department.

• Final part of payment to the supplier shall be made after the completion of SDS based on the confirmation given from the shop floor.

Short Term Plan for SDSScrap Specific Disposal Contract :- • Since procurement of all the items are done well

in advance it may not be possible to switch over to Long term SDS immediately.

• Specific contracts shall be awarded to remove the scrap generating from specific areas – Ex: packing materials of items supplied to Under frame.

• The contractor shall require to gas cut lengthy channels used in packing and move them out daily in suitable vehicle, ie. In mini lorry or three wheeler, not necessarily waiting sufficient load for a lorry

PAINT DRUMS• Disposal of paint drums is one of the important

area which needs immediate attention.• Approximately 750 empty paint drums are

generated from Shop-54 & 36 per week.

Long term plan • As said earlier companies which are supplying

paints shall be made to take back empty drums – can be made as tender conditions.

Short term plan• Exclusive contracts shall be awarded to

dispose the empty paint drums on weekly basis.

Sheet Metal ScrapItem RM Size

after cut to length

RM weight

No. of PC / Sheet (weight)

Final products weight

Scrap weight

BG Cross Bearer

5 x 1250 x 2554

126 kg 3 (37kg) 111 kg 15 kg

Body Pillar

2 x 1250 x 2950

58 kg 6 (5.9kg) 35.5 kg 22.5 kg

Carline 2 x 125 x 3300

65 kg 8 (4kg) 32 kg 33 kg

Disposal of Sheet Metal Scrap• Due to scaling down of detail manufacturing

activities scope of reclamation of sheet metal scraps are very limited.

• Scrap Disposal Requisitions (SDR) have to be released with Raw Material Requisition (RMR), duly mentioning the amount of scrap to be disposed out of every RMR.

• Separate squad shall be formed or Separate contracts shall be awarded to dispose these types of high value scrap.

• Reverse flow of information has to happen on SDR

Reorganisation of ‘D’ & ‘E’ Shed• In ‘D’ Shed forging activities has been closed leaving

only skeleton and number of work centres in Gas cutting & welding area is also come down – which can release almost 70% of covered area of ‘D’ shed.

• No. of work centres in machining activities & sub assembly welding activities in ‘E’ shed has come down – Some of the space released are being used for stocking of materials in unorganised way.

• By reorganising the work centres in ‘E’ shed 30% of covered area can be released.

• Released covered shed area can be utilised for manufacturing activities like Head Stock or

• stocking of materials – particularly items like Head stock, bolsters etc which are now stored in open area leading to corrosion.

Cleaning Contracts 1. Cleaning contracts have to be decentralised

– each Works Manager has to execute separate cleaning contracts for Shops under him.

2. Cleaning activities after regular working hours so that cleaning can be done more effectively.

3. Cleaning contracts which are quoted under the value of estimated cost shall be rejected.

4. Provision of sufficient weighing machines in all sheds.

Role of Group ‘D’ Staff in shop floor• Role of Group ‘D’ staff in shop floor is very

vital to keep them clean & tidy.• Not only planning & scheduling will help in

improving the house keeping, but availability of enough number of Group ‘D’ staff will have positive impact on good house keeping.

• Infact there is an element of supervision in the duty of Group ‘D’ staff in assisting Supervisors & Technicians in the shops.

• Group ‘D’ staff shall be given short term training on the need to have good house keeping and on financial & Safety advantages ICF can get out of House keeping

Posting of Group ‘D’ staff in shops

Un even distribution of Group ‘D’Sanctioned Available Vacancy % Vacancy

Outside Non-Incentive

249 224 25 10%

StoresNon-Incentive

189 189 0 0%

SHOPS - Incentive

Mech / Shell 614 519 95 15.5%Mech / Fur 342 327 15 4.4%Electrical 91 66 25 27.5%Shops Sub Total

1047 912 135 12.9%

Total Helpers

1485 1326 160 10.8%

Other than Helpers

610 613 -3

Sufficient flow of Group ‘D’ staff to shop floor• Posting of Group ‘D’ staff to the shop floor are getting

delayed since the employees have to come through two previous stages.

• It is natural that initial stages are getting filled and vacancies are allowed in final stages.

• It also denied the shops getting Group ‘D’ staff when they are fresh & young.

• It puts core activity of ICF (Shops) in disadvantageous position.

• Present system shall be altered in such a way that vacancies in shop floor shall be filled immediately on top priority.

• In addition to the available strength atleast 500 Group ‘D’ staff shall be recruited and employed in shop floor.

Role of Progress WingMech In-house man

hoursOut-sourced man hrs

Total man hours

% of out sourcing

Shell 85,00,000 45,00,000 1,30,00,000 35%

Fur 69,00,000 49,00,000 1,18,00,000 41.5%

In outsourcing activity, role of Progress is very vital like scheduling of raw materials, semi finished and finished items, supply of items in time & in right quantity, organising the priority of materials, co-ordination with shop floor, stores & planning, etc.Managing the ratio between in-house manufacturing and outsourcing is one of the important new elements of work emerged out of new scenario. Any short comings in the outsourcing have to be managed in the shop floor with the full coordination of progress.Stocking of materials in the order of demand and retrieving them for use is another important function particularly when ICF is not having sufficient space.

Attaching Progess wing with Shops

• But unfortunately progress wing is being under estimated in ICF and being down sized.

• It is also wrong perception that RCF is not having progress organisation.

• RCF is having progress organisation as part of Group Incentive System attached to shops.

• To manage the outsourcing more effectively, to improve the tractability & accountability of materials and to optimize the utilization of men & infrastructure, staff working in progress wing shall be attached with respective shops.

• Organic fertilizer has vital role in replacing chemical fertilizers, the reason being, it is NATURAL and has no Chemical actions.

• Vermicastings is the Best Organic Fertiliser accepted Worldwide by Agricultural Experts.

• It is a process in which well decomposed organic substances are converted into a useful castings(excreta) by earthworms for certain period.

• This is probably the best way of composting kitchen wastes.

VermiCulture in ICF ColoniesSources of organic wastes

• Four colonies of ICF are having around 3000 staff quarters.

• Two statuary canteens in shell & Furnishing, GM Administrative block canteen and private canteen in TTC are having kitchens.

• Kitchens of ICF Golden Jubilee marriage halls & Community centre in South Colony.

• Outside agencies can be allowed to utilise the organic wastes to produce organic fertilizers.

• Family members of ICF employees shall be trained and encouraged to do vermiculture in small scale at their home.

Advantages• There is unlimited scope for solar electricity

to replace all fossil fuel energy requirements (natural gas, coal, lignite and crude oil).

• Environmental advantages.• Matching peak time output with Peak time

demand.• Modularity and scalability.• Flexible locations.

Potential Solar Power

• Theoretical solar potential of India is about 600 TW

• Installation of solar power plants require nearly 2.4 hectares (6 acres) land per MW capacity

• 2,766 MW solar capacity during 2014 and India expects to install an additional 10,000 MW by 2017, and a total of 20,000 MW by 2022.

• IOCL is leading the race for solarization of petrol pumps with aggressive targets.

Using Solar Power in ICF

• Roof tops of shops, Administrative blocks, Hospital etc shall be used to harvest solar power.

• Platform trucks, Fork lifts, other material handling equipments can be operated on batteries charged using solar power.

Clean Coach• When one of the Former Member Railway Board written an

article about the cleanness in coaches in an National Daily, many of the public who reacted on his article said that Railways don’t provide sufficient waste disposal provision inside coach.

• In their response to the article some of them said that passengers are forced to litter inside the coach or at stations since dust bins provided under wash basin are inadequate.

• It is also true that dust bins provided under wash basin are inadequate particularly in long distance trains which is not having ‘on board cleaning’.

• Littering done by catering staff increase the trouble further.

• Vestibule area can be utilised to provide additional dust bins.

Vestibule Arrangement

1220 mm size of foot plate shall be increased by 200 mm to accommodate dust bins without reducing the moving space for passengers

By simple methods we can contribute 1. While travelling on train or bus we can carry

suitable paper bag (environment friendly) to collect the waste generated by us and dispose them in the dust bin at the destination station.

2. When going for shopping always go with reusable cloth or Jute bags to carry the items purchased - to avoid use of plastic carry bags. – Because 60 to 100 million barrels of oil are required to manufacture a year's worth of plastic bags worldwide, and it takes approximately 400 years at least for a bag to biodegrade.

Thank you