ABrief on

Improvements inKota Stores Depot

Inspection by(Sh.)

11th Feb., 2012

Introduction Stores Depot came into existence in 1962 to cater the material

requirement of Workshop.

During initial years, Kota Stores depot was primarily responsible for supply of raw materials like Steel and Lubricants for in-house manufacturing.

Targeted POH of Kota Workshop increased from 250 FW units per month in 1960 to 400 Vehicle Units over a period of 50 years in a gradual manner.

This has been made possible by outsourcing of more and more shop manufactured items to trade.

Key Activities Feeding wagon components to Wagon repair shop Kota and Kota

division. Centralized scrap disposal depot for Wagon Repair shop Kota,

Kota division and Jabalpur Division. Apart from centralized scrap yard, this depot is also operating two

wagon cutting yards – cutting up Yard and POH yard.

Challenges facedIncreased workload

Increase in number of stock items and their AAC value Receipt & Issue : approx 10000 MT of steel/ other

material (approx) Increase in scrap disposal activity

Handling of scrap in scrap yard: approx 40000 MTs per annual (incoming outgoing).

Shortage of manpower40% staff retirements in next 5 years

Increase in receipt and issue of materials Increased work load in past few years is reflected

by increase in number of stock items and their AAC values.

Year Total No of items Stocked AAC Value

2010 796 60 cr

2012 1027 81 cr

Manpower Position

InitiativesMechanisation of material handlingBetter use of manpowerImprovement in infrastructureUse of IT tools

Improvements in Material Handling in depotHandling multifold increase in workload without

increase in manpower was made possible through mechanisation of material handling activity at stores depot. In view of above, following improvements in material handling are started in depot :

Palletisation

Hand Pallet trucks : 08

Forklifts : 3

Pallets : 50

Tipper : 1

Receipt & Stocking Wards At, present man power is used for loading and unloading

of Railway material received from various sources in Receiving section at this depot and movement to stocking wards. Now these works are dealt with palletisation to reduce multiple handling of material and for safety of workers.

Past Present

Palletisation

Scrap yardLot of un accounted material lying in mixed

conditionDisputes in scrap deliveryWeighbridge of 30 Mt capacity undergoing

frequent breakdowns

Depot ModernizationKota Stores Depot has been planned to be modernized

along with Wagon Repair workshop. Following machines and works have been sanctioned in the workshop modernization project:-

M& P Sanctioned under Modernisation Program

Works sanctioned under Modernisation Program

• Goliath crane cap. 10 MT -286.62 Lakhs

• Adjustable Racking System -30.00 Lakhs

• Tri Stacker -29.58 Lakhs

• Mini truck – 3.78 Lakhs

• Lister Truck-2.57 Lakhs

• Construction of 03 Nos asbestos sheds for stocking CBC items=25 Lakhs work has been completed

• Up gradation of stores office= 6.51 Lakhs

• Upgradation of ward 80= 4.47 lakhs

M&P and Works Programme: Machines Proposed under M& P Program Status

05 MT Road mobile crane Sanctioned by GM in 2009-10 M& P Program. Under Procurement with COS/JBP

Apart from above M&Ps, GM/WCR has sanctioned following works for improvement in material stocking and its protection.

Works Proposed Status

Provision of safety wall of wagon cutting up yard

Sanctioned by GM for cost of 13 lakhs. Work completed

Improvement in infrastructure of Kota store depot for faster turnover of scrap sale activity

Sanctioned by GM/WCR at cost of 47 lakhs. Tender under finalisation

Implementation of MMIS Kota stores depot is first depot to achieve

100% reconciliation of stocks in MMIS. All material receipt, issue and scrap sale

activities are being done through MMIS in this depot.

Online availability of information of any item.

Mechanisation of material handling activities Sr. No

Description Quantity Nos

Date of commissioning

1 Diesel Tripper cap 6.3 MT 01 2010

2 Hydraulic Road Mobile TIL Crane 18 MT

01 2009

3 Diesel Fork Lift Cap. 03 MT 03 2009

4 Diesel Hydraulic Road Mobile Crane cap. 5 MT

01 2008

5 Ashok Leyland Truck cap 10 MT 01 2005

6 Diesel Lister Truck cap 03 MT 01 1999

Steel Yard

Presently unloading of steel items viz. heavy sheet plates, channels etc unloaded from wagons and trucks by road mobile crane which need more man power and consume lot of time.

Future: Goliath crane cap. 10 MTProgress:-sanctioned by railway Bd under modernization program Under tender stage.

Present : road mobile crane cap 16 MT

Improvement in layout of depot To improve efficiency of material transportation, A new 100 ton capacity weighbridge is to be installed with approach road and a separate entre gate to scrap yard.

• increase output of scrap delivery team(Stores, Account, RPF) as capacity to deliver material to scrap purchasers at a time would increase from 20 MT per truck to 60 MT per lorry

Results

Availability of Items

Item

Out of stock

As on 31.07.2011 As on 31.07.12

O/S Target

Total items O/S

O/S % Total Item O/S O/S

%

Safety <2% 169 6 3.55 169 3 1.77

vital <2% 129 2 1.58 129 2 1.58

Others 729 15 2.05 729 15 2.06

Total <5% 1027 23 2.24 1027 20 1.94

Inventory controlApart from smooth supply of material, depot has

managed its inventory to low levels. This depot achieved target TOR of 20% in the last two financial years

Year Cum. Receipt Cum. Issues Closing Balance T.O.R.

05-06 67.16 51.74 32.43 63%

06-07 98.37 98.86 30.16 31%

07-08 52.41 61.64 20.00 32%

08-09 65.86 67.60 18.26 27%

09-10 61.17 67.24 12.19 18%

10-11 81.90 79.39 15.20 19%

11-12 (upto Jan.- 2012)

75.50 70.86 19.08 22%

Year Cum. Receipt Cum. Issues Closing

Balance T.O.R.

08-09 65.86 67.60 18.26 27%

09-10 61.17 67.24 12.19 18%

10-11 81.90 79.39 15.20 19%

11-12 87.81 87.63 14.62 17%

Inventory control

(Figs. In Crores of Rs.)

Apart from smooth supply of material, depot has managed its inventory to low levels. This depot achieved target TOR of 20% in the last three financial years.

Sale of scrap Kota stores depot achieved highest sale of

scrap during its history in financial Year 2011-12 with sales of 207.10 Crs. The year-wise position of scrap disposal is as under:

* Sales for current year is 25 cr against annual target of Rs 150 Cr

THANKS!

/kU;okn!