Organization of Rolling Stock Production & Maintenance Department
Corporate Objectives-101, Mission Areas for Rolling Stock Production & Maintenance Department-102 Organisation-103 Railway Board and RDSO-104 Production Units-105 Zonal Railways-106 Rolling Stock Maintenance Organization in Zonal Railways:-107
Zonal Railway workshops-108 Chief Workshop Manager (CWM) -109 Chemist and Metallurgist-110 Workshop Personnel Officer-111 Environment and Safety Manager-112 Workshop Civil Engineer -113 Workshop Electrical Engineer -114 Workshop Mechanical Engineer-115 Workshop Accounts Officer -116 Workshop Materials Manager-117 Production Engineer-118 Important duties of the Production Engineer -119 Production Engineer’s office-120 Planning and Production Control-121 ERP manager-122 Workshop Security Officer (WSO)-123-24 Workshop Supervisors 125-26 Duties of Supervisors-127 Categorisation of shops 128-29 Maintenance and Inspection of Boilers -130 Maintenance of weigh bridges and weighing scales -131 Classification of staff in Workshops-132 Staff strength 133-34 Agility-135 Open Line divisions136-37 Customer orientation138-40 Indian Railway Conference association (IRCA) and Neutral Train Examiners-141 unitary Command and Control-142 Acts relevant to Rolling Stock Production & Maintenance Department-143 Important Codes and Manuals of Indian Railways-144 Mid life rehabilitation (MLR): - Annex 1.1
Production Units
General-201 Organization- 202-03 Costing in Production Units of Indian Railways -204-05 Process Costing System:-206-07 Batch Costing System-208 Features of Batch Costing System:-209 Batch size-210 Work Orders-211 Cost Classification-212 Materials-213-14 Pairing of Issue Notes and Advice Note of Returned Stores-215 Finished Parts Stores Depot:-216 Component Costing: -217 Assembly Costing-218 Collection of cost under Groups and Assemblies -219 Overheads - As a general rule,-220 Allocation and Apportionment of Overheads-221 Quarterly Review-222-23 Job Costing-224 Workshop General Register:-225 Completion Certificate:-226 Drawl Books-227-28 Batch Cost Report:-229 Transfer of Final Cost to Railway Board-230 Cost Report to GM-231 Managerial Statements-232 Development Suspense-233 Transfer Price-234Guidelines for Rolling stock manufacture by repair workshop-235
CHAPTER-III
Employees' Duties and Responsibilities
Hours of Work-301 Working Hours-302-04 “Gate Attendance System”-305 Deliverables of a modern “Gate Attendance System”-306 Modernization of “Gate Attendance” system using smart card and biometrics-307 Biometric System of “Gate Attendance”-308 Time Office-309 Opening and closing of workshop gates-310 Late Attendance-311-12 Work during meal hour and on Sundays-313 Attendance of Supervisory Staff-314 Working Hours of Shop Clerks-315 Employee’s Biometric Identity Number (BIN)-316 Leaving shops during working hours-317-19 Duty Certificate-320 Night Shift-321-324 Overtime Requisition-325 Overtime Register-326-27 Overtime Allowance-328Material Gate Passes329-30 Muster Roll cum Labour Pay Sheet-331-32 Deductions for Absence-333-35 Chart of Labour Charges-336 Inter-shop Transfers-337-38 Staff Register-339 Hours of work-340 Exemptions to limitation of hours of work-341 Remaining on duty-342“Attendance in LCDs”-343 Modern Gate Attendance System for LCDs-344 Disaster Management-345 Accident Relief & Medical Equipment Train-346 Accident Relief Trains-347 Breakdown staff-348 Accident checklist-349 Reprovisioning in ART/ARME-350 Important procedure of hour of work and period of rest Rules -2005 – Annexure 3.1
Administration's Duties and Responsibilities to workers
Introduction-401 Features of the Chittaranjan Scheme-402 Prerequisites for introduction of Incentive Scheme-403 Allowed Time-404 Timing of Operation-405 Time Study-406 Synthetic Times-407 Rating-408 Normalizing-409 Preparational Time (PT)-410 Extra Time-411 Job cards/Squad Cards- 412 Out-turn -413 Simplification of time taken with computerised GA -414 Time Saved/Time Lost- 415 Material scrap -416 Guaranteed Basic wages -417 Incentive Bonus Rates and Ceiling on profits in CLW Scheme- 418 Abnormal Profits-419 – Losses-420 Incentive Bonus to essential indirect workers and Junior Supervisors-421 Incentive Bonus to Senior Supervisors-422 Payment of incentive bonus-423 Incentive to staff in the service shops-424 Workers booked on Incentive and day work systems-425 Overtime working in Incentive sections-426 Idle time-427 Deduction from supervisors for idle time-428 Allocation of bonus-429 Extension/ Contraction Proposals-430 Capping on IW and EIW strength-431 Checking of Job Cards-432 Group Incentive scheme-433 Main Features-434 Special Management responsibility in incentive schemes-435 Training-436 Categories of Employees-437 Training of new comers-438 Multi-skilling-439 Designing of courses and employee involvement-440 Improving trainee Participation-441 Salary Payment-442 Managerial And Exception Statements to be generated by the system-Ann. 4.1 Comparison between Chittaranjan and Group Incentive Scheme Ann 4.3 Administration responsibilities on industrial safety Ann 4.4 Administration responsibilities on Environment Management-Ann. 4.2
CHAPTER-V
Materials Management in Railway Workshops
Introduction-501 Sources from which Materials are obtained by shops and maintenance depots-502 Demands for materials to match with budget-503 Inventory Management - stock and non-stock items-504 Raw material norms-505 Sub Stores-506 Pairing of Issue Notes-507-508 Provisional adjustment of issue notes-509 Main stores sub ledger-510 Adjustment of cost of stores received from depots-511 Stores Purchased Direct-512-517 Stores Sub-ledger for Credits-518 Stores Sub-ledger for Out-turn of Process shops-519-521 Stores Charges Write-back Order-522-523 Other Miscellaneous Charges-524 Miscellaneous stores sub ledger-525 Summary sub ledger-526-530 Labour & Stores sub ledger- Annex. 5.1-5.3
CHAPTER-VI
Costing in Workshops
Introduction-601 Costing in Workshops of Indian Railways-602-03Job Costing System-604 Features of Job Costing System- 605 Planning-606- 607 Process Sheets-608 Revision of Control Work Order Series-609 Recoupment of Stock- 610 Issue of Production Documents-611 Route Card-612 Work order System in Workshops-613-14 Prime Cost-615 Direct Labour-616 Direct Material/Stores-617 Accountal of Material cost for costing data-618 Overheads/ on costs-619 Shop & General On Costs-620-21 Quarterly Review of on-costs-622-23 Costing of POH of Rolling Stock-624-28 Reconciliation and merger of Costing records with financial records- 629 Managerial Statements-630 Use of costing data-631 Revised Costing System-Ann. 6.1
CHAPTER-VII
Execution of works in Workshop/PUs
Introduction-701 Estimates-702-03 Estimates for Rolling Stock additions & workshop M&P Items for Workshops & Sheds-704-06 Estimates for Renewals and Replacements-707-11 Estimates of work for outside agencies-712-13 Charges for preparation of estimates-714 Interest Charges-715 Sanction for works to be executed in Workshops-716 Verification of Estimates-717Certificate of Accounts Verification-718-19 Sanction to Estimates-720 Record of all Estimates-721Currency of Sanction-722 Postal Vans-723-25 Saloon carriages & other vehicle reserved for exclusive use of other deptt./Ministries- 726-29 POH of Rolling Stock hired to/owned by defence deptt.-730 Loaning/Hiring charges for Rolling Stock loaned/hired to Outside parties and Government Departments -731 Loaning/hiring charges of the Rolling Stock-732 Hire charges for Plant & Machinery let out to Contractors-733 Sale of Heritage Rolling Stock-734 Sale of In-service MG rolling Stock-735 Methodology for sale-736Execution of Works-737-739 Analysis of expenditure-740 Work-order system-741-42 Revenue Standing Work orders-743 Other Standing work orders- 744 On-cost Work orders-745 Raw material stock work orders-746 Manufacturing work orders or Division work orders-747Part, Group and repair work orders- 748 Work order Register-749-751 Advice of Completion-752 Monthly Statement of completed work orders Compilation of the Workshop Manufacture Suspense Account-753 Work shop Manufacture Suspense Account-754 Workshop General Register-755 Check sheet-756 Calculation of On-cost Charges- 757 Out-turn Statement- 758-767 Workshop Deposit Schedule-768 Workshop Account Current-769-770 Workshop Manufacture Suspense Account Journal Entries-771 Up-to-date totaling of Workshop General Registers-772 Review of Workshop General Registers-773 Irregular booking of charges -774 Workshop Subsidiary Balance Register-775 Labour Book-776 Reconciliation with the General Books-777 Review of Balance under “Workshop Manufacture Suspense Account”-778-780 Completion Reports- 781-782 Completion Report Register- 783-785 Adjustment of charges and Credits reported on completed works- 786 Productivity Review- 787 Flow of data for WGR & WMS account current- Annexure 7.1
CHAPTER-VIII
Information Technology
Introduction-801-802 Enterprise Resource Planning (ERP)-803-804 ERP Infrastructure-805 System Security-806 Training-807 E-Library-808 Implementation of ERP in IR-809 Areas to be covered under Workshop ERP application-810 Work Order Computerization-811 Gate Attendance-812 Incentives-813 Supply Management and Stores Accountal-814 Quality Management-815 Post out turn rejection-816 ERP systems for open line depots and sheds.-817 Conclusion- 818 ERP Implementation Step by Step Process- Ann. 8.2
CHAPTER-IX
Quality
Quality – Definition-901 Quality & Process- 902 Quality Management Techniques:-903 Quality Standards-904 Origins of Defects-905 Defective design-906 Quality of Inputs-907 Defective Workmanship-908 Process Defects-909 Management Commitment to Quality-910 In process audit-911 Inspection and quality of output-912 Inspection and Measurement of Quality-913 Inspection by 3rd Party -914 Certification of Laboratories-915 Quality enforcement of outsourced work-916 Product Inspection-917 Inspection Vs Process Control-918 Quality enforcement through warranty obligation-919 Accountability for Defects-920 Quality assurance in shops and maintenance depots- Ann. 9.1
CHAPTER-X
Investment Planning
Planning:-1001 Goals for investments:-1002-04 Advance Planning for Rolling stock:-1005-06 Codal Life and Condemnation:-1007 Normal condemnation of Rolling stock:-1008 Underage condemnation: -1009 Overaged stock on line:-1010 Accident Damaged Rolling Stock:-1011 Officers authorized to condemn Rolling stock: -1012-13 Sale of Rolling Stock: -1014 Scope of the Rolling Stock Programme.-1015 Capital/Unit exchange spares- 1016 Estimation of requirements- New acquisitions-1017 Itemized Rolling Stock Program (IRSP):-1018 Machinery and Plant (M&P) Program:-1019 Nomenclature of M&P and T&P:-1020 Codal Life of Machines:-1021 Creation of new assets:-1022 Replacement proposals:-1023 Utilization of Workshop Space and Layout considerations:-1024 Plan Head “41” -1025 Works in Progress (WIP) :-1026 Monetary Ceiling for Preliminary M & P Programme:-1027 Format and Presentation of Proposals:-1028 Budgeting for M&P: -1029 Review of M&Ps under procurement-1030 Category of M&Ps & agency for procurement-1031 Cost and time overruns: -1032 End-loaded expenditure booking:- 1033 Budgetary Reviews:-1034 Machine maintenance and Annual Maintenance Contracts (AMCs)-1035 Disposal of condemned and surplus machines:-1036 Maintenance of asset Register:- 1037 Proposals under Plan Head 42- 1038-39 Standards for Maintenance Facilities-1040 Expansion Programs to meet capacity shortfalls:-1041 Checklist for proposals under Plan head 42: -1042 Head of allocation:1043 Powers for sanction and compilation of Approved Works-1044 Work Register & Reconciliation-1045 Direction and General Charges.-1046 Cost and time overruns-1047 Maintenance of civil infrastructure in sheds and workshops:- 1048 Rolling stock Programme- New Acquisitions- Ann. 10.1 Codal life of machines-Ann. 10.2
CHAPTER-XI
Capacity Optimization and Product Development
Background.-1101 Multi skilling tasking and Inter-shop transfers-1102 Outsourcing – need to outsource-1103 Outsourcing to units outside the workshops.-1104 Outsourcing or contracting for works within the Railway Premises.-1105-06 ERP based production Management -1107 RDSO’ s role in vendor approval and product inspections-1108 Innovation-1109 Strategies for innovation-1110 Utilization of surplus shop capacity-1111 Process of procuring outside orders.-1112 Profitability:-1113 Annual Maintenance Contracts for M&P- 1114 General-1115
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