DEMUsAN IN DEPTH ANALYSIS

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DEMUs-AN IN DEPTH ANALYSIS

• 
  By
• CPO (Admn.)
• Northern Railway

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Objective

• The aim of this exercise is to evolve a
  universally applicable yardstick for maintenance
  work of DEMU/DHMU of various capacities with a
  view to improving staff productivity, rightsizing
  of manpower on a rational and scientific basis.

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Area of research

• Visited for detail study - SCR
• Visited by nominated staff for collecting
  data-Jallandhar DEMU shed, EMU car shed Ghaziabad
• Discussion with - SER
• Mechanical dept. of NR

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Existing yardstick of the category, if any

• None prescribed by the Railway Board
• There are no yard sticks for DEMU staff by any
  authority
• There were no Norms conveyed vide Board letter
  dated 04.10.06
• No benchmark/All India Average has been issued by
  the Board for DEMU staff

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Specific details of the sub activities performed
by DEMUs staff

• POH which includes many minor activities
• Routine maintenance
• Shed housekeeping
• Shed infrastructure maintenance
• Rake housekeeping including cleaning,painting,fitt
  ing etc
• Running staff activities

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Specific details of the sub activities performed
by DEMUs staff

• Supervision/inspection of the work done through
  OEM which include air dryer,compressor,speedometer
  ,calibration of fuel injection system and
  bearing maintenance including refurbishment,repair
  and overhaul
• Rake formation,daily cleaning/washing,padlocking,s
  hutter dropping and rolling in examination if
  not performed by division CW staff

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Comparison of staff strength

• The cooperation received from executives for data
  collection study was not encouraging. No data
  received from any of the railways
• Out of a total holding of 152 sets across Indian
  Railways,59 are on Northern Railway. It is the
  Railway with the maximum experience in handling
  DEMUs
• The largest DEMU shed on IR is Jallandhar in NR

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Work study

• A study on staff requirement of DEMU sheds had
  been conducted by ER Dte in June 2002. It was
  circulated for comments to zonal railways
• There were some assumptions made in that study
  which over a period of time have not come
  through, these are-
• (a)The study was primarily on 3 car sets of
  700 HP vs the 4 car sets of HHP DEMUs currently
  in vogue

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Work study

• (b) the study assumes that daily cleaning/washing
  will be done by divisions CW staff
• (c) the study assumes the 5 day rake link
  maintenance norm is now moving towards 8 to 10
  day rake links
• (d) The report had split the staff in a shed into
  fixed component consisting of ministerial,running
  and some technical staff.

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Work study

• variable component based on per DEMU set
  requirement
• The above components were given separately for
  sheds up to 50 sets and for sheds with more than
  50 sets holding. Since there are no sheds with
  more than 50 sets holding this portion is
  practically of not much use

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Holding of DMUs,DEMUs DHMUS on IR ( AS ON
31/03/2006)
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An overview of DEMUs

• EP-braked HHP DEMUs were introduced in 2003
  shall be the standard form of DEMU for the next
  few years
• NR has 16 sets of EP-braked HHP DEMUs. Other
  railways are SECR with 2 sets and SER with 5 sets
• 8 to 10 day rake links will be the norm for
  EP-braked HHP DEMUs

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An overview of DEMUs

• POH shall continue to be on time basis of 18
  months
• Availability of unit exchange spares is assumed.
  In case these are not available then staff
  requirement shall increase
• A DEMU set consists of 1 DPC with 2 TCS with 1
  DTC or 3 TCs only

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An overview of DEMUs

• Out of DPCs,TCs DTCs it is the DPC which has
  the maximum maintenance requirement
• DEMUs run in rakes consisting of 2 or more sets
• Based on physical holding DEMU sheds can be
  classified as-
• Small sheds These have holding of 1 to 10
• sets (40 vehicles). There are 6 sheds across

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An overview of DEMUs

• IR under this category
• Medium sheds There are 5 sheds with holding of
  more than 10 sets and less than 40 sets (160
  vehicles)
• Large sheds There is at present only 1 shed with
  holding of 40 sets(160 vehicles)
• Mega sheds There is no such shed at present.
  Conceptually these are sheds with around 100 sets
  (400 vehicles)

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An overview of DEMUs

• POH Workshops There are 3 POH workshops across
  IR
• By default small sheds work in a single shift
  medium and large sheds work 2 shifts per day and
  mega sheds work 3 shifts per day
• Sheds have at least a general shift in heavy and
  rotating shifts in running
• Some sheds may have additional shifts e.g. in
  some sections such as Traction machines

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An overview of DEMUs

• Outsourcing as per current policy across the
  railways D E check maintenance schedules of
  the engines are done by the OEM only.
• Outsourcing has minimal effect on the supervisory
  requirement while reducing the Group C D
  requirement

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An overview of DEMUs

• Works which can be outsourced-
• (a) Shed housekeeping
• (b) Shed infrastructure maintenance
• (c) Rake housekeeping including cleaning,
• painting and fitting etc
• (d) Air dryers and compressors
• (e) Speedometer and calibration of fuel
• injection system

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An overview of DEMUs

• Bearing maintenance by OEM including
  refurbishment. repair and overhaul

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Staff requirement study
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Staff requirement study
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Staff requirement study
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Staff requirement study
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Staff requirement study
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Staff requirement study
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Staff requirement study
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Staff requirement study
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Staff requirement study
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Staff requirement study
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Staff requirement study
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Staff requirement study
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Comparison with other traction units

• Benchmarking for EMUs/MEMUs recommended by Rly
  Bd. is 7.26 staff per unit
• Benchmarking for electric locos recommended by
  Rly Bd ranges from 5.5 staff per loco to 7.0
  staff per loco for different types
• EMU car Shed/GZB is holding 509 coaches I.e.169
  sets (apprx.) with the staff strength of 941

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Comparison with other traction units

• DEMU Shed/JUC is holding 59 sets (apprx.) with
  the staff strength of 291 If we apply the yard
  stick recommended for EMU on DEMU (that is 7.26
  staff per loco) then the staff requirement shall
  be 426
• The major difference between EMU DEMU is that
  there is there is engine in DEMU which requires
  specific attention whereas EMUs have only motor
  car and no engine in strict sense thereby
  requiring less maintenance

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Grey areas of this research

• Cooperation received from the Railways for data
  collection study was not encouraging
• Policy of outsourcing for future needs to be made
  available as it has a direct bearing on the
  manpower requirement

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Grey areas of this research

• Framing of yardsticks requires careful and
  detailed study regarding
• time motion,
• time methods,
• time cost,
• time effort,
• time material etc.

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Recommendations

• Detailed work study needs to be conducted by each
  concerning railway by classifying various DEMUs
  shed on load factors
• Based on these studies, No. of staff to be
  deployed at each DEMUs shed needs to be decided
  keeping in view local conditions other factors
• Work content has to be defined with reference to
  the extent to which it has to be done in-house or
  outsourced

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Recommendations

• There have to be multiple yard sticks to take
  care of differences in capacity (700/1400 HP) and
  the type of stock ( DMUs, DEMUs, DHMUs)
• The method of working is critical for deciding
  the yard stick eg the staff requirement for unit
  exchange spares will be very different from
  normal replacement

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