ELECTRIC LOCOMOTIVE

ASSEMBLY(ELA)
SHOP-16
WAG-9HC(6000 HP), WAG-9HH(9000HP), WAG-9 TWIN
(12000HP), WAP-5 (AERODYNEMIC PUSH-PULL LOCOMOTIVE
SET)
 INTRODUCTION

 Electric
Loco Assembly Shop-16 is
engaged in loco Painting, Piping,
Pre-testing, Equipment Mounting,
Pn-testing And Commissioning of
WAG-9(HC), WAG-9(HH), WAG-9
(TWIN) and WAP-5(aerodynamic
push pull) locomotives.
PROCESS FLOW CHART
 STAFF STRENGTH
SECTION WISE STAFF STRENGTH OF ELA-16 AS ON 01.10.2024

SECTION Sr.Tech Tech-I Tech-II TECH-III Helpers TOTAL SSE JE O.S TOTAL Female

1611 24 18 9 13 0 64 3 1 0 68 6
1612 20 24 4 13 1 62 6 0 0 68 0
1615 10 10 1 1 1 23 0 2 0 25 0
1616 4 13 5 28 1 51 6 1 0 58 0
1617 23 17 6 20 2 68 4 2 0 74 0
1631 45 57 15 7 3 127 4 2 0 133 1
1632 34 68 0 0 1 103 6 1 0 110 1
1633 17 18 5 6 1 47 2 2 0 51 2
1634 30 31 13 4 4 82 7 2 0 91 3
1643 28 24 3 11 2 68 6 4 1 79 0

Progress 3 0 0 2 2 7 1 1 1 10 3

L/Desp 0 0 0 0 4 4 2 2 0 8 0
ISO 0 0 0 0 1 1 1 0 0 2 1

CONS. STORE 1 0 0 0 2 3 1 0 2 6 1

OFFICE 0 0 0 1 1 2 1 0 2 5 2

TOTAL 239 280 61 106 26 712 50 20 6 788 20

 KEY PERFORMANCE INDICATOR
ANNUAL LOCO PRODUCTION MONTHLY LOCO PRODUCTION 2024-
600 25
60

500
2023-24; 479
50 50 50 50 50 50 50 50 50 50 50 50
450
440
50 47
2021-22; 418
45
410
400 40 41 41 40
2022-23; 361
40

300 30

20
200

10

100

0
IL Y E LY T
EP C
T V EC N B H
P
R
M
A
JU
N
JU U
S
S O N
O D JA FE R
C
A G A
0 U M
2021-22 2022-23 2023-24 A

LOCO TARGET LOCO OUT-TURN TARGET OUT-TURN Linear (OUT-TURN)

 KEY PERFORMANCE INDICATOR
FTR FOR 2023-2024 FTR FOR 2024-2025
90
80
75.60 74.36 83.17
73.72 73.51
71.49
69.37 68.75 80
70 67.75 68.29 75.93 74.80
74.58
65.19
62.90 62.30 69.92
70
60
56
52
60
50
46 45
41 42
39 50
40 38 37 45
40 41 41 40
31 40
30 28
24
30
20

20
10

10
0
l
ri ay e ly g ep ct ov ec n b ch L
p n
Ju u O D Ja Fe ar TA
A M Ju A S N 0
M TO April May June July Aug Sep Oct Nov Dec Jan Feb March

LOCO OUT-TURN AVG FTR% Linear (AVG FTR%)

Linear (AVG FTR%) TOTAL 479
LOCO OUT-TURN AVG FTR% Linear (AVG FTR%)
 CUSTOMER FEEDBACK
IC0 defects received in FY 2023- IC0 defects received in FY 2024-
24 25
Design Equipme Misc Workmanshi Design Equipmen
Month Total Month Misc. Workmanship Total
Related nt . p Related t

April 5 8 5 4 22 April 22 2 0 2 26

May 0 2 7 2 11 May 0 0 0 0 0

June 0 0 0 0 0
June 1 4 0 1 6
July 3 3 1 1 8
July 11 11 3 10 35
August 0 0 0 0 0
August 3 7 1 4 15
Septemb
Septem 0 0 0 0 0
3 2 8 2 15 er
ber
October
October 6 5 8 9 28
Novem Novemb
30 8 5 3 46 er
ber
Decem Decemb
15 9 0 9 33 er
ber

January 7 2 5 11 25 January

February 0 0 0 2 2 February

March 2 0 0 0 2 March

Total 83 58 42 57 240 Total 25 5 1 3 34

 TRAINING PROGRAM
Training Plan for Supervisor/ Staff for Financial Year (FY) 2024 - 2025
October –
April – June July – September January – March
S.N December
Module of Training.
.
Target Actual Target Actual Target Actual Target Actual

1. OH&S-001 (OH&S training for all) 6 4 12 07

2. OH&S-002 (OH&S training for supervisors) 4 3 06 06

3. IRIS-01 (IRIS FOR SUPERVISORS) 6 6 04 04

IRIS-002 (WELDING TRAINING REFRESHER’S
4. COURSE RQMS) 3 0 10 00

5. MS-015 (SAFETY TRAINING FOR all) 24 24 10 12

6. MS-015A (SAFETY TRAINING FOR SUPERVISORS) 0 0 03 07

7. MS-016A (safety for rigger staff) 0 0 00 00

8. A/096/1 (advance computer application) 2 2 02 03

9. S/082 (prevention of fire & fire fighting) 7 7 06 07

10. EMS-001 (environmental awareness for all) 6 6 08 02

EMS-002 (environmental awareness for
11. supervisor) 2 0 08 06

12. TORQUING 0 0 00 00
 MATERIAL REJECTION
M-13 Cases Section-wise (Summary) for the Year M-13 Cases Section-wise (Summary) for the Year
2023-24 2024-25
Sectio Ap Ma Sep Oc No De Ma Section Apr May Jun Jul Aug Sept Oct Nov Dec Jan Feb Mar Total
Jun Jul Aug Jan Feb Total
n r y t t v c r
1611 00 00 00 00 00 01 01
1611 1 3 0 0 1 8 0 0 0 1 5 0 19
1612 01 00 01 03 01 00 06
1612 1 0 0 2 2 0 0 0 0 3 1 1 10

1613 0 0 0 0 0 0 0 0 0 0 0 0 0 1613 00 00 00 00 00 00 00

1614 0 0 0 0 0 0 0 0 0 0 0 1 1
1614 00 01 01 01 00 00 03
1616 2 0 0 0 7 10 0 3 1 2 4 0 29
1616 00 02 07 00 00 00 09
1617 1 4 0 0 1 0 0 0 3 1 3 3 16

1617 02 00 00 00 01 01 04
1631
0 0 0 0 0 0 0 0 0 0 0 0 0
U/F 1631
00 00 01 00 00 00 01
U/F
1631
1631
0 0 0 0 0 0 0 0 0 0 0 0 0 00 00 00 00 00 00 00
Bogie
Bogie
1632 02 01 01 01 03 01 09
1632 2 5 3 1 0 0 2 0 0 2 0 0 15

1633 0 0 0 0 0 0 0 0 0 0 0 0 0 1633 00 00 00 00 00 00 00

1634 0 0 0 0 0 0 0 0 0 0 0 0 0
1634 00 00 00 00 00 00 00

Paint Paint
0 0 0 0 0 0 0 0 0 0 0 0 0 00 00 00 00 00 00 00
Shop Shop

Total 7 12 3 3 11 18 2 3 4 9 13 5 90 Total 05 04 11 05 05 03 33
 SCRAP DISPOSAL
Empty steel
Copper Tube Cut Ferrous items Aluminum in
F. YEAR drums LOCO OUT-TURN
Pieces in kg In kg kg
Cap.20 Liters.
2022-23 8739.00 1,36,280.00 2156.00 15036.00 361
2023-24 6995 51410 2987 16616.8 479

Empty steel drums

FY 2024-25 Copper Tube Cut Pieces in Ferrous items
Aluminum in kg Cap.20 Liters.
LOCO OUT-TURN
Month kg In kg
in kg

April 800 7740 230 1896 40

May 708 50180 214 1625.80 45
June 0 1820 400 1416.80 41
July 920 2560 260 1355.20 41
Aug 950 1120 357 1496.00 40
Sept. 857 2840 196 1984.00 47
Oct.
Nov.
Dec.
Jan
Feb
March

Total 4235.00 66260.00 1657.00 9773.80 0.00

 DESIGN ISSUES & IMPLIMENTATION
Design issues of ELA- 16
Sl. Sectio Detail of issue Concerned Ref. Letter Action/Remarks by
n Dy.HOD Design
1. 1632 Countersunk screw Dy.CEE/D-III SSE/1632/ One loco fitted on trial
provision in Driver desk Design/02 dated basis. (TGHC 3102). Can
15.06.2023 be done and explored

2. 1632 Provision of 3 part Angle Dy.CEE/D-III DyELA/01/Misc. Firm has been advised to
cock in place of 2 part dated 21.11.23 supply material vide L.no
ELDD/3604/Pn. Dated
11.12.23
3. 1616 Fabrication of L bracket Dy.CEE/D-I DyELA/07/Design Implemented in all in
in underframe dated 21.11.2023 house locos.
4. 1632 Regarding failure of Dy. CEE/D- DyELA/07/Design Firms have been
brake system III dated 06.12.23 addressed vide letter no.
Components ELDD/3604/ Pn. dated
10.02.2024
Proposal for
modification of Air Dryer Dy. CEE/D- SSE/1631/
Letter for one loco
5. 1631 mounting bracket along III Design/02;
modification issued
with final filter mounting Dated 30.05.24
 INNOVATION/ SYSTEM IMPROVEMENT
Main
Sl Type/ Description Benefit
Section Equipment
No. Of Innovation To CLW
Assembly
Implementation of RDSO MS 493,
Probability of push pull rod
additional safety sling traction link in Body bogie
1. 1616 falling down while loco
locos TGHC 3506 and TGHC 3504 on connection
running will be reduced
17.04.2024
Fitment of Loco inspector seat in both
2. 1611 cabs of TGHC 3580 on trial basis for LI seat Compliance of RDSO MS-494
compliance of RDSO MS-494
Side wall and arch
Modification of self-gripping rubber for Minimizing water leakage
3. 1612 cross of TG 3677
roof hatch assembly from roof
and TG 3683
Solar reflective paint on roof To reduce temperature of
4. Paint shop Paint
(TGHC 3704) M/c room of locomotive
Modification of horn mount base in Cab To reduce water leakage
5. 1632 Horn
roof (TGHC 3350) from Cab roof
Servomotor pipe clamping arrangement
To reduce damage to pipe
6. 1632 on roof of locomotive Servomotor
of servomotor
(TGHC 3563)
Modified door way surround fitment near To reduce water leakage
7. 1633 Cab Door
cab door (TGHC 3803) from Cab Door
Material shortage of steel fitting
8. 1631 compromised by scrap steel fitting by 1 inch male adapter Reduce scrap
combination
 QUALITY WORK DONE
Main equipment/ Benefit
Sl Sectio Type/ DescriptionOf Innovation Assembly To CLW
No. n
Horn Lever
Shell Countersunk screw fitment in horn lever
and PTDC Better aesthetic design
1. Piping ring & PTDC cover in both cab in June 2023
valve
2. 1612 Modified Driver desk fitment and cab furnishing TP-217, 218 Gives aesthetic look
3. 1614 Modified Cab ceiling Do Improves quality
RS Handle of Implementation of RDSO’s
4. 1632 RS Handle modification as per RDSO MS-454
both cab MS
Introduction of silicon sealant on the
5. 1617 windscreen screw of Vande Sadharan WAP-5 Looks upgraded
Wind Screen
Loco
Installation of Vestibule in 12000 HP WAG-9
6. 1617 Vestibule Production of 1st Twin Loco
Twin Loco
Assembly
7. 1632 Modification of Horn mount base (TGHC 3350) Horn Minimize water leakage from
cab roof
8. 1616 Tamper check marker use for convenient visual Body bogie Easier for inspection to
method of identification for bolt tightness. connection check the tightened nut bolt

9. 1632 Bolting arrangement for pressure switch mounting Pressure switch Avoid welding operation in
bracket. painted loco
10. 1612 Introduction of Driver desk cover for avoiding Driver desk Safety from scratches,
scratches on painted driver desk surface. indents.
THANK
YOU