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Presentation Presentation Presentation Transcript

  • Modernization of Stores Depot Lower Parel through Intelligent Warehousing with Automated Storage and retrieval System Jogendra Yadvendu Dy.CMM-II,CCG, WR
  • Modernization of Carriage Stores Depot at Carriage Repair Workshop, Lower Parel, Western Railway Carriage Stores Depot at Lower Parel is the biggest Stores  Depot on Western Railway. Annual material issues value of Rs. 600 Million.  Accounts for approximately 25 % of the annual issues on  Western Railway. Caters to Carriage Workshop & Divisional Consignees (29).  It stocks around 1200 stock items out of which 167 are  safety, 257 are vital, 38 passenger amenity items . LHB Coach is a new technology with many items being  imported and limited indigenous vendors
  • Major activity at Parel Workshop Activity Type 2006-07 07-08 (estimate) POH ICF 1531 1550 LHB 62 36 Refurbishment of toilets, Laying of RSP ICF Stainless Steel Inlay, changing LP Sheet, Limpet Sheet Refurbishment of toilets, changing the LHB main door
  • What does modernization involve ? Pragmatic mix of IW-ASRS, Drive in Pallet System,  Selective Pallet System, conveyor systems etc. Structurally strong building with adequate free  height for vertical storage. Adequate material handling equipments and  transportation facilities such as platform trucks, forklifts , LMV, HMV . RDBMS based IT application for purchase &  Inventory management with adequate Hardware resources.
  • Estimated cost of the project Sanctioned in M&P Program for the year 2007-08  under plan head 42. Cost: Rs. 138 Million.  Components involved;  IW-ASRS;  Drive in Pallet & Selective Pallet System.  3 & 5 Ton Forklift  5 Ton Road Crane  Truck 9 & 16 Ton  Multi-utility Vehicle  Platform Trucks & Others.  3 Ton EOT Crane. 
  • Why use IW-ASRS at Parel Depot Parel workshop has one of the smallest footprint to  Coach POH ratio. Located in the heart of Metropolitan city-Mumbai  with costly land where lateral expansion is not an option. POH target of ICF, LHB increasing.  Area can be released for workshop modernization &  expansion activities only by releasing the dead space being occupied by multifarious stores godowns. This is where IW-ASRS comes into play.  IW-ASRS utilizes vertical storage capacity leading to  efficient storage & retrieval
  • Proposed site at Lower Parel Central ward of Parel Depot  Measures 50m * 45 m  50% area with mezzanine floor  Max. free height available 6 m.  Free height available in mezzanine area  is 3 m. Cemented flooring. 
  • General Specifications of IW-ASRS S/R Machine:  Construction: Modular component design. All parts designed  for 100% duty cycle. Welded steel frame. Single mast tube, strut braced. Structural steel base. Drive and Idler Wheels: Flanged forged alloy steel. Case  Hardened to 55 Rockwell C. Reground for concentricity. Heavy-duty pillow block bearing support. Fork Extractor Mechanism:  • Construction: Precession fabricated steel  • Load Capacity: 1500 Kg.  • Load Support: Industrial Standard Forks  • Extractor Drive: Patented ball screw and rotator with  variable frequency drives, industrial gear reducers, and brake.
  • Crane Rail with V-H Drives Crane Rail:  • Floor mounted , Rail mounted .  Vertical & Horizontal Drives:  High performance sine-coded, pulse width modulated AC  vector motor drives which generates an adjustable voltage/ frequency three phase output for complete speed control. Automatic stall prevention and voltage boost prevents  nuisance tripping during load or line side transient conditions. The drives will not induce any voltage or distortion back  into the utility line and maintains a displacement power factor of not less than 0.98 throughout its speed range.
  • Communication & Controls Communication:  • Infrared Modem  S/R Machine Controls:  Electrical Components: IEEE code compliance  throughout. IEEE rated enclosure, sensors, and wiring. Panel-mounted diagnostic indicator lights. Panel-mounted maintenance controls. Logistics and Positioning: Onboard  programmable controller A-B SLC-500® communication by infrared modem. Steel code bar, optical address readers. Fine positioning, motor-mounted resolvers with 1/16'' accuracy or 1 deg. Accurate positioning on start-up.
  • Rack & Pallets Safeguards:  Front and rear aisle-obstruction detectors. Onboard  and off-board emergency stops. Load and centering sensors and interlocks. Rack Structure:  Virtually any post and beam (conventional) existing or  new racks capable of safely bearing the pallet loads (pushback and flow rack). Continuity of vertical shelf distance from floor not required. Common depth dimension recommended, but differing depths can often be accommodated. Racks must be attached to the floor but no shimming is needed except with extreme floor conditions. Maximum Height: 100 ft.  Pallets:  Any two or four way pallet capable of being used. 
  • Activities involved in ASRS Civil Engineering work of site preparation  Leveled flooring with adequate bearing  capacity Adequate free height for 15-20 m for  vertical storage & movement of vertical crane. New light weigh roof  Power requirements 
  • Modus Operandi of execution Prepare detailed sub estimate of electrical, civil & mechanical  portion . Obtain sanction of respective HOD.  Prepare STR & DPR.  Obtain sanction of GM.  Prepare material schedules for purchase components .  Prepare tender schedule for works portion.  Obtain dispensation from COFMOW.  Float only one works tender to take care of mechanical, civil as  well as electrical work to be carried out by a single agency on a turn key basis. Have provision for operation for 2 years by the contracting  agency along with training to be followed by five years comprehensive AMC.
  • 0 100 200 300 400 500 600 700 Preliminary 07 Work JULY- Detailed 3030 30 60 Estimate 15 7 AUG-07 DPR & STR 75 Associate 15 07 15 finance vetting 90 HOD’s 10 07 30 Approval 100 HQ finance 10 07 20 SEPT - SEPT OCT vetting 110 GM’s Sanction 10 120 COFMOW 30 OCT 07 Dispensation Material 30 07 30 NOV schedule 150 5 Works Tender 155 FEB 08 Advertised 45 tender 200 Tender 90 deliberations 290 Placement of 15 08 15 DEC 071 1 MAY 15 08 MAY work order 305 Engineering 180 08 Construction 485 ASRS 90 Assembly & 575 Testing 15 15 15 FEB 1 Commissioning 09 NOV 09 APRIL 590
  • Management of stores functions during construction in central ward Shift the employees to the new office  building coming up under GM’s Power. Shift bogie items to bogie sub stores.  Create sub stores in paint shop for paint  items & use the released space for bogie components. Create sub store in furnishing for  furnishing items. Use timber ward for large & costly stores.  Use jumbo siding for heavy, big stores. 
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  • PLAN, ELEVATION & SECTION OF PAREL STORES DEPOT
  • FRONT VIEW OF IW-ASRS AT PAREL STORES DEPOT
  • TOP VIEW OF PAREL STORES DEPOT WITH IW-ASRS
  • PALLET & SECTION AT “C”
  • Generation of Barcode at Purchaser’s Premises Barcode Components •Vendor ID •Item Code •Consignee Code •Order No, Date
  • ADC Technologies Voice systems  RFID  OCR  pick-to-light  laser scanners  Bar-coding  CCD scanners  hand-held batch and RF terminals  vehicle-mounted computers  wearable computers 