The document summarizes a case study of a value engineering project carried out at an Indian Railways electric locomotive shed to address the problem of gear in two halves (GITH) failures. The project identified issues with the design basis, pinion weight, and oil pump gear shaft as causing impact loading and GITH breakages. Solutions proposed changing the design basis to make the GITH the driving gear, reducing the pinion face width and weight using Teflon, and changing to an external threaded oil pump gear shaft with a castle nut to eliminate play. The project aimed to reduce locomotive downtime and maintenance costs by redesigning faulty components with standardized specifications.

1. A Management Perspective Value EngineeringA Case Study of the Indian Railways Dr. Chandan Vichoray BE, MBA, Ph.D

2. Introduction A Systematic Method to improve the value of goods or products and services by using an examination of a function Value is the ratio of function to cost Value can be improved by: Improving the function Reducing the cost

3. Types of Values There are Four Values: Use Value Cost & Exchange Value Esteem Value Scrap Value

4. The General Value Engineering Job Plan Following steps are generally followed: Information Gathering Alternative Generation Evaluation Presentation

5. The Indian Railways Case Study The Value Engineering Project was carried out at the Central Railway Electric Locoshed (ELS) Ajni. Problem identification was done based on resource utilization focussed on Use Value and Cost Value The Process involved redesigning of the Journal Bearing Lubrication Pump mounted on the Axle Shaft

6. Basics

7. Basics

8. Basics

9. Basics

10. Problem Definition The GITH or the Gear in Two Halves is a part of the Pinion – Gear arrangement wherein the gear is the GITH which drives the pinion as the train starts The Pinion actually drives an Oil pump gear assembly which is submerged in a sump of Oil This assembly provides for a thin film lubrication to the Journal Bearings mounted on the Axle Shaft of the Locomotive This lubrication keeps the friction away and also cools the wheel parts while the train runs Failure of this assembly results in seizures which can prove fatal for the train more so if it’s a passenger train leading to a derailment

11. Digramatically

12. The rise of the problem Breakage of the Gear in Two Halves (GITH) mounted on the Axle Shaft due to Impact Loading Changing GITH involved: Dismantling the body Removing the Central Transformer Removing the Traction motor of the affected Axle Shaft Changing the GITH Again Assembling the aforementioned parts

13. The Management Angle Involved 8 people plus a dedicated Gantry for lifting the Central Transformer, Traction Motors and other parts Required a total of 192 Man hours to change a small part Occupied Pit line for only this work for 24 hours Increased downtime of the Locomotive

14. Alternatives Initially a study of the design of the system was carried out It was found out that multiple procedures resulted in the fault

15. Alternatives Initially a study of the design of the system was carried out It was found out that multiple procedures resulted in the fault Based on the kind of problems the various solution alternatives were found out

16. The Identified Problems The Basis of design was changed Weight of the Pinion The Oil Pump Gear Shaft Non-Standard Specifications

17. Design Basis Problem The Basis of design was changed The Pinion in this case is the driven gear The Hardness of the GITH was less than that of the Pinion The GITH was the hardest to change

18. Design Basis Problem Solution The Basis of design was changed The GITH was the driving gear hence the design process was based on GITH The Hardness of the GITH was made more than that of the Pinion

19. Pinion Weight The Weight of the Pinion was one of the big hindrance Face width of the Pinion was broader contributing to the weight gain Broader face width was foreseen as a solution to proper meshing on turning tracks The weight acted on the Gear shaft of the oil pump gear

20. Pinion Weight Solution Weight of the Pinion was reduced by reducing the face width based on historical data Suggested on the use of Teflon material for manufacturing the Pinion to further reduce the weight

21. Oil Pump Gear Shaft Oil Pump Gear Shaft was tapped for screwing the shaft on to the pinion on the taper side The material clearance between the internal threading and key way was very less The less clearance was responsible for the breakage of the Oil pump shaft leading to impact loading on the GITH due to Pinion

22. Digramatically

23. Oil Pump Gear Shaft Solution Suggestion was given to change the type of threading from an internal threading to an external threading on an extended screw as a part of the Oil pump gear shaft Securing the OPGS with a castle nut so as to ensure zero play during meshing

24. Digramatically

25. Non-Standard Specification All specifications are non standard considering the manufacturing done by GEC Alsthom. Parts with such specifications are difficult to manufacture in local units Leads to productivity delays as sourcing has to be done from the OEM Costlier Proposition

26. Thank You