1. Modernization of Stores Depot
Lower Parel
through
Intelligent Warehousing
with
Automated Storage and retrieval
System
Jogendra Yadvendu
Dy.CMM-II,CCG, WR
2. 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
3. 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
4. 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.
5. 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.
6. 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
7. 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.
8. 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.
9. 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.
10. 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.
11. 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.
12. 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
13. 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.
14. 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
15. 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.
