ORGANOGRAM

Karthick
(Senior Service
Engineer)

Chandan Das Manoj Das Akash Garai

(Section (Engine (Junior Service
Supervisor) Foreman) Engineer)

Md Chotu Animesh Bhudheshwar

Shubham Rajib Majee (ITI Poltu Goswami
(Junior Service Mukherjee Singh Sarkar
Keshari (GET) Trainee) (Technician)
Engineer) (ITI Trainee) (ITI Trainee)

Production Capacity – 5 to 6 engine per month

ROLES AND RESPONSIBILITIES
Karthick – Senior Service Engineer
 Working with proper safety.
 Complete section work activities planning and monitoring.
 Spares planning for workshop and sites (as per requirements).
 Float Components Planning.
 Section Developments in facilities and resources.
 Arrange and provide required technical training to the team members.
 Team member performance monitoring and evaluation.

Chandan Das – Section Supervisor

 Working with proper safety.
 Engine overhauling, servicing and troubleshooting.
 Site visit and technical support.
 Daily section work plan.
 Receiving spares quality inspection.
 Conducting team meetings.
 Developing the junior technicians.
ROLES AND RESPONSIBILITIES
Manoj Kumar Das – Engine Foreman
 Working with proper safety.
 Engine overhauling, servicing and troubleshooting.
 Site visit and technical support.
 Maintaining Section 5s.
 Receiving spares quality inspection.
 Conducting tools audit.
 Developing the junior technicians.

Akash Garai – Junior Service Engineer

 Working with proper safety
 Engine overhauling, servicing and troubleshooting.
 Site visit and technical support.
 Repairing of Turbochargers.
 Developing the junior technicians.
 Section Job Reports Maintaining (Engine Overhauling Work Report and Job Summary Report)
ROLES AND RESPONSIBILITIES
Md Chotu – Junior Service Engineer
 Working with proper safety.
 Engine overhauling, servicing and troubleshooting. (As a team member)
 Site visit and technical support. (With the assistance of seniors)
 Preparing SOPs.
 Maintaining Section Job Reports ( In-Out Report and Float Components Report)
 Learning and developing (Self)

Shubham Keshari – Graduate Engineering Trainee

 Working with proper safety
 Engine overhauling, servicing and troubleshooting. (As a team member)
 Site visit and technical support. (With the assistance of seniors)
 Preparing SOPs.
 Learning and developing (Self)
 ROLES AND RESPONSIBILITIES
Poltu Goswami – Technician
 Working with proper safety
 Engine overhauling, servicing and troubleshooting. (As a team member)
 Site visit and technical support. (With the assistance of seniors)
 Learning and developing (Self).

Rajib Majee – ITI Trainee

 Working with proper safety
 Engine overhauling, servicing and troubleshooting. (As a team member)
 Site visit and technical support. (With the assistance of seniors)
 Learning and developing (Self).
ROLES AND RESPONSIBILITIES
Animesh Mukherjee – ITI Trainee
 Working with proper safety
 Engine overhauling, servicing and troubleshooting. (As a team member)
 Learning and developing (Self).

Bhudheshwar Singh Sarkar – Technical Assistant

 Working with proper safety
 Engine overhauling, servicing and troubleshooting. (As a team member)
 Learning and developing (Self).
 WORK PLAN CHART
Work Plan Chart in Days
Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Dismantling
Parts Cleaning
Dismantling Report
Repairing Works
Repaired Parts Cleaning
Measurements Recording
Assembling
Testing &Troubleshooting
Assembling Report
Dispatch
 WORKFLOW PROCESS
Record all the
measurements of all
Wash the engine and Verify the engine details Dismantling the Clean and wash the
major components like
send to dismantling area and update the report components components
Crank, Connecting, Cam,
Liner and Piston etc.,

Clean all the repaired

Make Parts requirement
and calibrated parts and Collecting spares from Undergo repair and
Procurement Process list (Standard
shift all the spares to store calibration works
Overhauling Spares List)
assembly bay
 WORKFLOW PROCESS
Check and record all the
Check the standard After complete
components for Check and record the Perform assembling clearance/tolerance values assembling, engine
quality and measurements of 5Cs as per SOPs and replace the parts in will mount Engine
measurements case of any deviation in Testing Dynamometer
clearance/tolerances

After successful All the mandatory

Testing/Troubleshooti
Engine Dispatch and testing engine will be connection will do
Job Close ng/Adjustments/Tun
Commissioning packed with testing and perform engine
ning
report load test

In case of any breakdown happened, technical

support will be given
WORK PLAN AND PROCESS
Complete Engine Rebuild Time
 For 6-cylinder engines – Maximum 23 Days (Model wise mentioned in TAT Chart).
 For 4-cylinder engines – Maximum 21 Days (Model wise mentioned in TAT Chart).

Section Productivity
 5 to 6 Engines per month (including 3 teams).

Job Receiving Process

 Job will be received only after submission of Service Requisition Form with all the necessary details
from the user.
 Service Requisition Form will be verified by the Section Head and will be sent to CEW Works Manager
for approval.
 Job will be accepted only after approval from CEW Works Manager. Job No will be created.

Process before Engine Entering to Dismantling Bay

 After job accepted, engine will send to Water Washing Area and engine oil need to be drained. (if the
work is General Inspection, not required to drain the oil)
 Engine will undergo through water wash. Before performing washing, all the opens need to be packed.
WORK PLAN AND PROCESS
Engine Dismantling Process
 After engine placed in Dismantling Bay, Pre-Inspection need to be done and recorded with
photographs.
 Proper arrangements of resources need to be done before starting the dismantling (Tools, Bins,
Pallets, Covers, Wrappers etc.,).
 If the nature of job is General Inspection and Service, after Pre-Inspection engine need to be started
and all the technical parameters need to be checked and recorded.
 If nature of job is to rectify any particular problem, all the possibilities are need to be checked.
 If the nature of job is complete overhauling, engine will be dismantled completely in an order and all
the defective parts are noted with photos.
Parts Cleaning and Planning Process
 Once the engine is dismantled, all the parts will be cleaned thoroughly and kept in an order.
 After cleaning of all the parts, inspections will be done to check and verify the measurements of 5c
and physical damages of parts.
 After completing inspection, Parts Indent List will be prepared with all the necessary details. (Based
on the nature of job).
 Along with that detailed Observation Report need to be done with all the data and photographs. Parts
need to be repaired also should mention in the report.
 If the job is against the Engine Failure, then RCA report also need to be done in detailed.
WORK PLAN AND PROCESS
Parts Ordering Process
 Parts Indent List and Observation Report will be sent to Section Head.
 Section Head will check the report and discuss with the team to clarify the things.
 Once Section Head get satisfied with report, will forward the Part Indent List and Observation List to
CEW Works Manager for approval to proceed the job.
 CEW Works Manager can ask for any clarifications if required.
 If the job is against Engine Failure, RCA should be analysed, and necessary action need to be taken.
 Once the job is approved, Section Head will share the Parts Indent List to store, to check the spares
availability. Available spares will be reserved against the Job No and Parts Requisition will be raised by
the store officer to Procurement Team.
 Then Procurement Team will process the requirement.
WORK PLAN AND PROCESS
Parts Machining/Repairing Process
 If the parts are available at store which are required for machining of 5c, 5c components will be sent
to machining work with all the required parts.
 If FIP, Injector, Turbocharger, Compressor are required to service, this items also will be sent for
repairing.
 If self-starter, Alternator, ECM and Harness are given to electrical department for repairing purpose
with work order.
 Dispatch will be done through store team with proper challan, and section team will record it in In-
Out register and get is signed by the store officer.

Receiving of Machining/Repairing Parts

 After receiving the parts, all the parts will be cleaned and checked by the team.
 If there is any quality issue in the repairing work, it should be check and clarified by the quality officer.
 If quality officer rejects parts, it should be communicated to the supplier through store officer and get
if rectified (team will assist for technical support)
 While receiving the parts, In-Out register should be updated and get it signed.
 Check and ensure all the expansion plugs are properly installed.
WORK PLAN AND PROCESS
Engine Assembling Process
 Once all the parts are received, team will shift serviced parts and spare parts to the assembly bay and
arrange it in a proper manner.
 All the resources required for assembling will be arranged properly like Documents, SOP and Torque
Sheet, Tools etc.,
 All the 5c measurement need to be check and recorded. Team will ensure all the tolerance and
clearances are with in limit. If there is any deviations, it should be inspected and get it rectified.
 Before start to assembling, information need to be given to Electrical Section to ensure the availability
of self-starter, alternator, ECM, wiring harness and battery.
 If all the readings are perfect, engine assembling will be started as per SOP. All the work activities are
should be recorded like torque value, clearances, parts condition etc.,
Engine Testing Arrangements
 After completing the assembling, engine will be removed from the assembly stand and mounted on
the test bench.
 Engine Oil need to be filled and all the required filters need to be tightened properly. Radiator
mounting and coolant top-up need to be done.
 Engine mounting bolts will be tightened, and all the required connection need to done in standard
way like air intake connections, engine exhaust connections, fuel connections, cooling connections
and Electrical Connections.
 Engine should not be started without air filter. Before starting the engine, fuel bleeding and coolant
bleeding should be done.
 Fan Belt and battery terminals need to be checked properly.
WORK PLAN AND PROCESS
Engine Testing
 After bleeding was done, Tapper cover and Turbo oil pressure pipe are need to be loosen.
 Cranking need to be done and oil circulation to the Rocker Assembly and Turbocharger need to be
ensured. Then tappet cover and turbo oil pressure pipe need to be tightened.
 Then engine will be started and will run in idle for minimum 1 hour. Leakages and Seepages are need
to be check and rectified (if any).
 Then engine RPM will be gradually increased, and pressure /temperature reading will be monitored
and recorded.
 Engine sound, smoke condition and blow by will be monitored. Troubleshooting/adjustments and
tunning need to be done (if required)
 Then load need to be applied gradually and all the parameters will be monitored and recorded.
Troubleshooting/adjustments and tunning need to be done (if required)
WORK PLAN AND PROCESS
Engine Dispatch
 After completing of testing, all the connection will be removed, and engine will be removed from the
test bed and mounted on engine stand.
 Complete Engine Work Report will be completed and send to the Section Head.
 Section Head will verify the report and send to CEW Works Manager for approval.
 After approval, engine will be dispatched with test report and dispatch report.
 Concern team person will do the commissioning at site.
 After successful commissioning, job will be closed. And up to 1000 hours concern team member will
monitor the performance of the engine. Technical support need to be done if any issue faced by the
site team.
 REPORT AND AUTHORIZATION SIGNATURE
Document Name Create Verify Approve
Manpower Allocation Team Section Supervisor/Foreman Section Head
Service Requisition Form User Section Head CEW Works Manager
Observation Report Team Section Head CEW Works Manager
Part Indent List Team Head Section Head CEW Works Manager
Repair and Development Form Team Head Section Head CEW Works Manager
Work Order Team Team Head Section Head
Assembly Report Team Section Head CEW Works Manager
Dispatch Report Team Section Head CEW Works Manager
Commissioning Report Team User CEW Works Manager
In-Out Register Team Engine Foreman Section Supervisor
Parts Requirement Form Team Section Head/Supervisor
WORK INSTRUCTIONS
 Maintain work discipline all the time.
 Everyone should use all necessary PPEs at work.
 Planned Leave should be applied before the leave day.
 Strictly follow the work process.
 Keep the working area clean always.
 Put back the tools on its place.
 Update the records with all details and signature from the responsible.
 File the FSR while visiting the site.
ADDITIONAL RESPONSIBILITIES
 Tools and Tackles – Shubham Kesari and Manoj Kumar Das

 Documents and Reports – Chandan Das, MD Chotu, and Akash Garai

 Assembly Room House Keeping – Manoj Kumar Das

 Dismantling Bay House Keeping – Chandan Das

 Testing Room House Keeping – Akash Garai and Poltu Goswami

 Cleaning Area House Keeping – Rajib Majee and Bhudheshwar Singh Sarkar

 Storage Area House Keeping – Md Chotu and Rajib Majee

 5s in charge – Manoj Kumar Das

 Work Activities In charge – Chandan Das

 Resources Maintenance – Poltu Goswami and Animesh Mukherjee

 FINANCIAL YEAR TARGETS
Name Target 1 Target 2 Next FY Plan
Karthick S Engine Test Bench Installation and Commissioning Standardizing the Work Process

Chandan Das Develop Md Chotu and Shubham as they can work Develop Md Chotu as he can perform all kind
independently of troubleshoot
Manoj Das Develop Rajib Majee and Animesh as he can work Develop Rajib Majee as he can perform all
independently kind of troubleshoot
Akash Garai Develop himself can perform all kind of Develop Bhudheshwar as he can work Will Lead Engine Section
assembling, Troubleshooting independently
Md Chotu Develop himself can perform all kind of Make SOP for all Mining Engines Assembling Power Train Section, Hydraulic Section
assembling, Troubleshooting
Shubham Keshari Develop himself can perform independently Make SOP for all Mining Engines Assembling Hydraulic Section, Power Train Section

Poltu Goswami Develop himself can perform all kind of
assembling, Troubleshooting
Rajib Majee Develop himself can perform all kind of
assembling, Troubleshooting
Animesh Mukherjee Develop himself can perform independently
Make SOP for all Exploration Engine Will Lead Exploration Engine Overhauling
Assembling
Make SOP for all Exploration Engine Exploration Section
Assembling
Will attend site troubleshooting

Bhudheshwar Singh Develop himself can perform independently Will attend site troubleshooting
REVISED ORGANOGRAM FOR FY 24-25

Akash Garai

Chandan Das Manoj Das Poltu Goswami

Bhudheshwar Animesh DET DET ITI

Singh GET
Mukherjee