Part-A DPR - Sample

PART A
TABLE OF CONTENTS
507 - FINAL DETAILED PROJECT REPORT
Part A Project Overview Page No
1.1 Preface ......................................................................................................... 1
1.2 Project Background ....................................................................................... 1
1.3 Principle ......................................................................................................... 2
1.4 Overview of 507 Army Base Workshop ........................................................ 2
1.5 Role of the Workshop .................................................................................... 3
1.6 Vision Statement ........................................................................................... 3
1.7 Project Objectives ......................................................................................... 4
1.8 Load Profile ................................................................................................... 4
1.9 Benchmark for Modernization ....................................................................... 5
1.10 Benefits of Modernization .............................................................................. 5
1.11 Execution Methodology ................................................................................. 6
1.11.1 Understanding the Process and Data Collection ................................. 6
1.11.2 Data Collection ..................................................................................... 7
1.12 Study Findings ............................................................................................... 8
1.13 Existing Infrastructure.................................................................................... 9
1.13.1 Administration Department .................................................................. 9
1.13.2 Production Department ....................................................................... 12
1.13.3 Works Department .............................................................................. 17
1.14 Proposed Facilities for Modernisation of Base Workshop ............................ 20
1.14.1 Layout of the Workshop ...................................................................... 20

1.14.2 New Buildings to be Constructed (Process) ....................................... 21
1.15 Capacity Enhancement Due To Modernisation ............................................ 22
1.15.1 Field Articulated Vehicle output........................................................... 22
1.15.2 FAV Engines output ............................................................................ 22
1.15.3 Process Improvements........................................................................ 23
1.16 Allied Requirements ...................................................................................... 27
1.17 List of Buildings Under Construction ............................................................. 28
1.18 Old Buildings to be Refurbished for New Application ................................... 28
1.19 Old Buildings to be Demolished .................................................................... 30
1.20 Key Features of Building Layout ................................................................... 41
1.20.1 Green Concept .................................................................................... 42
1.20.2 Structure of DPR ................................................................................. 45
1.20.3 Detailed list of DPR volumes............................................................... 46
Technical Process
1.0 Study Findings and Recommendations ……………………………………… 49
1.0.1 Existing Infrastructure ………………………………………………… 49
1.0.2 Need for Modernization ………………………………………………… 49
1.0.3 Master Plan …………………..……………………………………… 49
1.1 Production Group 51
1.1.1 KRAZ REPAIR GROUP (FIELD ARTICULATED VEHICLE GROUP)……… 52
1.1.1.1 Function of the group ………………………………………………… 52
1.1.1.2 Current process ………………………………………………………… 52
1.1.1.3 Current Workflow……………………………………………………… 53

1.1.1.4 PERT analysis for current process……………………………………. 53
1.1.1.5 Issues & Gap analysis ………………………………………………… 54
1.1.1.6 Improvement opportunities ………………………………………… 54
1.1.1.7 Future expansion needs …………………………………………… 54
1.1.1.8 Recommended process ……………………………………………… 55
1.1.1.9 Loading & Unloading ………………………………………………… 55
1.1.1.10 Water Washing Process …………………………………………… 59
1.1.1.11 Stripping Process …………………………………………………… 60
1.1.1.12 Degreasing and paint removal process …………………………… 61
1.1.1.13 Shot Blasting ………………………………………………………… 62
1.1.1.14 Sub-assembly repair & overhauling process ……………………… 63
1.1.1.15 Assembly Process ………………………………………………… 64
1.1.1.16 In – line Assembly …………………………………………………… 64
1.1.1.17 Effective ergonomics ………………………………………………… 67
1.1.1.18 Post-over Hauling Process …………………..……………………… 70
1.1.1.19 Pert Analysis of Kraz (FAV)…………………………………………… 70
1.1.1.20 Flow path analysis of FAV overhauling process …………………… 71
1.1.1.21 Loading & Unloading Process………………………………………… 72
1.1.1.22 Machinery Requirement ……………………………………………… 73
1.1.2 ENGINEERING EQUIPMENT GROUP
1.1.2.1 Function of the group ……………………………………………… 79
1.1.2.2 Current process…………………………………………………….. 79

1.1.2.3 Current workflow……………………………………………………… 79
1.1.2.4 Issues & Gap analysis ……………………………………………… 80
1.1.2.5 Improvement opportunities ………………………………………… 81
1.1.2.7 Recommended process..………………………………………… 82
1.1.2.8 Pert Analysis of EEG………………………………………………… 84
1.1.2.9 Machinery requirement …………………………………………… 85
1.1.3 Engine Repair Group (ERG) ……….……….……….……….……….… 90
1.1.3.1 Function of the Group ……………………………………………… 90
1.1.3.2 Current process …………………………………………………… 90
1.1.3.3 Current workflow……………………………………………… 91
1.1.3.4 PERT diagram findings…………………………………………… 91
1.1.3.6 Improvement opportunities ……………………………………… 93
1.1.3.8 Recommended process …………………………………………… 94
1.1.3.9 Cylinder block & Crankshaft section ……………………………… 97
1.1.3.10 Fuel Injection pump section………………………………………… 97
1.1.3.11 Head assembly section ……………………………………………… 98
1.1.3.12 Engine Test house …………………………………………………… 98
1.1.3.13 Experimental capabilities…………………………………………… 99
1.1.3.14 Recommended Engine Preservation Process …………………… 100

1.1.3.15 Pert Analysis of engine overhauling……………………………… 103
1.1.3.16 Machinery Requirement …………………………………………… 103
1.1.4 General Engineering Group ……….……….……….……….……….… 109
1.1.4.1 Function of the group ……………………………………………… 109
1.1.4.2 Current process ……………………………………………………… 109
1.1.4.4 Improvement opportunities …………………………………………. 110
1.1.4.7 Production Layout …………………………………………………… 112
1.1.4.8 Characteristics of a job shop ……………………………………… 113
1.1.4.9 Material estimation process........................................................... 115
1.1.4.10 Ancillary section............................................................................ 115
1.1.4.11 Carpentry shop ……………………………………………………… 115
1.1.4.12 Electroplating shop ………………………………………………… 115
1.1.4.13 Moulding shop ……………………………………………………… 116
1.1.4.14 Rubber moulding shop ……………………………………………… 116
1.1.4.15 Tool room …………………………………………………………… 117
1.1.4.16 Blacksmith shop ……………………………………………………… 117
1.1.4.17 Machinery Requirement …………………………………………… 117
1.1.5 FABRICATION GROUP (BODY REPAIR GROUP) ……….……….……….…… 128
1.1.5.1 Function of the group………………………………………………… 128

1.1.5.2 Issues & Gap analysis……………………………………………… 128
1.1.5.3 Improvement opportunities………………………………………… 128
1.1.5.4 Future expansion needs…………………………………………… 129
1.1.5.5 Recommendation…………………………………………………… 129
1.1.5.6 Overall cell plan……………………………………………………… 131
1.1.5.7 Block layout of cells and supporting areas………………………… 131
1.1.5.8 Detailed cell plan…………………………………………………… 132
1.1.5.9 Machinery Requirement…………………………………………… 132
1.1.6 Battery charging section ……….……….……….……….……….…… 136
1.1.6.2 Battery charging process…………………………………………… 138
1.1.6.3 Industrial safety and fire protection ……………………………… 138
1.1.7 OTRP……….……….……….……….……….…………………………… 139
1.1.7.1 Recommended process……………………………………………… 139
1.1.7.2 Machinery Requirement…………………………………………..…. 139
1.1.8 Electronics Repair Shop……….……….……….……….……….……. 140
1.1.8.1 Sub-Assembly Cleaning…………………………………………… 140
1.1.8.2 Typical ESD workstation……………………………………………. 140
1.1.8.3 Grounding……………………………………..……………….……… 141
1.1.8.4 Modular BGA/CSA Re-work station…………………………… 142
1.1.8.5 ESD Re-work station…………………………………………………. 144
1.1.8.6 ESD Test Equipments………………………………………………. 144

1.1.8.7 ESD Work Bench…………………………………………………… 145
1.1.8.8 ESD Chair………………………………………………………..…… 146
1.1.8.9 PCB Storage Racks…………………………………………….….. 146
1.1.8.10 (inspection System) Light Magnifier……………………..………. 147
1.1.8.11 ESD Aprons………………………………………………………… 147
1.1.8.12 Anti-static for cleaning purpose…………………………………… 148
1.1.8.13 Wrist Straps………………………………………………………… 148
1.1.8.14 ESD table Mat……………………………………………………… 149
1.1.8.15 Foot Wear………………………………………………………….. 149
1.1.8.16 ESD gloves………………………………………………………... 150
1.1.8.17 Synthesized Signal Generator…………………………………….. 150
1.1.8.18 Machinery Requirement …..……………………………………… 151
1.2 Works Department……….……….……….……….……….……….……….… 154
1.2.1 Method engineering / Indigenization section……………………………. 154
1.2.1.1 Function of the group……………………………………………… 154
1.2.1.2 Issues & Gap analysis……………………………………………… 154
1.2.1.3 Improvement opportunities………………………………………… 155
1.2.1.4 Recommendation…………………………………………………... 156
1.2.1.5 Reverse engineering………………………………………………… 156
1.2.1.6 Machinery list ………………………………………………………… 160
1.2.2 Workshop service Group……….……….……….……….……….………. 165
1.2.2.1 Function of the group………………………………………………… 165

1.2.2.2 Issues & Gap analysis…………………………………………….… 165
1.2.2.3 Improvement opportunities……………………………………… 165
1.2.2.4 Recommendation……………………………………………………. 166
1.2.2.5 Tasks…………………………………………………………………. 166
1.2.2.6 Machinery Requirement…………………………………………….. 167
1.2.3 OSS…………………………………………………………………………. 169
1.2.3.1 Introduction……………………………………………………………. 169
1.2.3.2 ASRS……………………………………………………………… 171
1.2.3.3 Overview……………………………………………………………… 171
1.2.3.4 AS/RS Components and terminology……………………………… 173
1.2.3.5 Types of AS/RS…………………………………………………… 173
1.2.3.6 Recommendations………………………………………..……..… 175
1.2.4 Material Controll Group………………………………………………… 175
1.2.4.1 MCO…………………………………………………………………… 175
1.2.4.2 Local purchase procedure…………………………………………… 182
1.2.4.3 Expense stores……………………………………………………….. 188
1.2.5 Technical Training Cell…………………………………………………… 189
1.2.5.1 Function of the group..……………………………….…..………. 189
1.2.5.2 Issues & Gap analysis……………………………………….……… 190
1.2.5.3 Improvement opportunities………………………………..………. 190
1.3 Work Study…………………….……………………………………..………. 199
1.3.1 Line balancing………………………………..………………………………. 200

1.3.2 Productivity improvement techniques …….……………………..……… 200
1.3.2.1 Technology based…………………………..……………………… 201
1.3.2.2 Employee based……………………………..………………………. 201
1.3.2.3 Material based………………………………………………………… 201
1.3.2.4 Process based………..………………………………………………. 202
1.3.2.5 Product based…..………………………………………………..…… 202
1.3.2.6 Task Based……..…………………………………………………….. 202
1.3.2.7 Principles of manufacturing……..………………………………… 202
1.3.2.8 Lean Building Blocks ……….……………………………………… 203
1.3.2.9 Operational Improvements………………………………………… 205
1.3.2.10 Administrative Improvements…………………………………… 205
1.3.2.11 5S or Workplace Organization………………………………….… 205
1.3.2.12 Recommendation for ABW 507…………………………………. 207
1.3.3 Mathematical modeling 209
1.3.3.1 Mathematical modeling of FAV assembly process……………… 209
1.3.3.2 Mathematical modeling of complete overhauling process of FAV 211
1.3.3.3 To calculate equipment capacity ………………………………… 212
1.3.4 Manpower Analysis 213
1.3.4.1 Manpower Analysis for FAV OH process………………………. 213
1.3.4.2 Manpower Estimation for Engineer Equipment Group…………… 216
1.3.4.3 Manpower Estimation for Engine Repair Group………………… 218
1.3.5 Existing Machinery 220

Process Buildings - New Buildings To Be Constructed
Part - A 2.1 Engineer Equipment Assembly Group ............................................................ 232
2.2 Field Articulated Vehicle Assembly Group ...................................................... 234
2.3 Field Articulated Vehicle Sub Assembly Group .............................................. 236
2.4 Engine Repair Group....................................................................................... 238
2.5 General Engineering Group ............................................................................ 240
2.6 Ancillary shed .................................................................................................. 241
2.7 Workshop Expense Stores / Battery Charging Section ................................. 242
2.8 Body Repair Group.......................................................................................... 243
2.9 Engine Test house .......................................................................................... 244
2.10 Caustic Soda Wash ......................................................................................... 245
2.11 OSS store / MCO Store / KRAZ stores ........................................................... 245
2.12 Vehicle Stripping Shed .................................................................................... 246
2.13 Engineer Equipment stripping / Sub Assembly Group.................................... 247
2.14 Outer traffic store ............................................................................................. 248
2.15 Effluent Treatment Plant.................................................................................. 249
2.16 UG Sump – 1 & 2 ............................................................................................ 249
2.17 Scrap Yard....................................................................................................... 249
2.18 Compressor room 1 & 2 .................................................................................. 249
2.19 Over Hauled Vehicle Parking – 1 (11Nos) ...................................................... 250
2.20 Chassis Dynamometer .................................................................................... 250
2.21 Repairable vehicle parking -1(15 Nos) ............................................................ 250
2.22 Repairable vehicle parking -2 (15 Nos)........................................................... 250

Process Buildings – Buildings To Be Refurbished For New Application
2.23 Painting Area & Dust Proof Painting Booth..................................................... 251
2.24 OTRP (Workshop Service Group)................................................................... 252
2.25 Receipt & Issue and vehicle washing Booth ................................................... 252
2.26 MAG 10 ........................................................................................................... 253
2.27 Method Engineering Section ........................................................................... 253
Buildings Under Construction
2.28 Workshop Service Group Tools Stores........................................................... 255
2.29 MCO Buildings ................................................................................................ 256
Power Requirements
3.1.1 General Requirements................................................................................... 259
3.1.2 Existing .......................................................................................................... 259
3.1.3 Proposed........................................................................................................ 259
3.1.4 Cable trenches and laying ............................................................................. 261
3.1.5 Lighting .......................................................................................................... 262
3.1.6 Power socket outlets...................................................................................... 262
3.1.7 Ceiling fan and Exhaust fan........................................................................... 262
3.1.8 Industrial Exhaust Fan ................................................................................... 263
3.1.9 Industrial Air Circulating Fan ......................................................................... 263
3.1.10 MV panel and Switchboard ........................................................................ 263
3.1.11 HT and LT Cables ...................................................................................... 264
3.1.12 LT Power Cables ........................................................................................ 264
3.1.13 Cable Selection .......................................................................................... 264
3.1.14 Voltage Drop in Cables .............................................................................. 265

3.1.15 MCCB ......................................................................................................... 265
3.1.16 MCB DB ...................................................................................................... 265
3.1.17 Earthing ...................................................................................................... 266
3.1.18 Power factor improvement ......................................................................... 266
3.1.19 DC rectifier Units ........................................................................................ 266
3.1.20 Safety Equipments ..................................................................................... 267
3.1.21 Air Compressor........................................................................................... 270
HVAC System
3.2.1 Proposed HVAC System for 507 ABW ...................................................... 273
3.2.2 Code and Regulation Standards ................................................................ 278
Water Supply System
3.3.1 Water Requirement .................................................................................... 281
3.3.2 Existing Facilities ........................................................................................ 282
3.3.3 Proposal ..................................................................................................... 282
3.3.4 Overhead Tank cum UG Sump .................................................................. 282
3.3.5 Distribution system ..................................................................................... 283
3.3.6 Industrial Supply ......................................................................................... 283
3.3.7 Water Treatment......................................................................................... 284
3.3.8 Drinking Water ............................................................................................ 284
3.3.9 Recommendation for Refurbishment Buildings ......................................... 284
3.3.10 Pump Requirement .................................................................................... 285
Effluent Treatment Plant
3.4.1 Installation of ETP ...................................................................................... 287
3.4.2 Treatment Processes ................................................................................. 287

3.4.3 Proposed System ....................................................................................... 288
3.4.4 Connection System .................................................................................... 288
Storm Water Management System
3.5.1 Storm water Drains..................................................................................... 291
3.5.2 Calculation of Run off ................................................................................. 291
3.5.3 Design of Drain Size................................................................................... 291
3.5.4 Drain structure ............................................................................................ 292
3.5.5 Slope of Drain ............................................................................................. 292
3.5.6 Road crossing............................................................................................. 292
3.5.7 Collection tank ............................................................................................ 293
Fire Fighting System
3.6.1 Existing fire Fighting System ...................................................................... 295
3.6.2 Proposed fire fighting System .................................................................... 295
3.6.3 Fire hazard Classification of Buildings at 507 ABW, Kankinara ................ 296
House Keeping
3.7.1 General ....................................................................................................... 306
3.7.2 Existing Scrap Dumping Unit ..................................................................... 306
3.7.3 Proposed Scrap Dumping Unit................................................................... 306
3.7.4 Proposed House Keeping Equipments for 507 ABW ................................ 306
3.7.5 Specifications for proposed housekeeping equipments ............................ 307
Assembly Line Integration – Road Network
3.8.1 General ....................................................................................................... 313
3.8.2 Existing condition of Road Network ........................................................... 313
3.8.3 Road Design ............................................................................................... 313

3.8.4 Design of Pavement ................................................................................... 313
3.8.5 Drainage system ........................................................................................ 314
3.8.6 Proposed cross section .............................................................................. 314
3.8.7 Proposed pedestrian walkway ................................................................... 315
3.8.8 Road delineators ........................................................................................ 315
3.8.9 Road Markings and Road Furniture ........................................................... 315
3.8.10 Proposed Road Network ............................................................................ 316
Budgetary Cost Estimate
4.1 Cost Estimate – Process Building Break up ................................................... 319
4.2 Cost Break up for Process Buildings .............................................................. 320
Recommendations
5.1 Trade Re – Structure ......................................................................................... 325
5.2 Benefits of Modernization ................................................................................. 331
5.3 Key Performance Indicator(KPL) ....................................................................... 335
Building Specification
6.1 Engineer Equipment Assembly Group ............................................................ 337
6.2 Field Articulated Vehicle Assembly ................................................................. 343
6.3 Field Articulated Vehicle Sub Assembly Group .............................................. 349
6.4 Engine Repair Group....................................................................................... 355
6.5 General Engineering Group ........................................................................... 361
6.6 Ancillary Shed.................................................................................................. 367
6.7 Workshop Expenses Stores / Battery Charging Section ................................ 373
6.8 Body Repair Group.......................................................................................... 379
6.9 Engine Test House .......................................................................................... 385

6.10 Caustic Soda Washing .................................................................................... 390
6.11 OSS Stores, MCO Stores & KRAZ Stores ...................................................... 395
6.12 Vehicle Stripping Shed .................................................................................... 400
6.13 Engineer Equipment Stripping and Sub Assembly Group .............................. 405
6.14 Outer Traffic Stores ......................................................................................... 410
6.15 Scrap yard ....................................................................................................... 413
6.16 Compressor Room (1&2) ................................................................................ 416
6.17 Overhauled Vehicle Paring 1 .......................................................................... 419
6.18 Chassis Dynamometer .................................................................................... 421
6.19 Repairable Vehicle Parking 1&2 ..................................................................... 423
Implementation Strategy
PART – A
Project Overview
Part-A DPR
DETAILED PROJECT REPORT

PART A – PROJECT OVERVIEW
1.1 Preface
507 ABW Kankinara is one among the eight ABWs responsible for providing base repairs
(overhaul land last echelon repairs) of Field Articulated Vehicles, Engineering equipment and its
engines to the Indian Army. 507 ABW is located about 35 km north of Kolkata. The role of this
Workshop is to overhaul all types of special vehicles of foreign origin and Engineering
Equipment. In addition, it overhauls various types of engines, manufacturing of spares, and
production of Jigs & Fixtures for various weapon systems besides indigenization commitments.
1.2 Project Background

A Military Department was created in the Supreme Government of the East India Company at
Kolkata into the year 1776, having the main function to sift and record orders relating to the
Army issued by various Departments of the Government of East India Co. The Military
Department initially functioned as a branch of the Public Department and maintained a list of
Army personnel.
With the Charter Act of 1833 the Secretariat of the Government of East India Company was re-
organized into four Departments, including a Military Department, each headed by a Secretary
to the Government. The Army in the Presidencies of Bengal, Bombay & Madras functioned as
respective Presidency Army till April 1895, when the Presidency Armies were unified into a
single Indian Army. For administrative convenience, it was divided into four Commands viz.
Punjab (including the North West Frontier), Bengal, Madras (including Burma) and Bombay
(including Sind, Quetta and Aden).
The supreme authority over the Indian Army vested in the Governor General-in-Council, subject
to the Control of the Crown, which was exercised by the Secretary of State for India. Two
Members in the Council were responsible for military affairs, one of whom was the Military
Member, who supervised all administrative and financial matters, while the other was the
Commander-in-Chief who was responsible for all operational matters. The Military Department
was abolished in March 1906 and it was replaced by two separate Departments, the Army
Department and the Military Supply Department. In April 1909 the Military Supply Department
was abolished and its functions were taken over by the Army Department. The Army
507 ABW 1
Part-A DPR
Department was re - designated as the Defence Department in January 1938. The Department
of Defence became the Ministry of Defence under a Cabinet Minister in August 1947.
The Corps of EME is the technical Corps of Indian Army for providing engineering support
(primarily maintenance, repair and overhaul) to all equipment held by Indian Army (electronics,
mechanical, optical, armament, vehicles, aviation or any other variety), As maintenance
engineers for all the weapons and equipment held by the Indian Army, the Corps of EME follows
an echelon based service delivery model. The delivery of engineering support is executed by a
mix of combatants and civilian skilled workforce through a mix of in-house and outsourced
delivery models throughout the lifecycle of the equipment from conception till discard. This
presently is through the medium of well honed paper based transactions processes and
procedures.
1.3 Principle
The Ministry of Defence, Govt of India is interested in Consultancy to prepare a Detailed Project
Report (DPR) for Modernization on Turnkey Basis of 507 Army Base Workshop, Kankinara.
507 Army Base Workshop (ABW) is one among the eight ABW’s responsible for providing base
repairs (overhaul, last echelon repairs) to the equipment of the Indian Army.
The main principle of the study is to modernize the existing army workshop to world class
standards taking into the account demand for the next 20 –years. It is proposed to achieve this
objective by studying existing facilities and suggest most modern infrastructure categorizing into
present day requirement.
1.4 Overview of 507 Army Base Workshop

507 – Army Base Workshop (ABW) is located about 35 Km, north of Kolkata. By road it is 43
KM North of Kolkata on Barrack pore - Naihati Highway (Route No 85). The location is known as
Military Station, Kankinara. The military wing of the workshop is located across the Road. The
total technical area occupied by the workshop is 80 acres. The Work Shop is headed by an
officer of the rank of COLONEL (Col.), designated as COMMANDANT (Comdt.) & Managing
Director (MD). The workshop is organized into three groups namely Administration group,
Production group and Works Management Groups. An officer of the Rank of Lieutenant Colonel
(Lt Col.) heads each department and has associated subordinates to facilitate efficient
functioning of each department.
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Part-A DPR
The workshop is located in low lying area and its existing infrastructure and facilities have
become outdated being old vintage which have been rendered deficient due to addition of load
over the years. The sheds of the old workshop are not suited to meet the present day
requirements of overhaul of present equipment with high technology. Hence there is an urgent
requirement to take stock of the present and future requirements in terms of infrastructure and
repair facilities required so as to modernize the workshop in a planned and holistic manner for
the next two decades which has become the scope of the consultant. The proposal aims at
identifying the works to be undertaken, Plant and Machinery and Service Equipment (PMSEs),
and miscellaneous equipment to be procured to handle the load of the workshop over next two
decades so as to ensure that 507 Army Base Workshop continues to be a bastion of excellence
for repairs and overhaul.
1.5 Role of the Workshop:

The role of this Workshop is to overhaul all types of Engineering Equipment and special
vehicles of foreign origin. In addition, it overhauls various types of engines, manufacture of
spares, and production of Jigs & Fixtures for various weapon systems besides indigenization
commitments. Present load of 507 Army Base Workshop is as under:-
 Overhaul of Earth Moving Equipment.
 Special 'B' vehicles (Army & Air Force).
 Excavator Loaders.
 Specialist vehicles of foreign origin (Army & Air Force).
 'B' & 'C Vehicle engines
 Repair of Class ‘B’ Stores/Deposit Repair Work Orders (DRWOs).
 Manufacturing of Spares/Local Manufacture (LM).
 Indigenization of Spares.
1.6 Vision Statement:

Keeping above objectives in view, a vision statement has been evolved. Vision of 507 Army
Base Workshop is to modernize itself extensively both technically and administratively, to
ensure quality output and to enhance combat potential of the field Army by way of the
following:-
• Centre for Industrial and Technological Excellence for overhaul of Automatic Gear Box
507 ABW 3
Part-A DPR
Testing
• Centre for Industrial and Technological Excellence for overhaul of Rubber & Plastic
Moulding
• Centre for Industrial and Technological Excellence for Designing and Manufacturing of
spares.
• Centre for Industrial and Technological Excellence for Reverse Engineering
• Centre for Industrial and Technological Excellence for Hydraulics
1.7 Project Objectives

The following are the long and short term objectives of the workshop
• Centre for Industrial and Technological Excellence for overhaul of Automatic Gear Box
Testing, Rubber & Plastic Moulding, Manufacturing of spares, Reverse Engineering &
Hydraulics
• Modernization of the entire workshop
• Reorganization of Method Engineering Group to include Computer Aid Design (CAD) /

Computer Aided Method (CAM) Centre including E-CAD
• Establishment of infrastructure for overhauling of specialist vehicles
• Establishment of chassis manipulator and dynamometer
1.8 Load Profile
Existing Load Future Load

Overhauling of • Overhauling of
• Specialist vehicle of Russian origin.  Field Articulated Vehicles and its
• All types of Earth moving Equipments. variants
• 'B' & 'C Vehicle engines.  All types of Engineering Equipments.
• Manufacture of Mock ups of Armoured  All types of Engines
Vehicle. • Indigenization in manufacturing of spares
• Manufacturing of Spares/LM. • Manufacture of Mock ups of Armoured
• Pilot overhaul of selective equipment vehicles and pilot overhaul of selective

equipment
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Part-A DPR
1.9 Benchmark for Modernization

Modernizing 507 Army Base Workshop on turnkey basis aims at identifying the works to be
undertaken, Plant and M achinery and Service Equipment (PMSEs), and miscellaneous
equipment to be procured to handle the load of the workshop over next two decades so as to
ensure that 507 Army Base Workshop continues, to be a bastion of excellence for repairs and
overhaul of the modern equipment / vehicles. It is to be designed as a package to include all
facets of infrastructure resources while making the optimum use of existing resources.
1.10 Benefits of Modernization

The modernization proposal is designed to get the following tangible and in-tangible benefits of 507 ABW
1. Tangible Benefits
a. Increase in capacity to overhaul of FAV to 156 vehicles / year
b. Increase in capacity to overhaul of Engineer Equipment to 56 vehicles / year
c. Increase in engine overhauling capacity to 204 engines
d. Establishment of centre of excellence for Automatic Gear box testing, Hydraulics, Rubber
and Plastic moulding, Manufacture of spares and Reverse Engineering
e. State of art engine test house
f. Segregation of dirty area for stripping and cleaning process and clean area for assembly
process
g. Establishment of Manufacturing Execution system along with its support facilities
(Networking system)
h. Buildings designed to conform to green building concepts to save energy
i. Installation of the latest security system
j. State of art buildings with modern allied facilities for fire fighting, housekeeping etc.
k. Establishment of Modern CAD/CAM centre
l. Increase in overhaul productivity
m. Increase in Quality of product and reduction in no of failures
n. Increase in Machine utilization with higher efficiency
o. Increase in Mean Time between Failures (MTBF)
p. Reduction in Mean Time to Repair(MTR)
q. Increase in Overall Equipment Efficiency (OEE)
r. Reduction in
• Rework Percentage
507 ABW 5 Mukesh & Associates

Part-A DPR
• Rework hours
• Rejection rate
• Waste generation
• Power consumption
• Fuel & Oil consumption
• Maintenance cost
• Tooling cost
• Procurement / Ordering cost
• Cost of inventory
• Sparer retrieval time
• Absenteeism
• Accidents
2. Intangible Benefits
• Capacity and capability enhancement of the workshop
• Efficient utilisation of men, machine and material
• Safe Material management
• Improved working Environment
• Improved quality of the component in wide range
• Improved Quality of Overhauling process
1.11 Execution Methodology

1.11.1 Understanding the Process and Data Collection
On detailed study and understanding of the existing process, the emerging requirements of 507
ABW in respect of Mechanical, Electrical, Civil & Allied Services and its sequence, facilities &
limitation in existing infrastructure have been noted is as follows
• Multi-storied buildings (to Maximize space utilization) with dust, temperature & humidity
control environment.
• Procurement of state of art PMSEs and test equipment.
• Efficient Material Handling Equipment (MHEs) and storage systems
• Online spares management
• Automation of Processes

Part-A DPR
• Modern safety and security system
• Sound communication system
• Partially automated housekeeping and scrap disposal facilities
1.11.2 Data Collection

Available data and information relevant to the Study was collected. The data includes the
following:
Climate
• Cloud bursting in the months of April & May
• Continuous rain in the months of June & July
• Normal rain in August & September

Emerging Requirements of the workshop and the details of Existing Buildings, type of activities
(Say Technical, Administrative and Amenities) and conditions have been studied and analyzed.
Existing Pavement
• Stone blocks pavement of diagonal pattern
• C.C pavement and Bituminous pavements
Condition of Cross-Drainage Structures
• The existing condition of the drainage is insufficient and ineffective
• Most of the drain’s require proper desilting
• Road crossing drainages are blocked due to insufficient sizes of the drains.
• Drainage Outlet point is blocked with oily silt
• The water from other common areas were also found to be entering into ABW campus
• Since the buildings are constructed way back, the levels area almost same as the floor
level of the existing road level
• Administrative block level goes down about 0.30m from the existing road level
• The floor level of newly constructed Method Engineering Group was found to be of 0.30m
below the road level
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Part-A DPR
Sub-Surface and Geo-Technical Data
• Black cotton soil observed at the depth of 2.5 to 3.0 m
Traffic Survey
• Identification of type of vehicles utilizing the pavement
• All types of Engineering Equipments
• KRAZ Group Special ‘B’ Vehicles
Details of Source and Quantity of Water
• 4 No. of Bore wells located in the campus
• Over Head Tank with a capacity of 1 lakh liters
• MES supply for ABW & ESD
• Details of Existing Machinery in each workshop including year of installation, type of

activities, Maintenance history and present working condition have been studied and
analyzed
• Details of Machines that can be refurbished and machines which have to be replaced has
been analyzed
• Emerging Requirements for machinery, storage facilities, material handling equipments,

tools etc. have been studied and analyzed
• Details of Existing Security System and Fire Fighting System has been studied
1.12 Study Findings

The existing Master plan was studied and the problems faced by the existing master plan of the
507 Army Base Workshops which necessitates the modernization are listed below
• The buildings are old and infirm
• Inadequate drainage system that causes flooding of low lying buildings during rainy
season
• Non-availability of quality power backups
• Inadequate range and numbers of Material Handling Equipment (MHE)
• Inadequate assembly Line Layouts
• Non availability of LAN and Database Management Software
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Part-A DPR
• Dependence on outdated and inaccurate machines and work processes in all groups
• Lack of automation in manufacturing processes
• Lack of conductive environment and storage facilities
• Lack of automation in inventory control and management
• Lack of automation in human resource administration and other office operations.
• Lack of integrated and automated system of information flow
• Lack of smoke detectors and automated fire fighting arrangements
• Technologically outdated safety and security systems.
• No central sewerage system
• Some sheds of production group are very old and are required to be demolished.
• Some Electrical Operated Travel (EOT) Cranes are also very old and are outdated.
• Parking sheds in the Workshop for parking of vehicles of different categories is

inadequate.
• Old vintage of plant and machinery.
1.13 Existing Infrastructure

1.13.1 Administration Department
An officer of the rank of Lt. Colonel, designated as General Manager (Administration), heads the
department. The department is responsible for overall administration of both combatants as well
as civilians (Civ). Its main functions include Security, establishment, pay and allowances,
discipline, welfare and documentation. The above functioning of the department is facilitated by
the following sections.
1.13.1.1 Administrative sections/groups:
• Establishment section (Est. Sec)
• Mechanical Transport Section (MT Section)
• Finance section (Fin Sec)
• Medical Inspection room (MI Room)
• Civilian Assistant Security Officer (CASO)
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Part-A DPR
1.13.1.2 Special Needs for the group

The Department requires service system like Air-Conditioning, ventilation, lighting, public
address system, fire & safety, plumbing and sanitary needs. The new buildings have been
integrated with the existing buildings. Adequate parking facilities have to be provided.
1.13.1.3 Evaluation of constraints of existing Infrastructure
• The buildings and facilities are not properly grouped which does not produces a
systematic layout. The facilities in these areas are not automated. The worn out buildings
are not aesthetic & multi-storied.
• The high roof sheds are of Madras terraced supported with I beams which are perennially
leaking and as a hazard to the expensive equipments.
• The outdated vintage building has lack of accommodation for the other rank officers and
modern toilets. Parking sheds are not covered and the space is not properly managed for
parking of different categories of vehicles
• Since the buildings are low lying, the inadequate draining system causes floods during
rain. This in turn affects the housekeeping and disposal facilities
1.13.1.4 Scope of work

The Administrative facilities including installation of Biometric computerized attendance and
identification equipment at both entry gates with improved security system, parking sheds and
new buildings for other ranks living accommodation with modern toilets. Keeping this objective
in mind the following scope of work is to be undertaken.
1. The buildings have been designed keeping in mind the concept of climatic conditions like
wind belts, sun rays etc., to prevent cost spent on lighting and ventilation systems.
2. Buildings have been designed in a manner where there is no hazard to sensitive and
expensive machine equipments. The buildings will be planned to minimize and ease in
the maintenance processes.
3. Spaces have been provided in necessary places for safety of employees during any
disasters and these places can be reached by the employees with ease. Provisions will
be given for preventing the leakage in the roofs during rainy season by repairing any
damaged sheets.
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Part-A DPR
4. Ventilators provided wherever required where the heat generated is more in the present
buildings due to the increase in the work load. Quality power connections will be made in
the present buildings, thereby making the building more efficient and safe.
5. The buildings were provided with proper security, safety and fire fighting equipments. Also
adequate parking, housekeeping and scarp disposal facilities have been included.
6. A structural analysis of the existing building were carried out and checked if they can be
refurbished or they have to be demolished to have a new modernised building to meet
good ventilation, natural lighting and clean work space requirements.
The department houses the following offices and facilities.
• Offices of the Commandant
• General Manager- Works
• General Manager- Administration
• General Manager- Planning &Progress
• R & D cell
• Establishment Officer
• Sub major
• Cashier
• Senior (JCO)
• Mill wing.
• MW and R&P
• Accounts officer
• Civilian Labour officer
• Head clerk
• Administrative Office
• Commandant Secretariat
• Telephone Exchange
• Coord Library
• ISO Cell
• Conference Hall
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Part-A DPR
• Establishment Office
• Legal Cell
• Union Office
• Accounts Office
• Timekeeper Section
• Computer Centre
• Server Room
1.13.2 Production Department

1.13.2.1 Engine Repair Group (ERG)
The Engine repair group is responsible for overhaul of engines of Engineer Equipment
undergoing overhaul in the workshop and also carrying out the overhaul of all types of
Engines as per integrated Headquarters of Ministry of Defence (Army) serials and direct
withdrawal.
 Issues & Gap analysis
• For overhauling all types of engines, the sheds having 3 bays with tapered roofs
supported with I sections in the middle and enclosed by RCC structures are not adequate
which are infirm and old.
• The high roof A.C sheeted building and its rooms are not adequate for assembling,
washing and stripping. The coverage is inadequate for overhead cranes.
• The space is constraint to establish overhaul and repair facilities and are not adequate to
adopt technical advancements. Ventilation of the building is very poor which affects the
workshop activities.
• The shop floor which is old and gets flooded during monsoon affecting the house keeping
and disposal facilities. Ventilation of the building is not sufficient for the repair works.
• The working State of the existing infrastructure is poor.
• The cleaning bays which are old high roof A.C sheeted building. The storage facilities are
not sufficient for positioning of the machines.
 Future expansion needs
• Demolition of old Industrial Shed and provision of new shed with raised platform to avoid
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Part-A DPR
the shop floor which is getting flooded during rainy seasons and to maintain dust, temp &
humidity control environment in the buildings
• The planned buildings are of RCC framed and steel construction with profile sheeting and
the floors are provided with proper cable trenches. The flooring will be with hardener
topping
• The new buildings have to be integrated and orientated to minimize energy consumption
as per the functional aspects.
• The buildings have to be provided with proper security, safety and fire fighting
equipments. And also adequate parking, housekeeping and scarp disposal facilities has
to be included.
• The internal drainage of large flat roofs introduces another piping system similar to that
for sanitary wastewater, to carry away storm water to separate underground storm
sewers. Heavy rainstorms can introduce huge influxes of water into storm sewers, and
sometimes this surge effect is tempered by the use of storm water retention ponds on.
1.13.2.2 KRAZ Repair Group (High Mobility Heavy Vehicle Group)

The KRAZ repair group (HMHV) is responsible for carrying out the overhaul of specialist 'B'
Vehicles of Russian origin for both Indian Army and Air force.
• For overhauling special ‘B’ VEHICLE, the sheds with GI sheeted roof supported with I
sections in the middle and enclosed G.I sheets are not adequate which are infirm and
old.
• The high roof G.I sheeted building and its rooms are not adequate for assembling,
• The space is constraint to establish overhaul facilities and is not adequate to adopt
technical advancements. Ventilation of the building is very poor which affects the
overhauling activities.
• The shed is not provided with repair ramp and ramps and pits for inspection. Separate
paint chamber are not available. The compressor room is old AC sheeted.
• The shop floor which is old and gets flooded during monsoon affecting the house
keeping and disposal facilities. Ventilation of the building is not sufficient for the repair
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Part-A DPR
works.
• The working State of the existing infrastructure is poor.
• The cleaning bays which are old high roof A.C sheeted building. The storage facilities
are not sufficient for positioning of the machines.
• Parking facilities are not adequate for hard standing machines with proper sheds.
• Demolition of old Industrial Shed and provision of new shed with raised platform to
avoid the shop floor which is getting flooded during rainy seasons and to maintain dust,
temp & humidity control environment in the buildings.
• The planned buildings are of RCC framed and steel construction with profile sheeting
and the floors are provided with proper cable trenches. The flooring will be with
hardener topping.
• The buildings have to be provided with proper security, safety and fire fighting
equipments. And also adequate parking, housekeeping and scarp disposal facilities has
to be included.
• The new buildings have to be integrated and orientated to minimize energy

consumption as per the functional aspects. The electrical wiring needs to be
modernized to improve the constraints and to meet the consumption requirements.
• The buildings which are to refurbished have to be upgraded or revamped for columns
and structures and by checking the column capacity of the columns for the EOT/ HOT
cranes.
1.13.2.3 Engineer Equipment Group

The Engineer Equipment Group is responsible for carrying out the overhaul of all types of
Engineer Equipment of Indian Army like Dozers, Backhoe equipment etc.
• For overhauling of Coles cranes on deposit repairs, the sheds having 2 bays with high
tapered roofs supported with I sections in the middle are not adequate which are infirm
and old.
• The high roof G.I sheeted building and its rooms are not adequate for assembling,
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Part-A DPR
• The shed is not provided with repair ramp and ramps and pits for inspection. Separate
paint chamber are not available. The compressor room is old AC sheeted.
• The shop floor which is old and gets flooded during monsoon affecting the house
keeping and disposal facilities. Ventilation of the building is not sufficient for the repair
works.
• The state of the existing infrastructure is poor.
 Future Expansion needs
• The unsafe buildings have to be demolished and newly constructed with better shop
aesthetics and with dust free environment in the buildings.
hardener topping.

consumption as per the functional aspects. The electrical wiring to be modernized to
improve the constraints and to meet the consumption requirements.
cranes.
• The workshop is to have a modern repair and inspection ramps in each shed is to be
designed and installed.
1.13.2.4 Fabrication Group

The Fabrication group is responsible for fabrication loads like body building of KRAZ & JCB
operator cabin
• For fabrication activities of the workshop for ‘A’ vehicles, the shed having 3 bays with
tapered roofs supported with I sections in the middle is adequate which are infirm and
old.
• The high roof A.C sheeted building is old and to be modernized
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Part-A DPR
• The unsafe buildings have to be demolished and newly constructed with better shop
aesthetics and with dust free environment in the buildings
hardener topping.

cranes.
The Fabrication group is to be divided in to the following sections based on their activities
• Bus body repairs & its ancillary sections
• Brake and Transmission Units
• Electrical Units
• Tyre section
• Machine Shop & Reclamation
• Chassis overhaul
• Repair and Scrapping
• Inspection Section & Chemical Lab
• Material Control, Wheel alignment, Work Study section
1.13.2.5 General Engineering Group & Ancillary Group

The General Engineering Group (GEG) is MOS for depot and spares for KRAZ Vehicle and
also it is responsible for the manufacture of jigs & fixtures for INSAS weapons system.
The Ancillary Group is responsible for manufacture of dies, spares and other items required by
production groups and also various depots and field units. It provides the central ancillary
support to the entire production group.
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Part-A DPR
• Lay out of the building are not centralized for the manufacturing and production works
with poor internal drainage system.
• The machine shop building is of old and infirm roof with steel fabricated pillars. The
carpenter shop located is outdated. The building is ventilated with centrally high roofed
truss G.I sheeted with 3 x 3 bays
• Electro plating area is enclosed by walls fixed with tiles at the inner side.
• Provisions for heat treatment and hydraulic pressing are limited.
• The moulding section is of GI sheeted roof with north lighting ventilation.
• The rooms for the tools and technical store are not provided.
• The internal drainage system has to be re-designed was noted.

• Demolition of old Industrial Shed and provision of new shed with raised platform to
avoid the shop floor which is getting flooded during rainy seasons and to maintain dust,
temp & humidity control environment in the buildings.
hardener topping.
• The buildings were provided with proper security, safety and fire fighting equipments.
And also adequate parking, housekeeping and scarp disposal facilities to be included.

cranes.
1.13.3 Works Department

1.13.3.1 Methods Engineering / Indigenization Section
Method Engineering Group is responsible for the methodization of production work. It
calculates the man-hours, costing, tooling and material requirement for line assembly work.
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Part-A DPR
This group is also the main R&D and design hub for indigenization of the spare parts. It
consists of following departments.
The Madras terraced roof building is very old with poor working State. Separate laboratories for testing
and training for the concerned staffs are not adequate
 Improvement opportunities
The purpose of the Method Engineering group is set up methodology for manufacture of
spares and also the indigenization of spares, they play a very important role.
• The division has to be provided with state of art material testing lab equipped with modern
gadgets to test physical and chemical properties of all types of materials.
• The latest high configuration computers, work station, printers, plotters are to be procured
for methods engineering division.
• The material testing lab is to be modernized by installing both Destructive and Non-
Destructive testing methods. The machines Up-gradation of training and skill to handle
and equipments selected here are of high technology and sophisticated ones required for
repairs and calibration.
1.13.3.2 Workshop Service group

Workshop Service Group is responsible for formulating the perspective plans of the workshop
services, installation of new machines, repairs and maintenance of all technical infrastructure
and PSMEs, initiate MES works for buildings, electrical power, water and allied facilities like
compressed air and environment control and housekeeping. The group also maintains
machinery folders consisting of receipt inspection, periodic inspection, machinery card,
machinery usage card and machine wise annual repair cost.

Space in the A.C sheet roof shed is not adequate for storage
• The unsafe buildings need to be demolished and newly constructed with better shop
• The planned buildings are of RCC framed and steel construction with profile sheeting and
507 ABW 18
Part-A DPR
the floors are provided with proper cable trenches. The flooring will be with hardener
topping.
• The new buildings have to be integrated and orientated to minimize energy consumption
as per the functional aspects. The electrical wiring needs to be modernized to improve the
constraints and to meet the consumption requirements.
• The buildings which are to refurbished have to be upgraded or revamped for columns and
structures and by checking the column capacity of the columns for the EOT/ HOT cranes.
• The modern heavy duty portable ramp is included.
• Advanced optical line network connection for internet and intra-net facilities are also to be
provided
• New building and infrastructure facilities have to be provided for storing tools and spares
required to maintain the Base Workshop.
1.13.3.3 Technical Training Cell

The technical training of civilians conducting trade tests for different trades for promotion and
ACP scheme including recruitment and supervisory tests. The technical training of Combatants
conducting trade test for HMT & MT drivers. The technical training of Apprentice conducting
screening test, all India Trade test and conducting RI classes of Apprentices on all working
days. Component and base level training by original equipment manufacturers of various
equipment is also organized in the workshop under the aegis of TT cell.
• There is a lack of proper classrooms required to train both Army and civilian operators
regarding the latest equipment that has to be installed during the course of the
modernization.
• Currently the training cell does not have proper training machineries available
• There is also an absence of a proper library for students of the Training cell to study and
learn about latest technologies.
• Adequate number of Sophisticated and modern classrooms has to be designed
• The class rooms needs to be provided with modern and comfortable furniture, facilities,
cabins and storage keeping in mind the comfort of the students.
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Part-A DPR
• Modern teaching and training aides like multimedia projector, DLP projector, LCD display
products, etc have to be installed in each classroom to ensure proper parting of
knowledge.
• A modern technical library has to be provided along with computer and internet facilities to
enrich the TT cell's students on future technologies. A provision has to be made to have a
digital library consisting of relevant technical literatures and books.
1.14 Proposed Facilities for Modernisation of Base Workshop

1.14.1 Layout of the Workshop
• The total area of 25.90 acres of the workshop includes Process and Non-Process Buildings.
In Proposed Master Plan the buildings have been grouped under as Process buildings (P)
and Non-Process Buildings (NP) as shown in the master plan.
• The following table shows the utilisation of land in 507 Army Base Workshop at Kankinara
\ S. No Area Details In Acres In Sq.m Percentage
1 Total Site Area 25.90 104827.13 100 %
New Buildings To Be Constructed -

2 7.45 30159.00 28.78 %
Process - Industrial Sheds
New Buildings To Be Constructed -

3 0.58 2356.00 2.22 %
Process - RCC Buildings
Old Buildings To Be Refurbished For

4 New Applications – Process (Industrial 1.09 4429.86 4.22 %
sheds)
5 Under Construction Buildings, Process 0.40 1621.67 1.55 %
Remaining area (Open area, Road area,

6 16.38 66286.03 63.23 %
Other infrastructure)
• The buildings are grouped based on the technical process which leads to efficient workflow
• Provision of state of art of PMSE’s, material handling equipments, and testing equipments
for all overhauling process to meet future load of the workshop
• Provision of modern reverse engineering facilities for indigenization in manufacturing of

spares
• Establishment of Manufacturing Execution System for plant automation, production control

and traceability of sub-assemblies
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Part-A DPR
• The Proposed Master Plan aims at modernizing 507 Army Base Workshop with Multi-
storied Buildings with dust, temperature and humidity control environment
• Modernization Process involves Green Building Concepts which refers to the incorporation
of environment friendly and resource efficient processes at each stage of construction, right
from site selection and designing to construction, operation followed by maintenance,
renovation or even demolition
• Provision of proper ventilation, lighting, fume extraction and f looring of all proposed and
refurbished buildings
• Adequate Pneumatic lines are proposed for operation of power tools
1.14.2 New Buildings to be Constructed (Process)
• Engineer Equipment Assembly Group
• Field Articulated Vehicle Assembly Group
• Field Articulated Vehicle Sub Assembly Group
• Engine Repair Group
• General Engineering Group
• Ancillary Shed
• Workshop Expenses Store / Battery Charging Station
• Body Repair Group
• Engine Test House
• Caustic Soda Washing
• OSS, MCO & KRAZ Stores
• Vehicle Stripping Shed
• Engineer Equipment Stripping / Sub Assembly Group
• Outer Traffic Stores
• ETP
• Scrap Yard
• UG Sump - 1 & 2
• Compressor Room – 1& 2

Part-A DPR
• Overhauled Vehicle Parking – 1 (11 Nos)
• Chassis Dynamometer
• Repairable Vehicle Parking – 1 (15 Nos)
• Repairable Vehicle Parking – 2 (15 Nos)
Note:
1. Specifications for Each Building has been enclosed at the end of this Volume
2. Individual Floor Plan, Section and Elevation for all the Buildings are enclosed in Part - A / Volume –
1 / Annexure – IIA
3. Electrical, Water Supply & Sanitary Lines and Fire Fighting Drawings for each building are
enclosed in Part - A / Volume – 1 / Annexure – IIB
1.15 Capacity enhancement due to modernisation

1.15.1 Field Articulated Vehicle output
After modernization of 507 ABW, the target for Field articulated Vehicle (FAV) overhauling is
increased from current capacity to 156 vehicles.
The detailed output calculations as follows
• Number of days for one vehicle output in one assembly line = 5 days
• Number of working days in a month = 21 days
• Number of vehicles delivered per month per assembly line = 4 Vehicles
• Number of assembly lines =3
• Number of vehicles delivered per month = 13 Vehicles
• Total number of vehicles delivered per year (13 x 12) = 156 Vehicles
1.15.2 FAV Engines output

After modernisation of 507 ABW, the target for FAV engine overhauling is increased from
current capacity to 204 engines
• Number of days for one engine output / assembly station = 5 days
• Number of Working days in a month = 22 days
• Number of engines delivered per month per assembly station = 4.4 engines

Part-A DPR
• Number of assembly stations =4
• Number of engines delivered per month = 17 engines
• Maximum output capacity of engines per year (17x12) = 204 engines
In addition to the above, the capacity enhancements also include enhancement of Engineer
equipment to 56 Engineer Equipment.
1.15.3 Process Improvements

 Loading/unloading Process
The highly damaged/repairable vehicle is unloaded from the trailer by using the state of art
hydraulic automated unloading system. The recommended system enables loading and
unloading process in a quick manner, very less effort of manpower and safe in nature.
 Stripping process
In order to ensure faster stripping process, customized power tools, conventional tools,
material handling equipments are recommended for stripping of the vehicle. The dirty
stripping area has been located separately as to ensure a clean working area from assembly
area.
 Modern washing/ degreasing/ paint removal processes

A state of art facility for washing, degreasing, paint removal and r ust removal and painting
before reclamation and coating processes are provided after reclamation in the central facility
recommended for this workshop.
 Caustic Washing
Modern washing, degreasing and paint removal process is recommended for sub-assemblies.
The caustic washing booth is planned to remove grease, oil and paint on the parts of sub-
assemblies by following a sequence of flushing the cleaning agent and water with high
pressure for quick removal of paint, oil and grease. Immersion type degreasing process has
been completely eliminated by the above recommended process to avoid complexity in
handling of sub-assemblies during the cleaning process.
 Shot Blasting
Shot blasting and grid blasting machines have been proposed for additional surface cleaning
and rust removal of sub-assemblies. The shot/ grit blasting machine is the state of art
equipment which ensures faster and efficient process to clean the sub-assemblies.

Part-A DPR
 Sub-assembly reclamation
Modern power tools, PMSE’s and testing equipments have been provided for reclamation of
sub-assemblies. The sub-assembly reclamation is carried out in the concern groups and the
suitable machinery and test equipments have been provided for the particular sections. The
recommended modern test equipments ensure the quality of overhauled sub-assemblies with
standard quality parameters before final assembly.
 Assembly Process
The recommended assembly line consists of 5 workstations arranged in a linear fashion and
Double Slat Conveyor is proposed for automatic transportation of assembly process. The
assembly line and its stages are designed based on the flow process analysis. The specified
sub-assemblies are on kits and supplied to the stations in which a task is performed on the
assembly process. Two-sided lines: consist of two serial lines in parallel, in which pairs of
opposite workstations (left-hand side and right-hand side) process simultaneously the same
work piece. This configuration is highly used in automotive industry. Some tasks can be
assigned only to one side, some tasks can be assigned to either side, and some tasks must
be assigned to both sides of the line simultaneously.
The In-line assembly process is recommended by considering the bottlenecks in the current
process, lack of suitability of machines, modern material handling equipments and testing
equipments. The improvements are obtained by using ECRS principles (Eliminate, Combine,
Rearrange, and Simplify).
• In the In-Line assembly process, the assembly bay provided with two sets of double slat
conveyor for transportation of vehicle assembly from one station to another station.
• There are Five Assembly Stations recommended for FAV assembly process. The activities
carried out in each station is listed below
Assembly station :1 Hub axle, suspension and Engine fitment 3 days

Clutch assembly, gear box, transfer gear box winch gear
Assembly station :2 3 days
box fitment
Assembly station :3 Electrical, Pneumatic, Hydraulic fitments 3 days
Assembly station :4 Body, Cabin, Wheels, Steering gear box fitment 3 days
Assembly station :5 Final fitments & Testing 3 days

Part-A DPR
1.15.3.1 Modern Spares Supply system

 Kitting
A Kit is defined as a specific collection of components and/or subassemblies that together
(i.e., in the same container) support one or more assembly operations for a given product or
shop order. Several kits can be supplied to the assembly station at the same time but the
parts needed for each specific assembly object are held (“kitted”) together
1.15.3.2 PERT analysis of FAV
The Process Evaluation and Review Technique (PERT) of overhauling process of Field
Articulated Vehicle is given as follows.
• After washing FAV is brought to the stripping shed where, vehicle is stripped and the sub-
assemblies are sent to their respective overhauling sections.
• The body, cabin and engine are stripped on the first day. The wheels, hub axle and
suspension are stripped on the second day and sent their respective overhauling
sections.
• The gear box, transfer gear box, winch gear box, electrical & pneumatic line and all other
accessories are stripped on the third day and sent to their respective overhauling
sections.
• The completely stripped chassis is then sent to the caustic washing on day four and then
taken to the body repair section for reclamation process.
• The completely overhauled chassis after painting is brought to the assembly line. Since
each assembly stages are allocated three days, the subassemblies are assembled as
follows, (D - Start of overhauling process)
Station Sub-assemblies Assy End Day
Assembly station :1 Engine, Hub-axle, Suspension D+24
Assembly station :2 Cabin, Gear box, Transfer gear box, Winch gear box D+27
Assembly station :3 Electrical & Pneumatic D+30
Assembly station :4 Body & other accessories D+33
Assembly station :5 Final fitment & testing D+36
The process Flow Chart and PERT Chart of FAV is enclosed in Part – A / Volume – 1 / Annexure – I
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Part-A DPR
1.15.3.3 Technical Process

Based on the detailed work study made on the existing technical process of the 507 Army
Base workshop following groups/sections are recommended as Production and works
department.
Production Department
• Field Articulated Vehicle Group (FAV)
• Engineer Equipment Group (EEG)
• Engine Repair Group (ERG)
• General Engineer group (GEG)
• Body repair group
• Battery charging section
• Wheel Repair Section
Works Department
• Methods Engineering / Indigenization Section
• Workshop Service group
• OSS
• Material Control Group
• Technical Training Cell
1.15.3.4 Centre of Excellence

The following Center of Excellences are focused for 507 ABW, Kankinara
• Automatic Gear Box Testing
• Hydraulics
• Rubber & Plastic Moulding
• Manufacturing of spares.
• Reverse Engineering and indigenization
1.15.3.5 Automatic Storage and Retrieval System
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Part-A DPR
The workshop has been provided with state of the art ASRS system for spares storage and
retrieval along with the conventional storage system for bulk items. The ASRS system consist
of the following systems
• Pallet ASRS with loading capacity of 1000 kg
• Mini Load ASRS with loading capacity of 300 kg
1.16 Allied Requirements
The following are the major Allied Requirements proposed for modernization of 507 ABW
 Manufacturing Execution System (MES) / (IT Infrastructure for automation process) for
manufacturing processes.
 LAN for all offices
 The workshop has been provided with a robust support network (Tablets and workstations
suitable for MES) for capturing the real time data from the shop floor.
 Central Effluent Treatment Plant (ETP)
 The technical buildings have been provided with appropriate fire fighting equipments as
per the NBC 2005.
 Centralized air conditioning system has been provided in Engine repair group as per
requirement
 Improved safety and security system
 Uninterrupted Power Supply is proposed for the sensitive and electronic equipments
 Most appropriate and fool proof security system for information security and physical
security
 Access control system
 Fire detection and alarm system Microprocessor based
 Portable fire extinguishing system
 Fire Sprinkler System
 Heat and smoke detectors
 Fire alarm system
 Fire pump house
 Fire suppression system
507 ABW 27
Part-A DPR
 Effluents collected from various manufacturing processes in the workshops will be treated
using Effluent Treatment Plant.
 It is proposed to develop a wastewater management system for the entire site.
 Entire waste water would be collected by a separate network of drainage pipes from the
individual buildings
 Biometric computerized attendance and identification equipment for main entrance
 Energy Production of 300 kWh/kWp/ Year by providing Solar power system
 Box type wall mounted speakers have been provided in all the floor areas.
 Round type ceiling mounted speakers has been provided in every office room, conference
hall, & Technical HQ
 Wall mount type, miniature system speakers has been considered for the staircase areas
 Ceiling mount type dual speakers has been considered for the Parking Area
 Video conferencing system is proposed
 Modern housekeeping facilities
 Split Air conditioning units are proposed to achieve dust free environment and to maintain
the required temperature
 Air Shower & Air Curtains are provided to make dust free environment
1.17 List of Buildings Under Construction

 Workshop Service Group Tools Stores
 MCO Building / Overhauled Vehicle Parking
1.18 Old Buildings to be Refurbished for New Application
The following buildings and facilities are not become outdated, recommended for
refurbishment to meet the requirements of overhauling process.
S. No Existing Building Proposed Building
Process Buildings
1 Painting Area Painting Area
507 ABW 28
Part-A DPR
S. No Existing Building Proposed Building
2 Dust Proof Painting Booth Dust Proof Painting Booth
3 Workshop Service Group / OTRP OTRP
4 Receipt & Issue Receipt & Issue
5 Vehicle Washing Booth Vehicle Washing Booth
6 MAG-10 MAG-10
7 Method Engineering Section Method Engineering Section
 Recommendations
• Floor level of the existing building to be raised to match the proposed elevation level
• Glass panels on windows to be repaired and replaced as required
• It is recommended to provide weathering tiles with leak proof coat at the open terrace to
arrest the dampness and leakage on the building
• False ceiling to be repaired and replaced as per requirements
• Rainwater outlets to be checked for leakage
• Existing Water lines, sewer lines and storm water drains to be checked and suitable repair
and replacement to be provided
• Colour wash and Proper Painting required on walls
• Requirement of painting over the joineries
• Ceramic tile flooring to be provided as per the specifications and the toilets needs to be
renovated
• Damaged rain water outlet pipes and its gutters to be rectified
• Anti corrosive coating and painting to be done on steel truss and angles
• Galvalume sheet with polycarbonate sheet to be reworked for good lighting
• Windows found damaged to be repaired and Anodized aluminium window, UPVC window
and ventilator shutters to be provided as per the requirements
• Damaged windows, glass panels and AC Sheets to be rectified and replaced as per the
requirements
507 ABW 29
Part-A DPR
• Cracks found on the walls and ceiling to be repaired
• Drainage Network to be reworked and new channel for drainage flow to be provided for
the toilets.
In addition to the above emphasis will be given as on the following Refurbishment of Existing
Buildings
• Flooring – Damaged Flooring to be modernized with the facilities like Non-Skid Ceramic
tiles, wall dadoing etc
• Toilet lines found in poor and depleted conditions to be modernized
• Officer Rooms to be refurbished with split AC provisions
• False Ceiling to be provided for the rooms with AC Provisions
• Sunshades, roof tiles found damaged to be rectified
• Rain water Pipes to be refurbished with new pipes
• Septic tank, Manholes, Plinth Protection to be refurbished
• Damaged Doors & hinges to be replaced
• All Locks to be checked and refurbished in working condition
• Dilapidated Electrical wiring to be replaced
The extent of damage of the existing building can be exactly accessed only during the commencement
of Rectification works since the building is presently in use and also the implementation schedule may
take at least 3 to 4 years from the date of assessment of existing condition of the buildings.
1.19 Old Buildings To be Demolished

Since the existing infrastructure and facilities have become outdated being old vintage and have
been rendered deficient due to addition of load over the years, in terms of range (type) and
quantity, the old Workshop sheds are not suited to meet the present day requirements of
overhaul of present equipment with high technology and quality.
507 ABW 30
Part-A DPR
List of Buildings to be demolished
Year of
S.No List of Buildings Vintage Remarks
Construction
The Building is to be demolished due to its

OBD-01. Machine
1 1942-43 72 Years vintage & cannot withstand the proposed
Shop
process of General Engineering Group.
The Building is demolished due to its vintage

& cannot withstand the proposed process of
OBD-02.
2 1943-44 71 Years Field Articulated Vehicle Sub Assembly
Engine Repair Group
Group, Engineer Equipment, Assembly
Group.

& cannot withstand the new process of Field
OBD-03.
Articulated Vehicle Sub Assembly Group,
3 MCO Group & Coles 1943-44 71 Years
Field Articulated Vehicle Sub Assembly
Crane
Group, Engineer Equipment, Assembly
Group.

OBD-04. & cannot withstand the new process of Field
4 1943-44 71 Years
Body Repair Section Articulated Vehicle Sub Assembly Group &
Also For New Road Infrastructure.

OBD-05.
5 1950-51 64 Years & for New Road Infrastructure & Body Repair
Shed NO 9
Group, ERG, Engineer equipment group etc.
The Building Is Demolished Since It Is Not In

OBD-06.
6 NA NA Use & To Construct New Engine Test House,
Abandoned
New Road Infrastructure & STP

OBD-07. Battery
7 1943-44 71 Years & to construct ancillary shed with new road
Charging Shop
infrastructure.
507 ABW 31
Part-A DPR
Year of
Construction
The Building is demolished for the new

8 OBD-08. Toilet 1950-51 64 Years
formation of road infrastructure.

9 OBD-09. Toilet 1950-51 64 Years
OBD-10.
10 KRAZ Blacksmith 1950-51 64 Years
Shop
The Building is demolished to construct guard

11 OBD-11. Building NA NA
shelter & site development work.

OBD-12.
12 NA NA shelter & for the new formation of road
Guard Room
infrastructure.
The Building is demolished to construct

OBD-13.
13 2001 13 Years caustic soda wash & for the new formation of
Engine Washing Bay
road infrastructure.
OBD-14. Central The Building is demolished for the new

14 2007 7 Years
Compressor formation of road infrastructure.
OBD-15. The Building is demolished for the new

15 1942-43 72 Years
GEN MGR Prod formation of road infrastructure.
The Building is demolished for Repairable

OBD-16. vehicle parking shed, WES / Battery Charging
16 1942-43 72 Years
Shed section and for the new formation of road
infrastructure.
The Building is demolished to construct pm &

OBD-17.
17 NA NA qc office & also for the new formation of road
EMS
infrastructure.
507 ABW 32
Part-A DPR
Year of
Construction

OBD-18.
18 NA NA & cannot withstand the new process of
MI Room
General Engineering Group.

OBD-19.
19 NA NA & to construct ancillary shed with new road
MCO Stores
infrastructure.
OBD-20. The Building is demolished due to its vintage

20 1950-51 64 Years
KRAZ Stores & to construct OSS MCO & KRAZ.

21 1943-44 71Years
Shed formation of road infrastructure.

22 1943-44 71 Years
Shed formation of road infrastructure.
OBD-23. Painter &

Decorator Carpenter The Building is demolished due to its vintage
23 1950-51 64 Years
Upholster & Pattern & to construct OSS MCO & KRAZ.
Maker

OBD-24.
24 1942-43 72 Years & to construct OSS MCO & KRAZ & also for
Ladies Lunch Room
the new formation of road infrastructure.

OBD-25.
& to construct repairable vehicle parking &
25 Renovated REC 1950-51 64 Years
also for the new formation of road
Room
infrastructure.

26 1950-51 64 Years
Water Tank formation of road infrastructure.
507 ABW 33
Part-A DPR
Year of
Construction
The Building is demolished to construct car

OBD-27.
27 NA NA parking & also for the new formation of road
VIP Car Parking
infrastructure.

OBD-28.
28 1943-44 71 Years & for the new formation of road infrastructure
Shed
& Technical HQ Building

OBD-29.
29 1976 38 Years parking & also for the new formation of road
KOT
infrastructure.

OBD-30.
30 NA NA formation of road infrastructure & also for
CMD
landscaping architecture

OBD-31.
31 1943-44 71 Years & to construct KOTE & also for the new
MT Shed
OBD-32.
Electroplating
32 1943-44 71 Years Combatant Lunch hall, MT Parking & also for
T/Coppersmith
the development of road infrastructure.
Blacksmith

33 OBD-33. Moulder NA NA construction of Medical Inspection and for the
formation of road infrastructure

34 Fire Station & Guard NA NA construction of car parking and for the
Room formation of road infrastructure

construction of car parking and for the
507 ABW 34
Part-A DPR
Year of
Construction

OBD-36.
36 1986 26 Years construction of car parking and for the
Guard Room

OBD-37.
37 1986 26 Years security complex & also for the development
Guard Room
of road infrastructure.
OBD-38. Cycle The Building is demolished for the new

38 NA NA
Stand formation of road infrastructure
The Building is demolished to construct outer

OBD-39.
39 1986 28 Years traffic stores & also for the new formation of
Guard Room
road infrastructure

OBD-40. Labour
40 NA NA shelter & also for the new formation of road
Room
infrastructure

41 1943-44 71 Years
Shed & for the new formation of road infrastructure

42 OBD-42. Canteen NA NA combatants Trade Centre & also for the new
The Building is demolished to construct MT

parking & Combatant Lunch hall

507 ABW 35
Part-A DPR
Year of
Construction
OBD-45. Security The Building is demolished for the new

45 NA NA
Office construction of Technical Head Quarters

OBD-46.
46 1942-43 72 Years & to construct technical headquarters & also
Est Office
for the new formation of road infrastructure
The Building is demolished to provide

47 OBD-47. Shed NA NA
Compact Substation – 2 with 500 KVA
OBD-48. The Building is demolished to construct two

48 NA NA
Cycle Stand wheeler parking & pump house
OBD-49. The Building is demolished for the site

49 1943-44 71 Years
Shed Development

50 1943-44 71 Years
Shed formation of road infrastructure

OBD-51.
51 1943-44 71 Years formation of road infrastructure & also for site
Shed
Development

OBD-52.
Shed
Development

OBD-53.
Shed
Development

OBD-54.
Shed
Development
507 ABW 36
Part-A DPR
Year of
Construction

OBD-55.
Shed
Development

OBD-56.
Shed
Development

OBD-57.
57 1943-44 71 Years repairable vehicle parking & for the new
Adm Blocks

OBD-58.
58 1943-44 71 Years repairable vehicle parking & for the new
Shed

59 NA NA
Bedi formation of road infrastructure.

60 1959-60 55 Years
Toilet formation of road infrastructure.

OBD-61.
61 NA NA technical headquarters & also for the new
Water Reservoir

OBD-62.
62 NA NA parking & also for the new formation of road
Car Wash
infrastructure

63 NA NA
Bedi formation of road infrastructure
OBD-64. The Building is demolished to construct

64 1943-44 71 Years
Shed general engineering group
507 ABW 37
Part-A DPR
Year of
Construction

65 NA NA

66 1959-60 58 Years
Toilet & for the new formation of road infrastructure

OBD-67.
67 NA NA security complex & also for the development
Temple
of road infrastructure.

68 1986 28 Years
Guard Room formation of road infrastructure

OBD-69.
69 1959-60 55 Years traffic stores & also for the development of
Toilet

70 NA NA
Water Reservoir general engineering group

71 1959-60 55Years
Toilet general engineering group

72 1959-60 55 Years
Toilet formation of road infrastructure

73 NA NA
Water Reservoir formation of road infrastructure

74 1959-60 55 Years
Toilet formation of road infrastructure

75 NA NA
OBD-76. The Building is demolished to construct body

76 NA NA
Water Reservoir repair group & engine repair group
507 ABW 38
Part-A DPR
Year of
Construction
OBD-77. Caustic The Building is demolished to construct body

77 NA NA
Tank repair group

OBD-78.
78 1943-44 71 Years formation of road infrastructure for engine
Shed
repair group

79 1959-60 55 Years
Toilet & for the new formation of road infrastructure

80 NA NA

81 1943-44 71 Years
Shed & to construct engine test house

OBD-82.
82 NA NA formation of road infrastructure for loading &
Water Tank
unloading area


84 1959-60 55 Years

85 1986 28 Years
Guard Room formation of road infrastructure
OBD-86. Guard The Building is demolished for the new

86 NA NA
Room formation of road infrastructure

OBD-87.
87 NA NA traffic stores & also for the development of
Cycle Shed
OBD-88. Engine The Building is demolished to construct car

88 NA NA
Test House parking & also for the development of road
507 ABW 39
Part-A DPR
Year of
Construction
infrastructure.
The Building is demolished based on the

requirement & Review meeting discussion
OBD-89. made with DGE & COMMANDANT for the
89 1950-51 64 Years
Kraz Group New Proposal of Body Repair Group - Engine
Repair Group & Engineer Equipment
Stripping / Sub Assembly Group.

90 NA NA
Cabin Repair Section formation of road infrastructure
The above buildings to be demolished due to
• Most of the buildings have built way back in 1960’s which is ineffective to meet the changing
requirements since the load profile of the workshop has changed considerably over the last 45
years with increased range of sophisticated, complex, multi-disciplinary equipment being
introduced in the Army
• In order to create space for new buildings
• The maintenance needs of the buildings are heavy, and are often ineffective (such as
perennially leaking roofs that pose a hazard to sensitive and expensive equipment)
• Old and Defect prone Electrical Operated Crane (EOT)
• Dilapidated and unplanned electrical wiring with ad-hoc electrical arrangements and improper
ear thing
• Damaged flooring
• Vintage and worn out buildings
• Requirement of additional space to establish overhaul and repair facilities for variety of ensuing
load
• Worn out internal and external paintings
• The workshop is facing quality space constraints
507 ABW 40
Part-A DPR
• To adopt technical advancements on the counters of civil counterparts
• Improper assembly line layouts
• The buildings are old and infirm
• Low lying area
• No Central Sewerage system
• Floors are damaged and slippery in nature due to oil leakage
• Inadequate drainage system that causes flooding of low lying buildings during rainy season
• Non-availability of quality power backups
• No central sewerage system
• Old vintage of plant and machinery
• Inadequate safety and security arrangements
• Poor ventilation and environmental control
• No proper storage systems

However, beyond the transition period the condition of the existing structures to be assessed by the
bidder at the time of bidding process
1.20 Key Features of Building Layout

The layout of the workshop encompasses the study and understanding of existing infrastructure
with its constraints, works already in progress and proposed construction of new and modern
state of the art infrastructure which is functionally efficient, re-appropriation of existing
infrastructure and demolition of unwanted and old infrastructure.
The features of the proposed layout are listed below,
• The layouts are proposed by grouping the buildings according to their functionality.
• The buildings are designed by keeping in mind the concept of climatic conditions like
wind belts, sun rays etc., to prevent cost spent on lighting and ventilation systems.
• Separate vehicles park zones are proposed for civilians and employees
• Separate buildings are proposed for accommodating individual and group employees.
• Adequate and careful electrical arrangements for more number of giant exhaust fans and
other accessories are proposed.
507 ABW 41
Part-A DPR
• The buildings are designed to work safely with high heat, open flame and environmentally
responsible.
• Since the machines are too compact in the manufacturing zone it will occupy only less
space thereby minimizing the construction costs of the new buildings.
• As they are grouped with respect to their functions shortening the logistics base of the
workshop is possible which the major advantage of the proposed layouts.
• The layouts are planned, presenting an organized look of the workshop and they are
redesigned as per the latest trends in industrial construction.
• Buildings are designed in a manner where there is no hazard to sensitive and expensive
machine equipments.
• Proper lighting and windows were provided in the buildings.
• The Layout is planned in such a way that even Phased out activities can be carried out
without disturbing the existing setup.
• The Layout is planned with Effluent Treatment Plant, Sewage Treat Plant and Rain water
harvesting system. This will facilitate the utilization of used water (Water Management) after
Recycling and it will avoid dearth within the campus.
• The Layout is prepared with separate block for Fire station with water – tank, this will
facilitate to avoid any huge damages caused during Fire at any part of the Building.
• Pedestrian Pathways are provided
• Ventilators are provided wherever required where the heat generated is more in the present
buildings due to the increase in the work load.
• The layouts are proposed with the adequate drainage system
1.20.1 Green Concept

Green buildings basically mean the environmental friendly buildings, which are constructed
in the healthiest way they can be to avoid hazardous impacts on the environment. The
resources like land, water, energy etc. are judicially used and the environment goals are set
prior from the starting of the construction of such buildings.
The making of these eco-friendly buildings fundamentally involves the following
consideration in the Base workshop
507 ABW 42
Part-A DPR
Initially, the environmental components like air, water and natural resources are used in the
most efficient way during design and other renewable energy sources have also been
utilized during construction Stage. Energy sources, which results to be harmful for the
environment, are avoided.
 Design Plans for the Buildings
• The master plan is prepared precisely keeping in view of the benefits of orientation of
the proposed buildings
• Ensuring Natural Light to all the Buildings.
• All the main rooms of the working spaces are placed in the direction of Garden and
towards the sunshine, while secondary/supporting rooms are planned towards the
avenue direction.
• The direction of prevailing winds is considered in order to ensure entry of fresh air and
ventilation into the working space.
• Before preparing the Master Plan, the site assets and features are studied, so that the
instruction of the proposal doesn’t harm the pristine nature of the site.
• In the premises, the environmental components like air, water and natural resources
are used in the most efficient way.
• Existing Water lines, sewer lines and storm water drains are planned for suitable repair
and replacement
• Effective External storm water drains are planned
• The layouts are proposed with the adequate drainage system
• The treatment of effluents collected from the various manufacturing processes in the
workshops will be carried out using Effluent Treatment Plant.
• The sewage/Domestic waste from all the buildings will be treated in the Sewage
Treatment Plant.
• The treated water from the ETP & STP will be used for Arboriculture, Landscaping etc.,
• It is proposed to develop a wastewater management system for the entire workshop.

Entire waste water would be collected by a separate network of drainage pipes from the
individual buildings
• Water conserving practices can reduce the landscape water requirement
507 ABW 43
Part-A DPR
 Maximize the use of Natural Daylight

There are two types of buildings were planned, Steel Structure & RCC Structure to house the
technical process & Non-technical process requirements, Use of natural daylight has been
the focus of modern architecture. By this all the buildings in the 507 ABW are designed to
ensure maximum daylight.
Roof of the Steel Structure is designed with double skin roofing of Galvalume sheet and
polycarbonate sheets with the slope of 1 in 10. Polycarbonate sheets are transparent panels
used to ensure maximum natural light to the building. Additionally, Ridge ventilators and
turbo ventilators are also provided for better Ventilation & Aeration. Turbo ventilators are
powered by the wind to create effective ventilation for workshop buildings. Turbo ventilators
are round metal vents with fins in them. Even the slightest breeze can be enough for the
turbo ventilator to rotate. Rotation causes a centrifugal force on the tip of the fins which suck
out the stale hot air from inside of the workshop building. The faster the wind, the faster the
turbine will rotate and exhaust the heat, smoke, fumes, humidity, etc.
All the RCC Buildings are planned with sufficient number of windows to allow the natural
daylight and provides better aeration.
 Environment - Friendly materials used for construction:

All the buildings are planned to ensure that the materials and resources used are
environmental-friendly. The recommended building materials are preferred keeping in the
mind of 'Waste reduction plans
 Design of healthy indoor air quality

HVAC (Heating Ventilation and Air Conditioning) is the technology of indoor and automotive
environmental comfort. The main purposes of a Heating Ventilation and Air-Conditioning
(HVAC) system are to help maintain good indoor air quality through adequate ventilation with
filtration and provide thermal comfort.
 Proposed HVAC System for 507 ABW

1. Split Units are provided wherever required in process buildings, to maintain the required
temperature in the office rooms, Conference halls & hydraulic labs and other rooms as
per requirement
507 ABW 44
Part-A DPR
2. Centralized Air Conditioning system is provided in engine assembly bay, FIP section
and other required areas in Engine Repair Group.
3. Air Shower & Air Curtains are provided to make dust free environment to the section,
the following buildings are planned with the same in the Process building,
• Field Articulated Vehicle Assembly Group
• Engineer Equipment Group
• Engine Repair Group
1.20.2 Structure of DPR

Detailed Project Report has been restructured as two parts, Part A & Part B
• Part A – Process Buildings
• Part B – Non-Process Buildings
 Part A Process Document (Technical Infrastructure)

This volume includes the particulars about the Process Buildings / Technical Infrastructure
that has been designed largely for the Base Workshops improvements and other necessary
Production / Overhaul oriented requirements as follows.,
1. PMSEs
2. Test Equipment
3. Material Testing Equipment
4. Process Buildings required to house PMSEs
5. CNC M/Cs
6. Power Management System for PMSE & Power Back up
7. Distribution Network Control System (Automation – Manufacturing Execution system)
8. IT Support for various process and Data capture
9. Internal Water supply, Sanitary, Electrical works and Fire fighting
10. Inventory Storage and Management
11. Heat Ventilation & Air Conditioning (HVAC)
507 ABW 45
Part-A DPR
 Part B – Non-Process Document

This volume includes all other non-process buildings / infrastructure other than
Process/technical Infrastructure that is not making direct impact on technical process of the
base workshop.
1.20.3 Detailed list of DPR volumes
The Part-A of DPR volume is divided into two volumes- Volume -1 DPR and Volume -2 RFP
volumes. The following table gives the details of the Part-A volumes – process document.
Part B – Non-Process Document is given in executive summary Part-B (Non-Process)
1. This report is given in Volumes as listed below.
Volume - 1 DPR
Annexure - I Process Charts
Annexure - II A Drawing Volume (Building Drawings)
Drawing Volume (Internal Electrical, Water Supply, Sanitary,

Annexure - II B
Firefighting drawings)
Annexure – III A Abstract Cost Estimate
Annexure – III B Detailed Cost Estimate
Cost Estimate for Plant Machinery Special Equipment

Annexure - IV (PMSEs), Testing Equipment ,Material Handling Equipment&
Inventory Storage
Annexure - V Geotechnical Investigation Report & Survey Drawings
Annexure - VI Manufacturing Execution System & Support Facilities
2. Request For Proposal (RFP)

The request for proposal consist of the following volumes
RFP – Process Buildings

Volume - 2 This volume consists of the general conditions for the project based on
Defence Procurement Procedure (DPP 2013)
507 ABW 46
Part-A DPR
Scope of LSTK Contract

Annexure - I This volume consists of all the scope of work for Civil, Mechanical, Electrical,
Water supply, Sanitary, Firefighting, HVAC, Housekeeping & Electronics
Specifications for Civil Works

Annexure - II
This volume consists of specifications for civil works
Specifications for Plant, Machinery & Special Equipments

Annexure – III
This volume consists of specifications for PMSE’s
Annexure - IV Specifications for Testing Equipment

This volume consists of specifications for Testing equipments
Annexure - V Specifications for Material Handling Equipment

This volume consists of specifications for Material Handling Equipment
Annexure – VI Specifications for Electrical Works and HVAC system

This volume consists of specifications for Electrical works and HVAC works
Annexure – VII Specifications for Storage solution, & Support facilities for
Manufacturing execution system
This volume consists of specifications for Storage solution, Solar Power
System & Support facilities for Manufacturing execution system
Annexure – VIII Specifications for Fire Fighting & Housekeeping Equipment

This volume consists of specifications for Firefighting & Housekeeping
Equipment
Annexure - IX Specifications for Water Supply, Sanitary & Effluent Treatment Plant
This volume consists of specifications for Water Supply, Sanitary & Effluent
Treatment Plant
Annexure - X List of Vendors & Contractors

This volume consists of all the vendors and contractors for PMSEs, Testing
Equipment, Material Handling Equipment and allied services
Annexure - XI Format for Bid Analysis

This volume consist of Technical Evaluation Matrix for all the PMSEs, Testing
507 ABW 47
Part-A DPR
equipment and Material Handling Equipment
Annexure - XII Draft Supply Order

This volume consist of Draft Supply Order for all the PMSEs, Testing
equipment and Material Handling Equipment
Annexure - XIII Bill of Material

This volume consists of bill of material for PMSEs, Testing Equipment, and
Material Handling Equipment & Inventory Storage.
507 ABW 48
Technical Process
Part-A DPR
Part-A
Technical Process
1.0. STUDY FINDINGS AND RECOMMENDATIONS

1.0.1 Existing Infrastructure
The limitations of the existing infrastructure at 507 ABW, Kankinara are as under:
 Non-availability of quality power backups.
 Inadequate range and numbers of Material Handling Equipment (MHE).
 Inadequate assembly Line Layouts.
 Non availability of LAN and Database Management Software
 Lack of conductive environment and storage facilities.
 Lack of automation in inventory control and management.
 Lack of automation in human resourceadministrationandotheroffice operations.
 Lack of integrated and automated system of information flow
 Lack of smoke detectors and automated fire-fighting arrangements
 Lack of safety and security systems.
 No central sewerage system
 Lack of Parking Systems.
1.0.2 Need for Modernization

Keeping in view the change in the technical load on the workshop over the years and
limitations of the existing infrastructure, all the infrastructure needs of the workshop as far as
buildings, electricity and water have been covered in the modernization plan. However, there is
a requirement to take stock of present day situation and future technical requirements in terms
of modern production, processing and repair facilities required so as to modernize the
workshop in a planned and holistic manner.
1.0.3 Master Plan

The Master Plan is designed based on grouping the process buildings at the nearest locations
and the general facilities like stores and washing booth are centrally located.
 The master plan layout is divided into three major zones such as process buildings are
located in the North zone called as technical zone, Manufacturing of spares and stores
are located in middle zone and Administrative buildings are in South zone
507 ABW 49
Part-A DPR
 In a master layout, grouping of building is designed in a way to minimize the movement of

vehicles, equipment andmaterial handling equipments.
 Two gates (Gate – B and Gate – D) are designed for easy access of the trailer during
loading and unloading activities of the repaired heavy vehicle and engineer equipment.
 The R&I building, vehicle water washing booth, caustic washing booth, stripping shed,
FAV assembly Group, FAV sub-assembly Group, Engineer Equipment Group, Engine
Repair Group, Body & cabin repair group, Post overhauling group, OTRP, Painting shed
and parking sheds are closely located within a maximum distance of 400m.
 Separate Parking sheds has been designed forrepairable, repaired vehicles and
equipments.
 State of art hydraulic ramp is designed at the loading and unloading point.
 The roads at the technical zone are designed by considering the adequate turning radius
for trailer, heavy vehicle and engineer equipment access.
 The Production Manager Office Complex has been centrally located to the technical zone
for easy supervision and interactions
 The Production Manager Office Complex is integrated with QA & QC sections consisting
of inspection standard cell and testing laboratory along with sample room.
 In the master plan, the Power House is planned and located adjacent to the process
buildings to minimize the cost of cable networking.
 ETP has been located near the water washing booth, caustic washing booth, stripping
shedand Engine repair group to minimize the cost of pipe line networking.
 In the master plan two gates (Gate – A& Gate – C) are provided with mustering facilities
for civilian entry.
 Scrap Yard has been designed in the technical zone (near the painting shed)
 The administration zone of the master plan includes administrative block, officers car
parking shed, KOTE, workers amenity hall, MI room, fire station, MT parking, MT Stores,
Method engineering group and WSG Stores.
 There are threeGuard Sheltersand one security complex building has been included in the
master plan.
 The security complex located at Gate – A carries mustering system, fire alarm control
room, CCTV monitoring control room, a duty JCO room and a CASO room in the ground
floor and accommodation facilities in G+1 and G+2 floors
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 The Guard Shelter located at Gate – B has been accommodated for Guard Room and
Guard Rest Room
 The Guard Shelter located at Gate – C designed with scanning &biometric mustering
systems along with duty JCO room in the ground floor and JCO Rest Rooms in G+1 floor
 The FOL station and its store are located centrally between OSS stores and ERG for fuel
filling of both overhauled vehicles and MT vehicles.
 The Workshop Expense Store and Battery Charging station has been accommodated in a
single building where, the storing can be done in ground floor and the first floor acts as a
battery charging station
 UG Sump has been planned near Engine Test house and MAG-10 building
 Partially covered parking sheds for reparable vehicles are planned at three locations such
as
(i) Shed behind painting shed
(ii) Shed in frontof Power house
(iii) Shed adjacent toOSS/MCO building
The master plan is designed with the following constraints in the work shop.
Constraints:
1. The location of WSG (Existing building).
2. The painting area and the dust free painting both are (existing buildings) located for away
from the process buildings.
3. Shortage of land area for future expansions and future load
4. Method engineering group is located for away from the process buildings.
5. The WSG stores’ building (Under construction) is also located for away from the process
buildings.
1.1 PRODUCTION GROUP
The production group consists of the following groups
 Kraz Repair Group (Field Articulated Vehicle Group)
 Engineer Equipment Group (EEG)
 Engine Repair Group (ERG)
 General Engineer group (GEG)
 Fabrication Group
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1.1.1 KRAZ REPAIR GROUP (FIELD ARTICULATED VEHICLE GROUP)

1.1.1.1 Function of the group
The KRAZ repair group (Field Articulated Vehicle Group) is responsible for carrying out the
overhaul of specialist 'B' Vehicles of Russian origin for both Indian Army and Air force.
1.1.1.2 Current process

The current process flow chart of heavy vehicle is given in the Annexure 1.1.1 – Aand the
current process is given below.
The vehicle with the work order is received from the R&I section, the work order includes the
P.I report which details the works that are to be completed on the vehicle.It also includes the
list of spare parts that the overhauling will require. Once the vehicle is taken for overhauling it is
then washed in the group and then stripped. The body of the vehicle is sent to the fabrication
group along with the chassis for any repairs in the body & cabin. During the stripping process
the stripped components are classified into three items
 Serviceable
 Unserviceable
 Re-workable
The serviceable components are sent to the concerned overhauling sections and then sent to
assembly. Unserviceable components are completely replaced and new components are fitted.
Re-workable components are those which only need minor works and then they are sent to
assembly area. Currently the assembly of vehicle is carried out as gang type assembly system.
The chassis of the vehicle is located at an assembly point in the assembly bay and all the
overhauled components and sub-assemblies are brought from the service sections and stores
and then assembled on the vehicle. In this gang assembly system, men, materials and
machines are moved to the assembly point, which leads to improper process control. Once the
components are assembled on the vehicle, certain testing process is carried out of components
fixed on to the vehicle is done. After testing, the body and cabin received from the fabrication
shop after repairs is fixed onto the vehicle. The initial offer is made and WI is done, any defects
found during the initial inspection are rectified at this stage and the vehicle is given for final
offer and WI inspection. Once the vehicle has passed the inspection the painting process of the
vehicle is done and the work order is completed and the overhauled vehicle is sent for
dispatch.
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1.1.1.3 Current workflow

The current workflow has been given in the flowchart (Annexure 1.1.1 - A) and detailed
workflow has been given in the PERT diagram. The PERT diagram tracks the flow of all major
assembly of the engine with the number of man-hours needed for overhauling of each
component. The PERT diagram also gives the present Gaps in the process, given in Annexure
1.1.1 – B. The PERT diagram gives the overall process time for the entire process to be
completed. The process time is arrived by adding up of days for components which has the
highest value among a group of similar operations like overhauling. The PERT diagram clearly
marks out the days needed for each process; from this the bottlenecks in the process can be
identified.
1.1.1.4 PERT analysis for current process:

The PERT diagram of current overhauling process of heavy vehicle is given in the Annexure
1.1.1 - B and the PERT diagram has been analyzed as below.
The PERT diagram of the overhauling process of heavy vehicle repair group shows the lead
time and the total man-hours needed to overhaul a vehicle. Both the lead time and the total
time are calculated by excluding the engine overhaul time, because a spare engine is
considered to be readily available and the old engine is swapped for an overhauled engine
received from ERG. The process time required for overhaul of a vehicle is 54 days. The
process time is arrived from the following processes in the PERT diagram
 Inspection report - 3
 Stripping - 8
 Washing - 8
 Suspension Assembly - 14
 Assembly - 11
 Initial offer & painting - 4
 Final offer & documentation - 6
 Total - 54 days
From the PERT diagram it can be observed that the O/H of suspension system needs higher
time and the gear box section needs lesser time. Also it is observed that the gap in idle time
between suspension and gear box section is almost two times. Two gear boxes can be
overhauled during overhauling time of one suspension assy. The bottleneck condition of the
process is observed that the entire process of O/H the vehicle is waiting for the arrival of major
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sub-assemblies like suspension system. The new process plan proposed has been designed to
eliminate these bottlenecks in the overhauling process.
1.1.1.5 Issues & Gap analysis

The need of new modern plant and machinery for KRAZ (FAV) overhauling group was
studied.
 Lack of modern test rig & testing facility was noted.
 Lack of space for stripping, washing, paint and repair ramp were observed.
 Need of compressed air line for the entire plant was noted.
 Need of modern chassis dynamometer & manipulator were noted.
 The parking space of the KRAZ (FAV) vehicles needs to be hard floored to prevent
flooding during rains and also a new shed is too constructed was observed.
1.1.1.6 Improvement opportunities:

The vision Statement of 507 Army Base Workshop has incorporated an objective for FAV
group. The aim of this group is to become the “Centre for Industrial and Technological
Excellence for overhaul of all Specialist Vehicles of Russian Origin”.
 The current process layout has been studied in detail and a current process flow was
determined and its drawbacks found out and based on these studies a new process
layout has been designed to ensure stream line stage wise overhauling process, smother
flow of work in various stages, and better shop aesthetics
 The current plant & machinery capabilities to meet the current and future requirements
were studied. Based on the studies equipment requirement for the group was analyzed
and a machinery list has been proposed.
 Provision of proper material handling equipments to meet the future load of the group
 Provision of component level testing to ensure quality standards are met.
1.1.1.7 Future expansion needs:

 While the process layout was studied, provisions were also given for designing
workstation layout with an ergonomic study to ensure that the worker has an ease of use
of the machine and to avoid fatigue and injury. The ergonomic layout also incorporates 5S
principle and lean manufacturing principles to ensure higher production rate.
 The workshop is to have a modern repair and inspection ramps in each shed is to be
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 Modern and heavy duty CNC Milling and Turning centers with multi-axis movements along
with NC controller system are to be installed to ensure handling the future loads of the
workshop in an efficient way.
 Modern and heavy duty EOT cranes are to be installed to replace the existing OHT cranes
and these cranes are designed to have movement in both X-Y axes in order to access the
entire work area easily.
 The modern and latest Electrical forklifts with excellent hydraulic system are most suitable
for material handling purposes.
 Due to installation of newer and advanced machine system in the workshop, the entire
pneumatic and hydraulic systems are to be designed based on the load.
 Modernized caustic soda washing units along with hot water washing units are to be
incorporated in the workshop for cleaning of sub-assemblies.
 A separate painting section with automatic sprayers is to be developed and installed.
 For the testing of the finished vehicles, there is a need to establish an automated heavy
vehicle chassis dynamometer with modern sensors, data acquisition system integrated
with computer and latest software for data processing.
 A detailed plan for the electrical layout of the plant is developed to accommodate the
newer machines that are to be installed in the workshop. A modern industrial electrical
wiring system is proposed to meet to the needs of extreme conditions, offering premium
safety against electrical shocks, High electrical conductivity and durability.
 The electrical plan is also to include separate plans for the special need conditions of the
workshop including the equipments needed to maintain HVAC conditions and Clean
Room conditions
1.1.1.8 Recommended process:

The following are the recommended process improvements for FAV group. (Annexure 1.1.1
– C)
1.1.1.9 Loading & Unloading:

The State of art hydraulic ramp is recommended for loading and unloading of High Mobility
Heavy Vehicle and Engineer Equipment. The trailer that carries the heavy vehicle is parked at
the loading / unloading location, where the vehicle is unloaded by a hydraulic ramp. The
hydraulic ramp rises up from the ground level by pillar type of actuating mechanism, up to the
trailer level. Once the vehicle is completely parked on the ramp, the winch rope hook is
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dismantled and the ramp is operated to move down with smooth manner to the ground level.
Portable crane or TATRA AV-15 vehicle can also be used to pull the repaired vehicle from
trailer to the hydraulic ramp.
Transportation of Repaired Vehicle:

Two options are recommended for this process
Option -1: Mobicon Transportation system
Option – 2: Utility trailer
Option – 1:Mobicon system

A modern state of art material handling system, Mobicon is recommended for transportation of
repairable heavy vehicle and engineer equipment from one point to other locations. The
Mobicon system handles the transportation of a container in an excellent manner, therefore the
same functionality of Mobicon is recommended for handling repairable vehicle. The vehicle can
be easily loaded on the transiflats (without side gates) as shown in the figures (1,2 & 3) and
removable hand lid can be fitted on the transiflats to restrict the motion of repairable vehicle
and can be transported by mobicon to wherever required location. Customization of present
Mobicon model would be highly suitable to meet this transportation need.
Option – 2:
A new technique consisting of Utility trailer has been recommended for transportation of
repaired vehicle from one place to another place.
The utility vehicle is a low level trailer having a sliding bracket which is fitted with a winch rope
system as shown in figure 4. When the winch rope gear box is operated by a motor, the
bracket will move from one end of the trailer to another end (Forward and backward direction)
depending upon the direction of rotation of the winch drive. The trailer carries a roller platform
at both the sides of the sliding bracket. The roller platform enhances the trailer to pull the
repaired (even punctured) vehicle from ground level to the trailer level in an easy manner.
Once the vehicle is loaded on the low level trailer, it can be transported anywhere in the
workshop by means of a towing truck. Wherever required, the low level trailer can be parked
and the winch drive is operated to push out the repaired vehicle smoothly by means of the
sliding bracket. The roller platform of the trailer is used to load and unload the repaired vehicle
with less friction and less effort.
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Fig1: Mobicon with vehicle mounted on transiflats platform
Fig 2: Transiflats platform
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Fig 3: Typical Mobicon- Handling container
Fig 4: Schematic diagram of the utility trailer
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The FAV overhauling process can be divided into a number of stages as follows.
1. Water washing process
2. Stripping process
3. Degreasing & paint removal process
4. Sub assembly repair & overhauling process
5. Assembly process
6. Test & Review process
7. Defect rectification process
8. Finishing & painting process
1.1.1.10 Water Washing Process:

A state of art water washing booth is recommended for complete cleaning of heavy vehicle.
The water washing booth is a fully covered booth with sliding doors in the front side for easy
loading and unloading of heavy vehicle inside the booth. All the walls excluding the door, top
and bottom sides of the booth carries array of water injecting guns through which pressurized
water is flushed out. The repaired heavy vehicle is parked inside the booth with the help of low
level utility trailer. The sliding doors are closed to avoid water leakage during washing.
The array of water guns increases the degree of washing process by flushing pressurized
water from all sides. The used water is collected at the bottom of the washing booth and it is re-
circulated after filtering the dust & rust particles. Special kind of clearing agents like soap oil
can also be supplied through the guns for some time to improve the quality of washing process.
The water washing process is recommended as sequential manner like water washing, soap oil
washing, and water washing.
By considering the volume and structure of the heavy vehicles and economical consideration,
the dryer system is not recommended in this process because after washing, the vehicle is
directly goes to stripping station. Hence it is observed that the drying process is not necessary
for heavy vehicle.
The existing washing shed of size 19m x 25m x 7m (L x B x H) is recommended for water
washing process. There are two washing booths of each size L x B x H = 5m x 12m x 5m
recommended in this shed for heavy mobility vehicle and engineering equipment respectively.
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Fig 5: Water washing plant

1.1.1.11 Stripping Process
The stripping shed of LxBxH – 30m x15m x 8m - is recommended for complete stripping
process of Field Articulated Vehicle (FAV). The shed is completely covered by walls in three
directions along with roofing structure. The front side of the shed is fully open for easy access
of repaired vehicle. The stripping shed is designed to strip sevenFAV vehicles at a time. One
20T EOT and 10T EOT crane is provided in this shed for handling of body, cabin, engine and
other heavy duty sub-assemblies. The stripping shed is provided with 12 nos. of power tools
kits along with four conventional tool kits for stripping process.
 The body and cabin are stripped and sent to caustic washing and repair section by means
of trailer truck (lengthy chassis truck).
 The engine is stripped and mounted on the engine stand and transported to the ERG by
means of battery operated truck.
 All other sub-assemblies are stripped and transported to the FAV sub-assembly repair bay
by means of battery operated truck.
 Finally the chassis is sent for caustic washing and then it is sent to body repair group for
any chassis repair work and painting process.
 The floor area of the stripping shed is provided with a slope of 1.5% for easy washing of
the floor and the effluent is drained to ETP.
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1.1.1.12 Degreasing and paint removal process:-

Modern degreasing & paint removal process is recommended at two locations as follows.
(i) Caustic washing shed provided near to the water washing shed for chassis, cabin and
body.
(ii) Caustic washing shed provided inside the FAV sub-assembly group for major sub-
assemblies like gear box, transfer gear box, axle unit, and clutch assembly.
 The caustic washing booth is a closed booth with sliding doors consisting of carriage on
rails. The parts like body, cabin and chassis are mounted on the carriage and loaded
inside the booth. The booth carries an array of flush guns on all five sides like rear, left,
right, top and bottom excluding the sliding door side.
 An efficient cleaning agent (not only caustic soda) is recommended for degreasing &
paint removal process. The cleaning agent impinges on the surface of the components
and sub-assemblies for a specified time to remove the grease and paint.
 The caustic washing booth is planned to remove grease, rust and paint on the parts of
sub-assemblies by following a sequence of flushing the cleaning agent and water with
high pressure for quick removal of paint and rust.
 Similarly the caustic washing booth is also recommended inside the FAV sub-assembly
overhauling group. The booth carries a carriage on rails and array of flush guns in all five
sides along with a sliding door. Any kind of sub-assembly like axle unit, gear box, transfer
gear box can be loaded onto the carriage table and sent inside the booth for degreasing
& paint removal.
 Immersion type degreasing process has been completed eliminated by the above
recommended process and also for easy handling of sub-assemblies like chassis, cabin
and body.
 In the recommended process, the caustic washing booth can be used for any kind of
parts & sub-assemblies and also any combination of sub-assemblies can be loaded on
the carriage table for paint stripping process.
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Fig 6: Degreasing plant

1.1.1.13 Shot Blasting
In addition to the degreasing booth, shot (or) grid blasting process is recommended in the FAV
sub-assembly overhauling group for paint removal process at component level.
Fig 7: Shot blasting plant
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1.1.1.14 Sub-assembly repair & overhauling process

After complete stripping of the heavy vehicle, the engine is sent to ERG for repair &
overhauling and all sub-assemblies like axle unit, suspension, gear box, transfer gear box,
winch gear box, clutch assembly, steering gear box are sent to FAV sub-assembly group.
 The Chassis, body and cabin are sent to the body repair shed after degreasing and paint
removal process.
 The wheels are sent to the OTRP for repair and reclamation process.
 One building of size 25mX115m is allotted for sub assembly over hauling process.
This Group consists of the following sections.
(a) Caustic washing booth – 117.6 m2
(b) Shot Blasting unit – 84.7 m2
(c) Painting section - 60 m2
(d) Clutch assembly on section - 143.56 m2
(e) Gear box – 126.1 m2
(f) Transfer gear box – 100 m2
(g) Steering gear box – 100 m2
(h) Axle unit section – 122.4 m2
(i) Winch gear box – 147.63 m2
(j) Hot & cold ancillary section – 148.55 m2
(k) Machine shop – 208.55 m2
(l) OSS stores – 94.77 m2
(m) Expandable stores – 45.59 m2
(n) Tool room – 45.59 m2
(o) Scrap stores – 47.92 m2
(p) Testing section -222.9 m2
Each and every sub-assembly OH section consists of facilities for stripping, minor repair,
reclamation, and assembly process.
 Sufficient work tables and power tool kits are recommended for all sub-assembly
overhauling sections.
 Major repair work with regards to sub-assembly is planned in the machine shop which
carries all kind of machining, welding, fabrication and polishing machines.
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 All testing facilities like test jig for gear box, transfer gear box, axle, clutch assembly,
winch gear box are centrally provided in the testing section.
 After overhauling, assembly and testing of the sub-assemblies, they are sent to centrally
located paint booth where the recommended painting process is carried out.
 After painting process the repaired sub-assemblies are stored in the respective sub-
assembly sections during assembly process.
1.1.1.15 Assembly Process:

The Assembly process of FAV group is recommended as follows,
1.1.1.16 In – line Assembly:

The basic assembly line consists of a set of workstations (5 Stations) arranged in a linear
fashion, with each station connected by a material handling device (Double Slat Conveyor).
The basic movement of material through an assembly line begins with a part being fed into the
first station at a predetermined feed rate. A station is considered any point on the assembly
line in which a task is performed on the part. These tasks can be performed by machinery,
and/or human operators. Once the part enters a station, a task is then performed on the part,
and the part is fed to the next operation. The time it takes to complete a task at each operation
is known as the process time. The cycle time of an assembly line is predetermined by a
desired production rate. This production rate is set so that the desired amount of end product
is produced within a certain time period. In order to improve productivity, various techniques
have been developed to handle problems from different areas such as work measurement,
method improvement, and quality improvement tools and line balancing technique. Efficiency
is a tool to measure any industry organization's performance while productivity is used to
measure this efficiency. The In-line assembly process is recommended by considering the
problems of bottleneck process, machine idleness and operator fatigue and improvements
can be done using ECRS principles (Eliminate, Combine, Rearrange, and Simplify).
Two-sided lines: consist of two serial lines in parallel, in which pairs of opposite workstations
(left-hand side and right-hand side) process simultaneously the same work piece. This
configuration is highly used in automotive industry. Some tasks can be assigned only to one
side, some tasks can be assigned to either side, and some tasks must be assigned to both
sides of the line simultaneously.
 In the In-Line assembly process, the assembly bay provided with two sets of double slat
conveyor for transportation of vehicle assembly from one station to another station.
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 There are five assembly stations are recommended for FAV assembly process. The
activities carried out in each station is listed below
Assembly station :1 Hub axle, suspension and Engine fitment 3days
Clutch assembly, gear box, transfer gear box
Assembly station :2 3days
winch gear box fitment
Assembly station :3 Electrical, Pneumatic, Hydraulic fitments 3days
Assembly station :4 Body, Cabin, Wheels, Steering gear box fitment 3days
Assembly station :5 Final fitments & Testing 3 days
 The chassis is repaired and painted in body repair shop and it is taken as the first part for
vehicle assembly process. The repaired chassis is transported by a utility truck from body
repair shop to FAV assembly line.
 The chassis is loaded on the fixture stands which are already mounted on the double slat
conveyor. The chassis is mounted on the fixture stand by using EOT crane so that the
front and back end portions of the chassis only mounted on the fixture stand.
 A separate tool line is provided for the location of pneumatic tools that are specialised for
the function of the assembly station.
 Also a separate Kit storage line is also provided in order to place the kits supplied by the
OSS store and also for temporary storing of sub-assemblies.
 There are three EOT cranes whose capacity are 20T, 10T and 5T provided in each
assembly bay for handling various sub-assemblies, body, chassis, cabin and Engine.
 In each and every assembly stage inspection by QA & QC team is recommended to
improve the quality of vehicle assembly process.
 During assembly process the sub-assemblies are taken from the respective sections by
means of battery operated trolley.
 The engine is taken to reclamation process from ERG by means of utility truck.
 The body and cabin are taken from body repair shop by means of utility truck.
 The wheels are collected from OTRP by means of utility truck.
 Other reclamation parts/ spares are collected from OSS stores.
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Assembly Line Balancing Problems (ALBP)

The distribution of the entire workload to the work stations of an assembly line, as the main
focus of assembly line balancing problems (ALBP) have been extensively studied.
Typical assembly line

As previously mentioned, the Assembly Line Balancing Problem (ALBP) consists in assigning a
set of indivisible tasks to an ordered sequence of workstations in such a way that precedence
constraints are maintained, the workload of each workstation does not exceed the cycle time
and a given efficiency measure is optimized. The term balancing arises from the fact that the
workload of each workstation is to be balanced. Since a perfect balance (i.e., an identical load
for all workstations) is rarely achieved, workstations idled time becomes a main optimization
objective. On the other hand, as the assembly line global cost is influenced by the number of
workstations, the classical objective of assembly line balancing problem is minimize the
number of workstations for a given cycle time, which is referred to as time-oriented line
balancing. Furthermore, production rate can be maximized by minimizing the cycle time of a
given number of workstations. Problems that seek to minimize costs are regarded to as cost-
oriented line balancing. On the other hand, profits oriented are those which implicitly consider
the profit attained by the line.
The objectives of ALBP are to minimize cycle time, reduce number of workstations, or level
manufacturing workload. Often, more than one efficiency measure is to be optimized. The
following are some of the minimization criteria: throughput time cost of machinery and tools,
inventory cost, dead time, number of buffers, line stoppage time, and variances in workstation
times. Some maximization objectives include production rate (which is equivalent to minimize
the cycle time), line efficiency and profit. A further objective considers that the workload of each
workstation needs to be as similar as possible.
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The benefits that assembly lines provided for businesses are mainly the following:
 Provides a regular flow of material; allows using of power looms and human capacity at
the highest level; aims to minimize blank of duration; distributes empty times between
work stations properly; minimizes production costs.
 In addition, in order to respond to diversified customer needs, companies have to allow
for an individualization of their products. Multipurpose machines with automated tool
swaps allow for facultative production sequences of varying models at negligible setup
costs. This makes efficient flow-line systems available for low volume assembly-to-order
production and enables modern production strategies like mass-customization, which in
turn ensures that the thorough planning and implementation of assembly systems will
remain of high practical relevance in the foreseeable future.
1.1.1.17 Effective ergonomics:

Ergonomics is an applied engineering discipline used to design the work environment to reduce
injury and illness and support human performance.
A successful ergonomics process can be defined as one that is sustainable, business driven,
and injury-reducing. Thus, the three critical elements of an effective ergonomics process have
been identified are:
 Risk reduction strategies: A proactive approach to ergonomics means that factors known
to contribute to injury or illness are identified and addressed early.
Observation is the most basic form of assessment, which by the aid of assessment tools, firstly
including the identification of risk factors, and then implementation of the solutions. The goal is
to capture existing insight and information from the work force, and then quickly move to
resolving problems. To take advantage of this simple approach to risk assessment, companies
provide basic ergonomics awareness training and develop a process for employees to identify
known challenges and provide suggestions. Providing a simple mechanism (like a feedback
form) can ensure that all input is captured and reviewed.
So, the three basic steps of risk management are: Recognition, Evaluation, and Control (REC).
REC is a systematic approach that must involve a cycle of measuring, improving, and re-
measuring to maintain a safe environment. The REC approach is simple and effective: identify
the challenge through basic awareness, evaluate the degree of risk, and then implement
control strategies.
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Those ergonomic risks that are not easily resolved require analysis with a higher level of
knowledge, usually from a specifically trained group of employees, engineers, or facility
managers. The assessment tools must provide quantitative data for identifying and prioritizing
ergonomic risks, and they should identify alternative job improvements. They must be simple
enough to be used reliably by health and safety professionals, engineers, and ergonomics
committee members, but they should provide enough information to be useful. Efficient
assessment tools help users to obtain information needed to make decisions with as little effort
as possible. A structured risk factor survey or office needs questionnaire is usually the best
approach. Some assessments make pre-approved, easy-to-implement solutions available,
while others may require more advanced control strategies and an in-depth analysis to reduce
risk.
 The element ― “Fix Once, Repeat Many” or FORM, is applied in avoiding the design
amnesia. Namely, many companies are focused just in fixing the existing ergonomics
problems, ignoring the future. This is known as design amnesia, a vicious circle in which
known problems are replicated in new designs even after effective solutions to the
problems have been defined and implemented. Since the designers have a greater
understanding of technical requirements and not in people requirements, the design
amnesia often occurs.
 Exclusion of the design amnesia is possible by the application of two simple
mechanisms: education for the specialists to recognize ergonomics problems and easy
access to the effective design solutions.
 With the application of FORM strategy, products, manufacturing equipment, and office
workstations optimize human performance, and one can prevent design mistakes from
the start. Design requires informed decision making to formulate the best solution while
balancing a wide range of trade-offs. The ergonomic quality of the design is often
overlooked for those who must use the product or equipment. This is simply due to the
lack of education for technical personnel in the principles of ergonomics and human
performance.
 Management of human capital is the third element of effective ergonomics.
 This element quantifies the bottom-line impact of improvements based on a healthy
workforce and improved productivity. With a good design, people perform more efficiently
and reliably and are less likely to get hurt. Too many business managers, however, the
benefits of good ergonomics are not so clearly defined.
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 A good investment – the investment in ergonomics is justified by the reduction of the

worker’s compensation cost.
Specifically, some of the goals of ergonomics are:
 Applied in the equipment design, as for the workplace, intend to maximize productivity by
reducing operator fatigue and discomfort. Benefits provided by ergonomics application in
assembly systems design are first of all linked to the reduction in occupational injury risks
and in the improvement of health condition and motivation of human resources.
 To accommodate differences in strength and body size among different workers.
 To remove barriers to productivity and performance.
 Continuous improvements and breakthroughs.
The reduction of injuries and illnesses related to inadequate workplace design requires a risk
management approach combined with the application of engineering solutions. Risk
management begins with the identification and measurement of workplace ergonomics risk
factors. After risk factors in the workplace are well understood, equipment and workstations can
be redesigned to minimize exposure to the risk factors. The application of engineering solutions
to reduce exposure to ergonomic risk factors requires a two-pronged approach: retrofit
solutions are applied to existing work stations and equipment, and the design of new
workstations and equipment encompasses ergonomic criteria (“Fit Once Repeat Many”).
Modern Assembly Line Methods

Using modern assembly line methods, manufacturing has become a highly refined process in
which value is added to parts along the line. Assembly line manufacturing is characterized by
concurrent processes, or multiple parallel activities that feed into a final assembly stage. These
processes require a well-planned flow of materials and the development of an advanced
materials and supply infrastructure.
Just-in-time (JIT) manufacturing methods have been developed to reduce the cost of carrying
parts and supplies as inventory. Under a JIT system, manufacturing plants carry only one or a
few days' worth of inventory in the plant, relying on suppliers to provide parts and materials on
an "as needed" basis. Future developments in this area may call for suppliers to establish
operations within the manufacturing facility itself to provide for a more efficient supply of
materials and parts.
Modular assembly is another advanced assembly line method that is designed to improve
throughput by increasing the efficiency of parallel subassembly lines feeding into the final
assembly line. As applied to automobile manufacturing, modular assembly would involve
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assembling separate module chassis, interior; body their own assembly lines, then joining them
together on a final assembly line.
1.1.1.18 Post-Over Hauling Process
Post overhauling process is recommended for FAV overhauling process includes Trials &
Review and Defect rectification process.
 Initial testing of the vehicle is carried out in the FAV assembly section where two sound-
proof rooms of size 14m x 8m is given for static testing
 The state of art multi classis dynamometer is provided in the parking shed for testing
and defect rectification purposes.
 After defect rectifications, the vehicle is taken to painting shop for final painting and
marking process and after that it is taken to covered parking shed.
1.1.1.19 Pert Analysis of Kraz (FAV)

The pert diagram for Kraz overhauling is given in the annexure 1.1.1-D. The Kraz vehicle
after washing is brought to the stripping shed where, the body, cabin and engine are stripped
and then sent to their respective overhauling sections. The wheels, hub axle and suspension
are stripped and sent to their respective overhauling sections. The gear box, transfer gear
box, winch gear box, electrical & pneumatic line and all other accessories are stripped and
sent to their respective overhauling sections. The completely stripped chassis is then sent to
the caustic washing and then taken to the body repair section. The completely overhauled
chassis after painting is brought to the assembly line on D+22. Since each assembly stages
are allocated three days, the subassemblies are assembled as follows
Station Sub-assemblies Day

Assembly station – 1 Engine, Hub-axle, Suspension D+24
Assembly station – 2 Cabin, Gear box, Transfer gear box D+27
Winch gear box
Assembly station – 3 Electrical & Pneumatic D+30
Assembly station – 4 Body & other accessories D+33
Assembly station – 5 Final fitment & testing D+36
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1.1.1.20 Flow path analysis of FAV overhauling process (Annexure – 1.1.1-E)

Transportation Mode of
Sl Name of item Distance
Transport
No From To (in m)
Duration
Working Process
Washing booth 365 Utility Trailer
1. Repairable FAV Parking Shed (AIN-17)
(RTIN-05)
Vehicle Washing booth Vehicle Stripping 75 Utility Truck
2. Repairable FAV
(RTIN-05) shed (TIN-12) 30 Sec
Stripping process
Vehicle Stripping Shed Caustic Washing Utility Truck
1. Body 43
(TIN-12) (TIN–10) 20 Sec
Caustic washing Body repair Section Utility Truck
2. Body 248
(TIN–10) (TIN-08) 1.3 Min
Vehicle Stripping Shed Caustic Washing Utility Truck
3. Cabin 43
(TIN-12) (TIN–10) 20 Sec
Caustic washing Body repair section Utility Truck
4. Cabin 248
(TIN–10) (TIN-08) 1.3 Min
Vehicle Stripping Shed Engine Repair group Utility Truck
5. Engine 182
(TIN-12) (TIN-04) 25 Sec
6. Wheels Vehicle Stripping Shed OTRP (RTIN-03) Utility Truck
379
(TIN-12) 1.5 Min
7. Sub-assemblies Vehicle Stripping Shed FAV Sub assembly Utility Truck
74
(TIN-12) Group (TIN-03) 35 Sec
8. Chassis Vehicle Stripping Shed Caustic Washing Utility Truck
43
(TIN-12) (TIN–10) 25 Sec
9. Chassis Caustic washing Body repair section Utility Truck
248
(TIN–10) (TIN-08) 1.3 Min
Assembly Process
1. Chassis Body repair Section FAV Assembly (TIN- Utility truck
20 2.3 min
(TIN-08) 02)
2. Sub-assemblies Battery
FAV Sub assembly FAV assembly bay
10 operated trolley
Group (TIN-03) (TIN-02)
20 Sec
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Transportation Mode of
Sl Name of item Distance
Transport
No From To (in m)
Duration
3. Cabin Body repair Section FAV Assembly (TIN- Utility truck
20
(TIN-08) 02) 1 Min
4. Body Body repair Section FAV Assembly (TIN- Utility truck
20
(TIN-08) 02) 1 Min
5. Engine Engine Test house (TIN- FAV Assembly (TIN- Utility truck
295
09) 02) 1 min
6. Wheels FAV Assembly (TIN- Utility truck
OTRP (RTIN-03) 178
02) 1 min
Post overhauling Process :-
FAV assembly bay (TIN- FOL Station (TSIN- Self movement
7. Repaired HMHV 197
02) 03) 1.2 min
Self movement
8. Repaired HMHV FOL (TSIN-03) Covered parkingShed 178
1.2 min
Painting Shed RTIN- Self movement
9. Repaired HMHV Covered parking Shed 135
01 2.3 min
Covered parking Self movement
10. Repaired HMHV Painting Shed RTIN-01 132
Shed 3 min
1.1.1.21 Loading & Unloading Process

 Loading of repairable parking shed - 30 Min
 Unloading of repairable at water washing Shed - 30 Min
 Loading of repairable at water washing shed - 30 Min
 Unloading at Shipping Shed - 30 Min
 Loading & Unloading of body - 30 Min
 Loading & Unloading of Cabin - 30 Min
 Loading & Unloading of Chassis - 30 Min
 Loading & Unloading of wheels - 01 Hour
 Loading & Unloading of Sup assemblies - 30 Min
Total Hours - 5 Hours
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1.1.1.22 Machinery Requirement:

Plant Machinery & Special Equipment
Sl.No Machine No Name of the Machine Qty
A) Stripping Shed
1 PTK001 Power Tool Kit 12
B) Sub Assembly Shed
1 RDM001 Radial Drilling Machine 1
• Drill Capacity (M.S/C.I) 80 mm
• Metric Threads fine pitch 65 ФX4 mm
• Any other Threads fine pitch 2 1/2',X 6.35 mm
• Light boring capacity in Steel 200 mm
• Power Supply A.C 415Volt, 3 Phase, 50 Hz
2 SGM001 Surface Grinding Machine – Model 1 1
• Grinding Capacity Length 300 x Width 600 x Height 300 mm
• Longitudinal Table Travel 620 mm
• Cross Table Travel 325 mm
• Max. Distance From the Spindle Centre to The Worktable Surface 400
mm
3 PWM001 Portable Welding Machine 5
• Primary Voltage 400 Volt, 3 Hp, 50-60 Hz, ±15%
• Fuse Size (slow) 30 A
• Protection/ Insulation Class IP23/H
• Current Range 5-400 A
4 GSM001 Gas Welding Machine 4
• Welding and Cutting Capacity (Thick) 1 Inch
• Oxy-Acetylene ratio for Welding 1.1:1-
• Oxy-Acetylene ratio for Cutting 1.5:1-
• Height 58/23 cm/in
• Diameter 16/6 cm/in
• Average Weight 11/25 kg/lb
5 PDM001 Pillar Type Drilling Machine 2
• Drilling capacity: 40mm
• Spindle nose: MT-4
• Dist. from column to spindle Max/Min: 1020-400mm
• Dist. from spindle to Base Max/Min: 1180-300mm
• Number of spindle speed: 8
• Spindle speed range: 90 to 1000 rpm
• Number of power feeds: 2
6 BGM001 Bench Grinder Machine 2
• Type: Double side
• Motor Power: 2 HP
• Speed: 2800 rpm
• Wheel size: 250 x 50 mm
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7 ACW001 Arc Welding Machine 1
• Primary Voltage 400Volt, 3Phase, 50-60 Hz ±15%
8 BDR001 Bench Drilling Machine 1
• Drill Capacity in steel 20 mm
• Tapping capacity in steel M 12 mm
• Power Supply A.C 0.75/1 HP
9 PHS001 Power Hack Saw 1
• Cutting Capacity of round bar 175 mm
• Cutting Capacity of square bar 175 mm
• Cutting Capacity 45º
• Stroke (approx) 60 – 75 mm
10 SBM001 Shot Blasting Machine 1
• Cabin size: 14620 x10000 x 4000
• Hook loading capacity: 5000 Kgs
• No. of turbines: 4
• Turbine power: 4 x 20
11 FES001 Fume Extraction System 1
Arm Dimension :
• Dimensions (Diameter x Length) : 180 x 2144 mm
Air Volume :
• Variable Speed Control : 115V
• CFM Low : 400
• CFM High : 1300
Base Unit :
• Dimensions ( L x W x H) : 765 x 765 x 1080 mm
12 HPB001 Hydraulic Press Brake 1
• Bending force 175Ton
• Working length 3100mm
• Distance between uprights 2550mm
• Throat depth 400mm
• Daylight 515mm
13 SSP001 Shaft Straightening Press 1
•Capacity : 100 Tons
•Stroke : 305 mm
•Bore : 205 mm
•Ram Speed:
•Press : 20 IPM
•Return : 26 IPM
•Weight : 5445 kg
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14 PGM001 Pedestal Grinding Machine (Heavy Duty) 3
Size of grinding wheel:
• Vitrified Bond : 600 x 75 x 203.2
• Resinoid Bond :600 x 65 x 203.2
• Wheel Centre distance :1280
• Diameter of spindle :50
• Motor Power :7.5Hp
• Speed of Motor :1440 rpm
15 UMM001 Universal Milling Machine 1

• Distance spindle to table surface 0 – 400 mm
• Distance between spindle center to vertical guide way 175 mm
• Motor 4 KW
• Table Size 1370 x 360 mm
• Table Travel 800 (750) x 300 mm
16 HHA001 Heavy Heating Arrangement for Localised Heating 1

Input Power
• 460–575 V,
• 3-Phase, 60 Hz
• 400 – 460 VAC,
• 3-Phase, 50/60 Hz
Output Frequency
• 5–30 kHz
Rated Output
• 35 kW at
• 100% Duty Cycle
17 MDM001 Magnetic Drill Machine 2

• Diameter : 52 mm
• Depth : 52 mm
• Twist Drills : # 2 Morse Taper 23mm

19 FIE001 Fitting Equipments 20
20 FIT001 Fitting Tools 20
21 CSW001 Caustic Soda Wash Booth 1
22 PAB001 Paint Booth 1
23 WKT001 Work Table 20

24 STR001 Storage Racks 45
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C) Assembly Shed
Arm Dimension :
• Flexible segment : Black Flex Sentry, hose, flame-retardant, with
255mm round capture hood
Air Volume :
• CFM Low : 400
• CFM High : 1300
Base Unit :
3 KIT001 Kit Trolley 40
D) Overhauled Parking Shed
1 PTK006 Electric Power Tool Kit 10
Testing Equipments:
S.No Ref. No. Name of Testing Equipment Qty
1 HCT001 Hydraulic Cylinder Test Rig 1
Test Pressure: Max. 200MPa ,
Power Source: AC 380V,50Hz,
Power : 8 HP,
Fully Automatic operation controlled by PC,
Dimension: 960X650X1200mm
2 PVT001 Pneumatic Valve Test Rig 1
Supply: 3/N/PE AC 50 Hz 400VNominal power: 2.8 kVA
Nominal current: 4 A
Compressed air 1: 7 to 10 bar (101 to 145 psi)
Test stand: Length: 2750 mm (9.0 ft)
3 PCT001 Pneumatic Cylinder Test Rig 1
Maximum burst pressure: 630 bar
Number of the test pieces:1 pressure port
Test medium: Pentosin-CHF 11s
Generation of pressure: pump and pressure intensifier
Energy demand: 3 kW
Dimensions of the test chamber (Width x depth x height): 1500x800x750 mm
4 GBT001 Gear Box Test Rig 1
(Automatic Transmission Test Rig)
• speed 0 - 6000 r.p.m.
• torque max. 150 Nm
• speed alternation - max. 3000 r.p.m./1 sec.
• inertia moment at drive shaft 0.1 kgm2
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S.No Ref. No. Name of Testing Equipment Qty

5 ATR001 Axle Test Rig 1
Weight: 15 metric tons
Dimensions (millimetres): 7167W x 7756D x 2560H
Load is applied to the two outputs by two 50 HP, 2400 RPM variable speed
motors each with a torque limiter set at 525 Nm and a torque transducer
rated at 500 Nm.
6 TGT001 Transfer Gearbox Test Rig 1
(Manual Type For Eeg)
• Drive speeds up to 6000 rpm
• Three available drive torque ranges upto 130 nm
7 SGT001 Steering Gearbox Test Rig 1
• power supply:380V 50Hz
• Pump supply:Three-phase electric motor
• Output power :4 KW
• Rotation rate:950 R/M
• Oil Pump:0-15 Mpa
8 BPT001 Brake Pressure Test Rig 1
• Two 3,000-PSI gauge assemblies
• Bleeder valve located at gauge manifold for relieving pressure.Dual scale
dial - standard scale 0 - 3,000-PSI and metric scale 0 - 300 kg/cm
• 4,500-PSIratedpressurehoseassembly
• 22-piece adapter set
9 CAT001 Clutch Assembly Test Rig 1
Dimension (L×W×H) : 940×940×1050 mmRelease load kN : 10,The
mounting screw hole on the cover assy. under real condition, manual
pressing work piece with pressure board, and clamping work piece with
pneumatic claws, the three ways can be optional one, Test range mm :
Φ180-Φ430
10 CHD001 Chassis Dynamometer 2
Absorber: Air-cooled eddy current load absorbers
Axle Weight: 30,000 lbs. (13,636 kg) maximum per axle Maximum Speed: 90
mph (145 kph) continuous
Power: 120 VAC single phase, 60 Hz, 15 Amps (controller)
11 WRT001 Winch Rope Test Rig 1
Total H.P.-6,Power Supply-3Ph,415V,50 Hz,
AC Accuracy of ± 1% in the range - 50-1000,Max.Ram Speed(mm / min) –
60
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Material Handling Equipments:

A) STRIPPING SHED
S.NO DESCRIPTION SPECIFICATION QTY.
1 EOT Crane 20T x 15m 1

3 Electric Operated Fork Lift 2 ton 1
4 Manual Trolley 0.5Ton 5
5 Hydraulic Hand Pallet Truck 1 ton 1
6 Battery Operated pick up van 5 ton 2
B) FAV SUB ASSEMBLY GROUP
1 EOT Crane 5 T x 25m 1

4 Battery Operated Trolley 0.2Ton 7
C) FAV ASSEMBLY GROUP
S.NO DESCRIPTION SPECIFICATION QTY

6 Material Handling Manipulator 1Ton 15
7 Double Slat Conveyor 75m 3
8 Jib Crane 2 Ton 2
9 Spares Kit Trolley 0.5Ton 15
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1.1.2 ENGINEER EQUIPMENT GROUP:

The Engineer Equipment Group is responsible for carrying out the overhaul of all types of
Engineer Equipment of Indian Army like Dozers, Backhoe equipment etc.

The current process flow chart of earth moving equipment is given in the Annexure 1.1.2 – A
and the work flow is given below.
The work order is received from the R&I section, the work order includes the P.I report which
details the works that are to be completed. Also it includes the list of spare parts required for
overhauling process. The equipment is washed first and then stripped. The body of the Earth
moving equipment is sent to the fabrication group for any repairs to the body. During the
stripping process the stripped components are classified into three groups
 Serviceable – These are marked with Green coat
 Unserviceable – These are marked with Red coat
 Re-worktables – These are marked with Yellow coat
The serviceable components are sent to its concern repair sections and then sent to the stores.
Unserviceable components like rubber lining are completely replaced by new components. Re-
workable components are those only need minor repair works and then they are sent to
assembly area. Currently the assembly is carried out as gang assembly system. The chassis of
the Earth moving equipment is fixed in one assembly point and all the components needed for
overhauling are brought from the repair sections and stores and then assembled on the Earth
moving equipment. After completed the assembly process, the Earth moving equipment is
ready for painting and testing process. After testing the body and cabin received from the
fabrication shop after repairs is fixed onto the Earth moving equipment. The initial offer is made
and WI is done, any defects found during the initial inspection are rectified at this stage and the
Earth moving equipment is given for final offer and WI inspection. Once the Earth moving
equipment has passed the inspection the painting and marking of the Earth moving equipment
is done and the work order is closed and the overhauled Earth moving equipment is sent for
dispatch.
1.1.2.3 Current workflow
The current workflow has been given in the flowchart (Annexure 1.1.2- A) and in depth
assy of the engine with the number of man-hours needed for overhauling of each component.
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The PERT diagram also gives the present Gaps in the process, given in Annexure 1.1.2– B.
The PERT diagram gives the overall process time for the entire process to be completed. The
process time is arrived by adding up of man-hours for components which has the highest value
among a group of similar operations like overhauling. The PERT diagram clearly marks out the
man-hours needed for each process; from this the bottlenecks in the process can be identified.
The PERT diagram (Annexure 1.1.2- B) of the Earth Moving Equipment group shows the lead
time and also the total man-hours of the overhauling process. Both the lead and total time are
calculated excluding the engine overhaul time, as for this case an overhauled engine is
considered to be readily available and the old engine is swapped for an overhauled engine.
The process time required for overhaul of equipment alone needs 1960 man-hours. The lead
time is arrived from the following processes
Man - Hours
 Inspection report - 315
 Stripping - 196
 O/H Ram and King Post - 420
 Assembly - 924
 Equipment assembly - 28
 Initial offer - 42
 Painting & marking of Eqpt - 35
Total - 1960 Hours
From the analysis it can be seen that by the time the Ram and King post is overhauled, other
sections like Axle O/H, Transmission O/H etc., give out twice the output, thereby leading to a
bottle neck condition with Earth moving equipments waiting for the Ram post. The new process
plan proposed has been designed to remove these bottlenecks in the system.
1.1.2.4 Issues & Gap analysis:

 Insufficient process layout was noted
 Highly old plant and machineries were observed in this repair group
 Need of space for stripping, washing and paint chamber were noted
 The material handling system in the current workshop to accommodate the future needs
of the workshop was identified.
 Need for a separate paint room was noted.
 A modernized repair ramp and compressor which is replaced were studied.
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The vision Statement of 507 Army Base Workshop has incorporated an objective for
EngineerEquipment Group. The aim of this group is to become the “Centre for Industrial and
Technological Excellence for overhaul of all types of earth moving equipments”.
and a machinery list has been proposed
 Provision of component level testing to ensure quality standards are met
 Provision of a modern hydraulic testing lab for testing of hydraulic cylinders in the Earth
moving equipments.
1.1.2.6 Future Expansion needs:

incorporated in the stripping space.
 New and modern air compressor unit to minimize the space occupied by the present
system. Highly equipped and modern pneumatic lines in the entire division to meet
various requirements in the plant.
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newer machines that are too installed in the workshop. A modern industrial electrical
Room conditions
 Clean room and dust free cabins are to be designed and installed in the workshop for
engine assembly room.

 Repairable Engineering equipment is taken from parking shed and taken to water
washing shed by means of utility trailer.
 After water washing, the equipment is taken to engineering equipment group shed for
over hauling process.
 For Engineer Equipment, the cellular type of process is recommended.
 The equipment is completely stripped at the stripping bay of this shed. The Engine send
to the ERG and sub- assemblies are send to the sub assembly repair bay provided in
this shed.
 The main body/chassis of equipment is pre-treated for degreasing and paint removed
process by using the caustic soda booth in which modern cleaning agent is
recommended for degreasing and paint removal process.
 In addition of that shot blasting machine is provided in this group for paint & rust removal
of main body, sub-assemblies and other structural members.
 There are two work stations are provided in this shed for sub assembly repair and testing
facilities.
 A centralized machine shop is provided for machining process during repair activity of
various sub-assemblies, body and other structural members.
 State of art testing facility for hydraulic and pneumatic equipments is provided in the
group.
 For reclamation, parts, spares stores and consumables stores are provided in this
station.
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 After paint removal, the main body is taken to paint booth for painting process and it is
taken to assembly bay of this shed.
 The sub-assemblies like gear box, clutch assembly, hydraulic equipments and pneumatic
equipments are repaired and tested and taken for painting process.
 In the assembly bay, the main body of the Engineering equipment is mounted on the
fixture stand.
 The Engine, sub-assemblies, wheel rollers, track wheels, hydraulic equipments and
cabin are claimed from the respective divisions and gang type of assembly process is
recommended for Engineering equipment.
 After defect rectification, the equipment is taken to painting shed located near the
substation (refer master plan) for final finishing and marking and sent to the covered
parking shed.
After the detailed study of the current process in ground visit and WPI, a new process
flow(Annexure 1.1.2– C) has been recommended to increase the capacity of the group from
present load of 5 Earth moving equipments in a month to 10 in a month. The new process
layout has been designed to ensure that the process flow gets streamlined and the zigzag
movements of man, machines and material are avoided. When the Earth moving equipment to
be overhauled arrives at the workshop it is unloaded by a ramp and taken to the closed
parking shed. After the inspection of the Earth moving equipment is done, the R&I section
issues a work order for the Earth moving equipment. The equipment is then taken to the
overhauling shed.
Cellular layout has been proposed as the preferred layout for the group as the group has to
deal with around 20 types of Engineer Equipment and at the same time the quantity of the
Earth moving equipment is low. Therefore cells are recommended for the group with each cell
equipped to perform a particular type of job. Three major cells have been proposed with each
of the major cells having separate specialised cells within them. The three major cells are
 Stripping section
 Washing & pre-treatment section
 Sub-assembly overhauling Section
 Assembly section
Each of these cells is provided with state of art machineries and testing equipments
according to the function of the cells. The provision of separate testing facilities for each cell
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increases the quality of the overhauled components. The state of machineries ensure that
precision machining can be achieved which results in interchange ability of the components
between different Earth moving equipments.
Once the components are overhauled they are sent to the O/H components stores where
they are kept till assembly. The assembly cell includes 4 separate stations where the
assemblies are carried out. During assembly the engine and fabricated cabin are brought from
ERG and body repair group respectively. Any new spares which will be required for expendable
parts are collected from OSS and local suppliers through MCO. As interchange ability has been
advocated through precision machining process, any O/H sub-assemblies can be fitted on any
equipment. This reduces the assembly time required as the assembly doesn’t have to wait for
their own components to be overhauled. After the assembly has been done the Earth moving
equipment is offered for initial inspection and once the Earth moving equipment is certified the
work order is closed and sent for dispatch.
Advantages of the proposed layout

 Provision of one 20T,10T and one 5T crane in the group enables ease in material handling
system
 Thick steel plates are provided on the floor to handle the tracked wheel of the earth moving
equipment
 States of art test facilities are provided for hydraulic and pneumatic equipment.
1.1.2.8 Pert Analysis of EEG

The pert diagram for EEG overhauling is given in the annexure 1.1.2–D. The Engineer
Equipment tracks are removed at the start and then brought to washing point. After washing,
the equipment is brought to the stripping shed where, the cabin and engine are stripped in 1
day and then sent to their respective overhauling sections. The structural members, hydraulic
and pneumatic equipments, gear box & clutch assembly, radiator, fuel tank, pump, alternator,
self starter, carrier rollers, track rollers, idler wheels, Driver wheel and other subassemblies
are stripped on the following days
Structural members - D+4
Hydraulic and pneumatic equipments - D+5
Gear box & clutch assembly - D+6
Radiator, fuel tank, pump, alternator, self starter - D+7
Carrier rollers, track rollers, idler wheels - D+8
Driver wheel and other subassemblies - D+9
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The completely stripped main body is then sent to the caustic washing on day ten and then
taken to the body repair section. The completely overhauled body after painting is brought to
the gang assembly on day twenty three. Since gang assembly is followed in EEG, the
assembly is done in four stages as follows
Assembly stages Sub-assemblies Day

Assembly stage – 1 Carrier rollers, track rollers, idler wheels D+23
Driver wheel and other subassemblies
Track Fitment
Assembly stage– 2 Engine D+26
Radiator, fuel tank, pump, alternator,
self starter
Assembly stage – 3 Structural members D+28
Hydraulic and pneumatic equipments
Assembly stage – 4 Cabin D+30
After the complete assembly, the vehicle is taken for test and defect rectification on D+31 and
then dispatched.
1.1.2.9 Machinery Requirement

Plant machinery & Special Equipment

• Drilling capacity: 40mm
• Spindle nose: MT-4
• Dist. from column to spindle Max/Min: 1020-400mm
• Dist. from spindle to Base Max/Min: 1180-300mm
• Number of spindle speed: 8
• Spindle speed range: 90 to 1000 rpm
• Number of power feeds: 2
• Power feed range: 0.20 – 0.10mm
• Column Diameter: 210mm
• Motor rating: 3 HP 1440 RPM
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• Speed: 2800 rpm
• Grinding Capacity Length 300 x Width 600 x Height 300
mm
• Max. Distance From the Spindle Centre to The Worktable
Surface400mm
10 SBM001 Shot Blasting Machine 1
• Cabin size:9770 x 7000 x 4000
• Hook loading capacity: 5000 Kgs
• No. of turbines: 4
• Turbine power: 4 x 20
11 WEM001 Weighing Machine – Model 1 1
• Weighing Capacity 12 Kg
• Resolution 0.1 Kg
• Repeatability (Standard Deviation) 0.1 Kg
• Linearity 0.1 Kg
• Stabilization Time ± 0.2 Kg
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Arm Dimension :
Air Volume :
• CFM Low : 400
• CFM High : 1300
Base Unit :
14 SSP001 Shaft Straightening Press 1
•Capacity : 100 Tons
•Stroke : 305 mm
•Bore : 205 mm
•Weight : 5445 kg
•Table : 1220 x 2440 mm
•Power : 10 Hp, 3 Phase
•Shipping Dimensions L x W x H : 2236 x 2745 x 2032 mm
• Distance between spindle center to vertical guide way 175
mm
• Motor 4 KW
16 WGM001 Welding Generator Arc Motor 1
•Rated Output : 3 to 25 Kw
•Rated Voltage : 400 V
•Rated Frequency : 50Hz
•Rated Current : 600 A
•Rated Speed : 1500 r/min
•Power Factor : 0.8 / Single Phase , 1.0 / Three Phase
•Size of grinding wheel:
• Vitrified Bond : 600 x 75 x 203.2mm
• Wheel Centre distance :1280mm
• Diameter of spindle :50mm
18 DGC001 Caustic Soda Wash Booth 1
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23 STR001 Storage Racks (Assembly Shed 40, Sub Assembly Shed 20) 60
Testing Equipments:
S.No. Ref. No. Name of Testing Equipment Quantity

1 HCT001 Hydraulic Cylinder Test Rig 1
Pressure: Max. 200MPa, Power Source: AC 380V,50H Power : 8
HP,Fully Automatic operation controlled by PC,
Dimension: 960X650X1200mm
2 HVT001 Hydraulic Valve Test Rig 1
Medium: water,Power : 8 HP,
Test pressure: Max. 690MPa,
Power source: 220V AC,
Takes air-operated pump as high pressure source
3 HHT001 Hydraulic Hose Test Rig 1
Fully automatic operation controlled by PLC, supports real time
display of pressure values and time, etc.
Test pressure: Max. 400Mpa,
Test medium: Water/Oil,
Medium temperature: -40 to 150
Power: 220V AC,
Dimension: 1500mm×1000mm×1200mm
4 PCT001 Pneumatic Cylinder Test Rig 1
Maximum burst pressure: 630 bar
Number of the test pieces:1 pressure port
Test medium: Pentosin-CHF 11s
Generation of pressure: pump and pressure intensifier
Energy demand: 3 kW
Dimensions of the test chamber (Width x depth x height):
approx. 1,500x800x750 mm.
5 PVT001 Pneumatic Valve Test Rig 1
Supply: 3/N/PE AC 50 Hz 400V
Nominal power: 2.8 kVA
Nominal current: 4 A
Compressed air 1: 7 to 10 bar (101 to 145 psi)
Test stand: Length: 2750 mm (9.0 ft)
6 PHT001 Pneumatic Hose TestRig 1
Hoses Maximum test pressure: 300 bar
Number of the test pieces: maximum 8 pieces
Test medium: Water, emulsion, apresol
Generation of pressure: pumps
Energy demand: 5.5 kW
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7 ATR001 Axle Test Rig 1
Weight: 15 metric tons
Dimensions (millimetres): 7167W x 7756D x 2560H Load is
applied to the two outputs by two 50 HP
, 2400 RPM variable speed motors each with a torque limiter set at
525 Nm and a torque transducer rated at 500 Nm.
8 SGT001 Steering Gearbox Test Rig 1

• power supply:380V 50Hz
• Pump supply:Three-phase electric motor
• Output power :4 KW
• Rotation rate:950 R/M
• Oil Pump:0-15 MPa
9 BPT001 Brake Pressure Test Rig 1
• Two 3,000-PSI gauge assemblies
• Bleeder valve located at gauge manifold for relieving pressure
• Dual scale dial - standard scale 0 - 3,000-PSI and metric scale 0
- 300 kg/cm
10 CAT001 Clutch Assembly Test Rig 1
Dimension (L×W×H) : 940×940×1050 mm
Release load kN : 10,
The mounting screw hole on the cover assy. under real condition,
manual pressing work piece with pressure board, and clamping
work piece with pneumatic claws, the three ways can be optional
one, Test range mm : Φ180-Φ430
11 HPT001 HYDRAULIC PUMP TEST JIG 2
Power:380v/50hz,
Power : 3kw amount to 5.5kw,
Measuring range:0-25mpa,
Net weight:600kg,Net dimension:1600*1300*1500mm
Safety features: drive coupler set back, integral test stand lighting,
side
panel control location,
safety glass view port, work table oil drain system.
Material Handling Equipment:

A) SUB ASSEMBLY GROUP
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B) ASSEMBLY SHED

6 Material Handling Manipulators 1 Ton 6
7 Pick up van 2 ton 2
1.1.3 ENGINE REPAIR GROUP (ERG)

The Engine repair group is responsible for overhaul of engines of Field Articulated Vehicle and
Engineer Equipment vehicle undergoing overhaul in the workshop and also carrying out the
overhaul of all types of Engines as per integrated Headquarters of Ministry of Defence (Army)
serials and direct withdrawal.
1.1.3.2 Current process:

The present process of engine overhauling (Annexure 1.1.3 - A) has been studied using the
flowchart and ground visit. Once the engine with the work order is received by ERG, the
stripping of the engine takes place. After the stripping the sub-assemblies are taken for various
cleaning process based on the type of material. The cleaning processes include caustic soda
bath, hot water wash, kerosene wash and Orion solution wash. After the washing is completed
the components are taken to their respective sections to be overhauled. After the overhauling
of the components they are sent to the assembly bay where the engine is assembled. After the
engine assembly the engine is sent for testing & rectification. Once the engine is tested it is
sent for preservation where the engine is packed and kept ready for dispatch to R&I. Based on
the given WPI, a PERT diagram is drawn for the present schedule of process. The PERT
diagram (Annexure 1.1.3 - B) clearly gives the time taken for each process and the
bottlenecks in the process. By reducing the bottlenecks, the current process can be re-
designed to accommodate the future load of the group. The current work flow of the entire
process is derived from the given flowchart of the process.
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1.1.3.3 Current workflow:

The current workflow has been given in the flowchart (Annexure 1.1.3- A) and in depth
assy of the engine with the number of man-hours needed for overhauling of each component.
The PERT diagram also gives the present Gaps in the process, given in Annexure 1.1.3– B.
The PERT diagram gives the overall process time for the entire process to be completed. The
process time is arrived by adding up of man-hours for components which has the highest value
among a group of similar operations like overhauling. The PERT diagram clearly marks out the
man-hours needed for each process; from this the bottlenecks in the process can be identified.
Two ways of solving the bottlenecks are suggested,
1) Increasing the machine capacity or providing multiple stations will ensure overhauling of
two similar (like two crankshafts) components at the same given time
2) Decreasing the man-hours needed for a process by the introduction of advanced
machinery.
1.1.3.4 PERT diagram findings:

This group handles the engines of the vehicles that are being overhauled in the workshop
including KRAZ, JCB and Dozer. The PERT diagram for all the engines have been drawn and
attached in the Annexure I. The PERT diagram for KRAZ has been analyzed below.
From the PERT diagram, process time for the overhaul of a KRAZ engine has been arrived to
be 314 man-hours. The processes and its man-hours which give the process time are as
follows
Man-hours
Engine Stripping - 32
Washing and de-greasing - 16
Major repairs - 128 ~Largest time for O/H process in the
Component Level
Assembly - 94
Engine Testing - 22
Painting and Packing - 22
Total - 314 Hours
From the analysis it is understood that by the time the major repairs are carried out other
processes give out nearly twice the output. Therefore in order to match the output of the other
sections the major repairs sections are provided with larger machining capacity. Due to this
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larger capacity the section can give twice the output for the same time, thereby reducing the
bottleneck at this section. Increasing this capacity increases the overall output of the engines to
twice the quantity in the same time frame
In addition to this, the lead time required to overhaul an engine is also decreased by reducing
the man-hours needed at the other bottleneck points. Since the output at the component level
is increased to twice the normal output, the stripping section is also re-designed to strip a
minimum of two engines at the same time. To facilitate this, pneumatic stripping tools and
advanced material handling systems are provided for ease of use and faster stripping.

Mechanical
 The old vintage plant and machinery were noted. Poor and insufficient material handling
equipments were observed.
 The lack of proper state of art stripping tools were noted
 The need of dust free assembly bay was noted for engine assembly section
 Lack of hot water washing during shipping of engine was observed.
 Effective volume coverage of overhead crane was noted as inadequate in the present
layout.
 Lack of state of the art machines for overhaul of engines was noted.
 Lack of technological advancements in testing facilities was noted.
 Lack of state of art test jigs like eddy current dynamometer, test rig for alternator & self
starter, test jig for testing of turbocharger was noted
 The cleaning bays which are old high roof A.C sheeted building. The storage facilities are
not sufficient for positioning of the machines.
 The painting facilities currently available are insufficient to handle the load of the facility.
 There is no separate dust free assembly room for Engine assembly.
 There is a need to improve the current workflow in order to ensure a smooth and proper
workflow
 Lack of proper material handling equipments for the movement of components between
sections
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The vision Statement of 507 Army Base Workshop has incorporated an objective for Engine
Repair Group. The aim of this group is to become the “Centre for Industrial and Technological
Excellence for overhaul of all types of engines”
 Provision of state of the art test facilities like Eddy current dynamometer, and test jigs for
Turbocharger, alternator and self starter.
 Re-work of the entire electrical lines in the workshop to international standards.
 Establishment of state of art pneumatic lines.
 Establishment of isolated washing facilities for washing of components inside the group
 Engine assembly area to be dust free area to maintain the quality of the overhauled
engines.

 Modern and heavy duty CNC Milling and Turning centers with multi-axis movements along
with NC controller system are to be installed to ensure handling the future loads of the
workshop in an efficient way.
 A modern centerline system is needed to correct and align valve faces to that portion of
the valve stem operating in the guide. Automated Valve seat cutting & grids fitment
Machine are to be installed to this effect.
 Special honing holders like Single Expansion Honing Holder & Double Expansion Honing
Holder are to be installed for roughing and finishing processes.
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 Advanced test benches with variable frequency speed regulator, digital display, and
special electrical equipment for control unit are proposed for testing large power
automobile generator and starter and possess high control sensitivity and strong
controllability.
incorporated in an isolated space near the stripping space.
Room conditions
 Dust free bay are to be designed for engine assembly.
1.1.3.8Recommended process
The engine on receipt from stripping shed passes through the following stages (Annexure
1.1.3-C)
 Inspection
 Washing & Stripping
 Inspection of sub-assemblies
 Repair/Overhaul
 Final assembly & Inspection
 Testing on test bed
The recommended process for Engine repair group is given below.
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 Engine repair group consists of two bays; in one bay the repair facilities for all Engine
parts are provided.
 The other bay is completely provided for storage of repaired Engine parts and Engine
assembly process.
 At the entry of this shed, repairable Engine storage is provided in the ground floor and the
rooms for officer, supervisor and foreman are provided in the mezzanine floor.
 The Engine is completely stripped at the stripping area provided in this group.
 The repairable Engine is completely washed at the water wash booth.
 After complete stripping, the ferrous components are washed by water and cleaning agent
wash for degreasing and paint removal process.
 The aluminum and copper bared components are washed in Orion solution bath.
 State of art Ultrasonic vibrator is recommended for kerosene washing of the specified
components.
 After washing process, the Engine parts like oil pump, water pump, cylinder head, crank
shaft, cam shaft, valves, starter, alternator, oil sump and other accessories are taken to
the respective components overhauling sections provided in the same bay. 2T capacity
EOT crane is provided in this bay for transportation of heavy components and battery
operated trolley is recommended for light weight components.
 The Engine block is taken to the respective section and the repair processes like line
boring, honing and lapping process. 1 Ton jib crane is provided in this section to handle
the Engine block.
 State of art block crack detector is recommended in this section to identify the cracks in
the Engine block.
 Similarly all other components are repaired in the respective sections. A centralized
painting booth is provided in this bay for painting of some Engine parts.
 In the assembly bay, FIP and injector calibration sections, OSS stores, storage rooms for
repaired Engine components and assembly stations are provided.
 The repaired Engine components are supplied to the storage rooms and claimed for
assembly process.
 There are six assembly stations are provided in this bay. Each assembly station having 1
Ton jib crane and the sections are designed as fully closed cabins.
 The entire assembly bay is air conditioned and dust free rooms.
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 The Engine block is mounted on the Engine trolley stand and taken to assembly station.
The other Engine parts are taken from the storage rooms by trolley.
 All assembly stations are provided with power tools kit for easy and faster assembly
process.
 After complete assembly of the Engine, it is stored in the repaired Engine storage section
for testing process.
 QA and AC team rooms are provided in the assembly bay for stage inspection during
assembly.
Another major factor for the improvement of the process is the layout of the shop floor. The
process groups in the shop floor are to be arranged in such a manner that there is a smooth
flow from one station to another. Based on the WPI, a new process layout has been designed
to ensure that the process flow gets streamlined and the zigzag movements of man, machines
and material are avoided. Annexure 1.1.3–C1
The stripping bay and the cleaning bay are located close to each other to reduce the handling
time of the components. In each of the stripping bay and the washing bay,overhanging
cranes are provided so that they can work independently on their own, rather than waiting for
common EOT- thereby increasing the output of the section. The O/H sections of engine parts
are grouped so that the components get overhauled in a sequential manner.
The overhauled components are stored very near to the assembly area so that easy access
can be obtained. The assembly area is provided with six assembly stations, each provided
with its own overhanging crane and power tools to get independent operation and minimize
idle time. Each bay is also provided with its own set of Jigs & Fixtures which are necessary for
its operation. This layout has been provided with number of portable engine fixtures which
also acts as a tilting table and caster wheels with brake. The tilting table of the fixture enables
ergonomic process during assembly of ‘V’ type engines. The caster wheels with brake enable
the fixture to move everywhere as a trolley leads to reduce the handling time of engine in each
and every stage. Also the layout provided with battery operated trolley for handling various
components of the engine. The stripping and sub-assembly repair bay provided with EOT 2T
crane for general purpose material handling. Forklift is provided for handling engine in storage
area.
In addition to this the entire assembly area is dust free with proper HVAC system to get clean
and precision assembly process. The advantages of the proposed layout are given below
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 Limited movement of components between sections

 Assembly sections are designed to be independent to each other thereby minimizing idle
time
 State of art test facilities is to be provided in the O/H sections, so that quality of testing is
improved.
 The technique of inter-changeability of engine components during assembly process
increases the productivity.
 Provision of proper material handling equipment such as fixtures with caster wheels
reduces the transportation time
 Provision of dust free air conditioned chamber for assembly section increases the quality
& quantity of the output.
 Sound proof test house proposed in the layout reduces the noise pollution of the
environment
 Centralized monitoring system of test engines during testing improves the workflow.
1.1.3.9 Cylinder block & Crankshaft section

The process flow is given in the annexure 1.1.3-D .When the cylinder block and crankshaft
assembly is received from the initial stripping, the sub-assemblies like cylinder block, cylinder
liner, crankshaft and flywheel are sent to their respective overhauling section. The cylinder
block is heated to 300 degree Celsius and then the cylinder liner got from the cylinder liner
section is fitted. The cylinder liner undergoes inspection and then the liner is grinded and honed
to meet the requirements for proper fitting. The crankshaft is inspected first and then the
crankshaft is grinded and polished and sent for assembly with flywheel. The flywheel after initial
inspection and overhaul is sent to the crankshaft assembly. The crankshaft and flywheel are
tested for balancing and then checked for any crankshaft leak test and then sent to final engine
assembly
1.1.3.10 Fuel Injection pump section

The process flow is given in the annexure 1.1.3-E .The fuel injection pump assy once received
from the stripping is further stripped for the following sub-assemblies
 Fuel injection pump
 Injection assembly
 Fuel filter
 Delivery Valve assembly
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All the sub-assembly are inspected and then any repair works needed are carried out and then
sent for calibration and testing of the sub-assy. Once the testing is carried out and the required
parameters are met the entire assembly is sent for final engine assembly.
1.1.3.11 Head assembly section

The process flow is given in the annexure 1.1.3-F.The head assembly got from stripping
section is further stripped to the following components
 Valve assembly
 Head assembly
 Camshaft assembly
 Exhaust manifold assembly
Each of the sub-assembly undergoes the following overhauling procedures
 Valve assembly – The valve assembly is grinded and then lock check-up is carried out
 Head assembly – After initial inspection, the valve guide check and replacement and seat
cutting is carried out. After this procedure, the valve assembly is fitted with the head and
final lapping is carried out
 Camshaft assembly – The camshaft is inspected and after overhauling, the camshaft
matching is carried out with the head assembly and then the entire assembly is sent for
final check-up.
 Exhaust manifold assembly – The exhaust manifold is inspected and necessary
overhauling is carried out and then the assembly is sent for final fitment.
1.1.3.12 Engine Test house:

An engine test stand is a facility used to develop, characterize and test engines. A
sophisticated engine test bed operates the engine in different operating regimes and offers
measurement of several physical variables associated with the engine operation. There are 8
number of engine test beds are provided in the engine test house and sufficient storage
provision is planned for tested engine. The engine test stand houses several sensors
(or transducers), data acquisition features, eddy current dynamometer and actuators to
control the engine state. The sensors would measure several physical variables of interest
which typically include:
 Crankshaft torque and angular velocity
 Intake air and fuel consumption rates, often detected using volumetric and/or gravimetric
measurement methods
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 Air-fuel ratio for the intake mixture, often detected using an exhaust gas oxygen sensor
 Environment pollutant concentrations in the exhaust gas such as carbon monoxide,
differentconfigurationsof hydrocarbons and nitrogen oxides, sulfur dioxide, and
particulate matter
 Temperatures and gas pressures at several locations on the engine body such as engine
oil temperature, radiatorwatertemperature, exhaust gas temperature, intakemanifold
pressure
 Atmospheric conditions such as temperature, pressure, and humidity
Information gathered through the sensors is often processed and logged through data
acquisition systems. Actuators allow for attaining a desired engine state (often characterized as
a unique combination of engine torque and speed). For gasoline engines, the actuators may
include an intake throttle actuator, a loading device for the engine such as an induction motor.
The engine test stands are often custom-packaged considering requirements of the OEM
customer. They often include microcontroller-based feedback control systems with following
features:
 Closed-loop desired speed operation (useful towards characterization of steady-state or
transient engine performance)
 Closed-loop desired torque operation (useful towards emulation of in-vehicle, on-road
scenarios, thereby enabling an alternate way of characterization of steady-state or
transient engine performance)
1.1.3.13 Experimental capabilities:

 Engine performance curve at full and partial load.
 Engine efficiency and fuel consumption variation with speed and load.
 Determination of the following engine parameters at different speed:
- Engine torque
- Engine power
- Volumetric fuel consumption
- Specific fuel consumption
- Air flow rate
- Air-to-fuel ratio
- Volumetric efficiency
- Brake Mean Effective Pressure (BMEP).
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1.1.3.14 Recommended Engine Preservation Process:

Engines contain the following kinds of corrosion protection
 Interior corrosion protection
 Exterior corrosion protection
The following corrosion protection work may only be carried out by persons familiar with it and
instructed in the potential dangers. Due to the following corrosion protection measure safer
shutting down the engine the requirements for 12 month protection are met. If these
measures are deviated from by exposing the corrosion-protected engines or parts to
unfavorable conditions (installation outdoors or storage in damp, badly aired places) or damage
to the corrosion protection layer, shorter corrosion protection duration is to be expected.
The engine corrosion protection should check about every 3 months by opening the covers. If
corrosion is detected, the corrosion protection should be renewed. At the end of the corrosion
protection work the crank drive may no longer be turned so that the corrosion protection agent
in the bearings, bearing liners and cylinder liners is not scraped off. Before operating a
corrosion protected engine, the corrosion protection must be removed.
Interior corrosion protection:

Interior corrosion protection is always provided by wetting of the walls with the implemented
corrosion protection agent in a corrosion protection running of the engine. The corrosion
protection (run can be performed once to protect the different systems.
Fuel system
 Fill the fuel tank with a mixture of:
– 90% distilled fuel
– 10% corrosion protection oil SAE 20W-20
 Perform a corrosion protection run with no load for at least 5 minutes.
Lubricating oil system

 Drain lubricating oil from warm engine.
 Thoroughly clean oil tray, cylinder head with rocker arms, valves, valve springs with diesel
fuel or cleaning agent.
 Fill the engine with corrosion protection oil SAE 20W-20 up to the MAX mark and perform
a corrosion protection run for at least 5 minutes so that all the components of the
lubricating oil system are wetted or all accessible parts are wetted with corrosion protection oil
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and pump corrosion protection oil through the engine with a separate pump until all bearings
and bearing liners are wetted.
Air compressor
With a mounted air compressor a corrosion protection agent should be sprayed into the air
compressor intake system after switching off the engine until the agent visibly emerges from
the adapter.
Cooling system
Depending on the series the engines are equipped with cooling air, cooling oil or cooling fluid
system (cooling water with cooling system protection agent).See the chapter Exterior corrosion
protection for the cooling air system. In engines of the oil-cooled series the circulating
lubricating oil serves simultaneously for cooling. The cooling chambers are protected
automatically against corrosion with the lubricating oil system. If a coolant with corrosion
protection properties is poured into liquid-cooled engines, no further action is necessary after
draining.
 If not, the coolant must be drained and, to ensure the formation of a covering layer on the
inside surfaces of the cooling system, a corrosion protection run performed with a mixture
of:
– 95% treated water
– 5% corrosion protection agent
 The duration of the corrosion protection run and the concentration of the corrosion
protection agent are specified by the manufacturer of the corrosion protection agent.
 Then drain the coolant.
Air intake pipes

After the corrosion protection run, remove the cylinder cover and dismantle injectors. The
respective piston must be set to LDC.
 The accessible part of the cylinder liner should be coated with corrosion protection oil with
a spray lance through the opening.
 Spray corrosion protection oil SAE 20W-20 into air intake pipe.
– Oil drips in lines are not permissible and must be sucked off if necessary.
Exterior corrosion protection:

The engine must be cleaned thoroughly with a cleaning agent before exterior corrosion
protection. Any signs of corrosion and damage to the paintwork must be removed.
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Cooling air system in air-cooled engines

The air duct space in V engines is unpainted and must be sprayed with a corrosion protection
agent.
Bare exterior surfaces and parts

Coat or spray all bare exterior parts and surfaces (e.g. flywheel, flange faces) with corrosion
protection agent.
Rubber parts
Rubber parts (e.g. muffs) which are not painted over must be rubbed down with talcum powder.
Belt drives
Remove V-belts and V-rib belts and store packed. Spray V-belt pulleys and tension pulleys with
corrosion protection agent. Toothed belts to the engine control may not be removed.
Engine openings
All engine openings must be fitted with airtight, water-tight covers to delay the liquefaction
process of the corrosion protection agents. With installed air compressor, the suction and
pressure connection must be sealed by a cap. Air should be locked out to avoid ventilation of
the engine (chimney effect) for the suction from an air supply pipe.
Storage and packaging

After being protected against corrosion, the engine must be stored in a dry, ventilated hall and
suitably covered. The cover must be placed loosely over the engine so that the air can circulate
around it to prevent condensation from forming.
Removal of corrosion protection

The corrosion protection must be removed from the corrosion protected engine before starting.
The packaging must be removed as well as all covers from the sealed openings. Any signs of
corrosion and damage to paintwork must be removed.
Fuel system
 If there is a mixture of diesel fuel/corrosion protection oil in the fuel tank, drain it.
 Fill the fuel tank and fuel system with the proper fuel.
Coolant system
 If the implemented corrosion protection agent is compatible with the intended coolant
system protection agent, this can be filled directly into the coolant system as specified.
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 If it is uncertain whether the implemented corrosion protection agent is compatible with the
coolant system protection agent, the cooling system should be purged with fresh water for
about 15 minutes before filling.
Removal of exterior corrosion protection

 Wash all surfaces and components coated with corrosion protection agent with distilled
fuel or a suitable cleaning agent.
 Wash out grooves of V-belts if necessary.
 Mount V-belts or V-rib belts as specified
1.1.3.15 Pert Analysis of engine overhauling

The pert diagram for Engine overhauling is given in the annexure 1.1.3–G. The engine after
stripping from the vehicle is brought to the Engine repair group where, the engine is water
washed and stripping of sub-assemblies takes place and then sent to their respective
overhauling sections. The sub-assemblies like Alternator, Self-starter, Turbocharger, Air
compressor, Fuel injection pump and other accessories stripped and sent to their respective
overhauling sections. The completely stripped engine block is then sent to the caustic washing
and degreasing and then repair works like boring, honing process and testing are carried out
and the overhauled engine block is then sent to the assembly section. The overhauled
subassemblies are brought to the assembly station where gang assembly of the engine takes
place in three days as follows
Assembly stages Sub-assemblies Day

Assembly stage – 1 Cylinder head, Crank shaft, D+13
Connecting rod
Assembly stage– 2 FIP, Oil pump, Oil sump D+14
Assembly stage – 3 Air compressors, Alternator, D+15
Self-starter, Turbo charger
1.1.3.16 Machinery Requirement
Plant machinery & special equipment:

• Daylight 515mm
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• Speed: 2800 rpm
5 VBM001 Vertical Cylinder Fine Boring Machine 3
• Boring Capacity - 50-200 mm
• Maximum Boring Depth - 508 mm
• Distance between spindlecentertocolumn - 400 mm
• SpindleSpeedRange-172-205-258-280-308-420 RPM
• Spindle feeds per revolution - 0.002”, 0.004”, 0.006”
6 CRB001 Connecting Rod Boring Machine 2
• Height of center of bed - 165 mm
• Min boring diameter - 20 mm
• Min grinding diameter - 30 mm
• Max. Boring diameter - 125 mm
7 IHM001 Internal honing machine 2
• Honing Capacity Diameter 50 - 200 mm
• Max. Honing Stroke 508 mm
• Max. Distance B/w Spindle & Table 1000 mm
• Spindle Centre to Column Distance 380 mm
8 CSG001 Crank Shaft Grinding Machine - Model 1 2
• Maximum distance between centers 1500 mm
• Maximum distance between chucks 1400 mm
• Maximum weight of the shaft 60 Kgs
• Swing over table 400 mm
9 CSG002 Crank Shaft Grinding Machine - Model 2 2

• Max. distance between center: 2600mm
• Max. distance between chucks: 2500mm
• Maximum Weight of Crankshafts: 200Kgs
• Swing over Table: 650mm
10 CSP001 Crank Shaft Straightening Press 1
• Maximum Distance Between ‘V’ Block 2900 mm
• Minimum Distance Between ‘V’ Block 250 mm
• Maximum Journal Diameter 130 mm
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11 WWB001 Water Wash Booth 1
• All the pipes in the shower area will be made of PVC.
• Nozzles will be of full cone type with 60° spray angle.
• Nozzles will be provided on the sides as well as on the top of the
shower area to spray water.
• The discharge capacity of nozzles will be 15 lpm+/-15% at 2 bar
+/- 15% pressure.
• The nozzle pitch will be 500 mm on the top and 500 mm on the
sides. (Longitudinal and transverse pitch)
12 LPM001 Lapping & Polishing Machine 1
• Wheel OD 720 mm
• Max. Work piece diameter 180 mm
• Max. Work piece thickness 75 mm
• Carrier driver type Pin Drive
• Maximum # of carriers 6
• Drive system 3-Way
13 LBM001 Line Boring Machine 1
• Boring Capacity 50-200 mm
• Maximum Boring Depth 508 mm
• Distance between spindle center to column 400 mm
• Surface of table 1890 X 400 mm
Size of grinding wheel:
• Vitrified Bond : 600 x 75 x 203.2
• Resinoid Bond :600 x 65 x 203.2
• Wheel Centre distance :1280
• Diameter of spindle :50
16 VLM001 Valve Lapping Machine 1
• Match lap parts 25 to 350mm diameter and up to 400mm high
• Fabricated steel body with adjustable levelling feet
• Heavy duty adjustable worktable
• Integrally mounted high torque drive unit with 0.37kW (0.5HP)
motor
17 VSC001 Valve Seat Cutter Machine 1
• Valve Seat diameter Range: 14 to 120 mm
• Max. Cylinder Head length
(with 360° rollover fixture):1118mm
• Max. Cylinder head length (with diesel Fixture) :1270 mm •
Spindle Diameter :80mm
• Spindle travel/Stroke vertical :203mm
18 KER001 Kerosene Wash 1
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19 DGC001 Caustic Soda Wash Booth 1
21 USV001 Ultra sonic Vibrator 1
Testing Equipment:

1 ATE001 Alternator Test Rig 1
Ammeter : 0-200 Amps
Ammeter : 0-30 Amps
Motor : 15 HP, 1440 Rpm
Power Supply : 3Phase, 415 V, 50H
Lamp : 110V Series Lamp
Speed Range: 800 to 7000 Rpm
2 STE001 Spring Testing Machine 1
Digital load indicator on the machine will be connected to a load
cell. The machine will have one load cell (capacity: 150 kgf.).
Non-memory resident digital length/ displacement indicator
having resolution 0.1mm and accuracy + 0.2mm using rotary
optical encoder. Power supply: 220V, single phase, AC supply
Loading Capacity: 150 kgf max.
3 DBM001 Dynamic Balancing Machine 1
Capacity: 350 lbs. Standard, 500 lbs. with optional motor
Power: 110VAC 10 amps or 220V 5 amps - 50Hz or 60Hz, plus
computer requirements
Motor: 1/2 HP DC variable speed, 3/4 HP optional
Balance Speed: Variable up to 1000 RPM, computer controlled
4 ETB 001 Engine Test Bed 4
AC Dynamometer
• Nominal torque 4,950 Nm
• Nominal power 750 Kw
• Maximum speed 4,000 rpm
Performances motor operation: 10% less than in generator
operation
• Overload capability (10s every 100s) 20%
Recovery load 90%
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6 ETB 002 Engine Test Bed 4
HYDRAULIC Dynamometer
• Max. Speed n max : 4.800 rpm
• Permissible Torque : 9.500 Nm
• Max. Coupling Weight on Coupling Flange m max : 200 kg
• accuracy ( total system ): ±0.2% F.S.*1
• Digital speed Torque measurement accuracy
( total system ) : ±1 rpm / ±1 digit
• Direction of rotation : single direction
7 OPT001 Oil Pump Leakage Test Rig 1
Power : 120kW (160HP)
Speed :0 - 10,000RPM (±1RPM)
Footprint (L x W x H): 4.4m(174") x 2.6m(102") x 2.5m(98")
Main Power : 600VAC, 3Ø, 60Hz, 200A
Inlet Pressure [Abs] 7BAR (100psia)
Flow Rate Accuracy : ±0.1% of Reading
8 WPT001 Water Pump Leakage Test Rig 2
Footprint (L x W x H) : 7.2m x 1.8m x 2.6m,
Main Power : 600VAC, 3Ø, 60Hz, 200A,
Power : 15kW (20HP) AC Motor,
Speed : 0 - 10,000RPM (±1RPM) Temperature Range: 10 -
120oC (50 - 248oF),
Outlet Pressure: 0 - 35BAR (0 - 500psi)
9 RCD001 Radiography Crack Detector 2
Dimensions: 2580 x 2000 x 2210 mm,
40 kHz operation
Microprocessor control
C-arm X-ray manipulator
10 FIP001 FIP Calibration 2

Capacity:
• Drive System : D.C Thyristor controlled.
• Drive Motor : 30 – 3000 RPM.
• Speed Range : Speed 0 to 2460 rpm.
• Power/ : 35 kw
• Torque : 330 Nm
Fuel Supply
• Digital display, resolution 1 rpm speed, stability ± 1 rpm.
• Gauge. 1 bar to 7 bar, 30 in Hg to 60 psi (8 bar option
available).
Pressure Phasing
• 0 to 45 bar.
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11 IJT001 Injector Tester 2
Pressure 0 to 700 Bar
Injection per minute 0 – 3000 with increments of 100
Rail pressure control: closed loop control using surrogate pump.
Tests up to 4 injectors at a time.
Timed Operation: 10 – 120 seconds (10 second increments)
Injection graduate 10ml – 158ml
12 SMT001 Starter Motor Tester 2

• Voltmeter 0-99.9vdc digital
• Pc based test bench with printer for reports
• Solenoid power supply of 300amps capacity
• Ammeter 0-303amps dc digital,Starter torque measurement
thro inline torque transducer of100kgm two 180amps hr battery
for supply to startet motor as sources

2 Electric Operated Fork Lift 2 Ton 1
3 Jib Crane 2 Ton 6
4 Battery Operated Trolley 2Ton 4
5 Battery Operated Trolley 1Ton 2
6 Hydraulic Hand Pallet Truck 1 Ton 2
7 Scissor Lift-Towable 0.2Ton 2
9 Material Handling Manipulator 1Ton 6
10 Trolley With Fixtures 2Ton 15
11 Pick up van 2TON 2
ENGINE TEST HOUSE

Single Girder EOT Crane 5 T x 12m 10
2 Double Girder EOT Crane 5 T x 15m 1
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1.1.4 General Engineering Group & Ancillary Group

The General Engineering Group (GEG) is MOS for depot and spares for KRAZ Vehicle and
also it is responsible for the manufacture of jigs & fixtures for INSAS weapons system.
The Ancillary Group is responsible for manufacture of dies, spares and other items required by
production groups and also various depots and field units. It provides the central ancillary
support to the entire production group.

The present process of manufacture of spares (Annexure 1.1.4- A) has been studied using the
flowchart and ground visit.
General engineering group has the function of manufacturing any spares that might be required
for the workshop. The production plan for the spares is received from the Methods Engineering
group. A work order is released to GEG to enable them to manufacture the spares. The Method
engineering sections issues the production plan listing the necessary processes needed for the
manufacture of spares. In case of any new components, the Method engineering gives the
necessary drawings to the General Engineering Group. Once the work order is received it is
registered and the required material for the pilot production is provisioned. The drawing
provided by the method engineering is then studied in detail regarding the steps needed to
manufacture the component. Once the required processes are identified, the required
machines and manpower is selected along with the necessary tools. Then the raw material is
sent for production and at each stage an inspection is carried out to ensure that the required
actions are carried out. If the component requires any heat treatment it is sent to the ancillary
where the heat treatment facilities are located. Once the final component is received it
undergoes various tests to ensure that the component fulfils the necessary requirement. Once
the component passes these tests the production plan is finalized and sent for job-lot
production. All the spares that are manufactured are then preserved and then dispatch to MCO,
who distribute the spares to the concerned group.

Mechanical
 Out dated machineries were observed in GE group.
 The lack of facilities like heave hydraulic press, casting of ferrous metals and precision
machines for manufacturing process were noted.
 Lack of automation in plant and machinery were observed.
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 Insufficient heat treatment facility was studied.

 The present machine layout needs to be reworked in order to provide a smooth flow of the
product throughout the cycle was identified.
 Heavy hydraulic press with a operating capacity of 140T & 160T needs to be installed
 Die making lathes and milling machines automation were studied.

The vision Statement of 507 Army Base Workshop has incorporated an objective for General
Engineering Group and Ancillary Group. The aim of this group is to become the “Centre for
Industrial and Technological Excellence for Designing and manufacturing of spares”.
were studied. Based on the studies equipment requirement for the group was analysed
 Provision of high precision CNC machining centres and state of art die making machines
along with CNC EDM &CNC wire cut machines.
 Provision of state of art ancillary facilities like heat treatment facility, casting section,
plastic and Bakelite molding section

 Demolition of old Industrial Shed and provision of new shed with raised platform to avoid
the shop floor which is getting flooded during rainy seasons and to maintain dust, temp &
humidity control environment in the buildings.
 The proposed buildings are of RCC framed and steel construction with profile sheeting
and the floors are provided with proper cable trenches. The flooring will be ironite and with
hardener topping.
 The new buildings will be integrated and orientated to minimize energy consumption as
per the functional aspects. The electrical wiring will be modernized to improve the
 The buildings will be provided with proper security, safety and fire fighting equipments.
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And also adequate parking, housekeeping and scarp disposal facilities will be included.
 The buildings which are to refurbished will be upgraded or revamped for columns and
 The columns with RWP will be integrated with proper drain. And the cable trenches will be
covered with proper cover plates.
 The modernization of the Workshop will need the following machinery to accommodate
the load requirements and future needs of the workshop.
 Modern CNC machines to perform various functions are to installed like
 CNC Wire cut EDM
 CNC Horizontal center
 CNC Vertical machining center
 CNC milling center
 Melting and holding furnaces that provide low fuel costs, superior fuel efficiency and
precise temperature control are to be identified and installed for melting of aluminum, zinc,
and other non-ferrous metals.
 The study arrived at the need to have an advanced sheet metal work section
incorporating both special need cutting and bending machines as well as machines for
manufacture of common sheet metal works
 The modern and latest High precision lathe machine & milling machines to manufacture
specialized parts are to be installed.
 A modernized Molding workshop is to be designed and installed to manufacture rubber
components need in the workshop
 A modernized Forging workshop is to designed and installed for the manufacture of forged
components
 The modern and latest new secondary operation lathe machine is to be installed
separately for manufacturing components of small & complex turned parts from bar, blank
& forgings.
 Modern Material testing facilities both Destructive and non destructive testing methods are
to be provided in the workshop to meet the quality standards set by QCE.
 The modern test, calibration instruments and sensors are designed to meet quality of
measurement during testing of spares.
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newer machines that are to be installed in the workshop. A modern industrial electrical
Room conditions

1.1.4.7 Production Layout
The GEG has the function of producing job lots of small sizes and the variety of job lots done is
larger depending on the production schedule. Therefore the best layout for such a system is
Job shop production layout.
Job shop production layout

A job shop is a type of manufacturing process in which small batches of a variety of custom
products are made. In the job shop process flow, most of the products produced require a
unique set-up and sequencing of process steps. The process-oriented layout can
simultaneously handle a wide variety of products. It is typically the low-volume, high-variety
strategy. Each product or product group undergoes a different sequence of operations. It is
produced moving it from one department to another in the required sequence. Different
products have different material flows. Thus, it is not efficient to arrange machines due to a
product-oriented layout (flow shop system) but according to a process-oriented layout.
A process-oriented layout consists of a collection of processing departments or cells. All

machines involved in performing a particular process are grouped together in a machine shop
(e.g. drill, weld). This concept is used when there are many low-volume, dissimilar products. It
is also used in case of rapid changes in product mix or volume, as well as when conditions are
such that neither product-oriented nor cellular manufacturing systems are useful. In comparison
with cellular manufacturing systems this layout concept is characterized by high degrees of
interdepartmental flow. A big advantage of this process-oriented layout is its flexibility in
equipment and labour assignment. The breakdown of one machine need not halt an entire
process; work can be transferred to other machines in the department.
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Advantages
 Better utilization of machines can result; consequently, fewer machines are required.
 A high degree of flexibility exists relative to equipment or manpower allocation for specific
tasks.
 The diversity of tasks offers a more interesting and satisfying occupation for the operator.
 Specialized supervision is possible
1.1.4.8 Characteristics of a job shop

The main characteristics of a job shop that has to be taken into account for a successful
integration are
Layout
In the proposed layout of GEG, similar equipment or functions are grouped together, such as
all drill press in one area and grinding machines in another in a process layout. The layout is
designed to minimize material handling, cost, and work in process inventories. The
manufacturing of parts has been designed to use general purpose equipment rather than
specialty, dedicated product-specific equipment as the variety of products is large. CNC
machines have been installed in the group to give GEG flexibility to change set-ups on the
various machines very quickly.
Routing
When a production order arrives in GEG, the parts in the work order travels throughout the
various areas of the shop floor based on the sequence of operations. Not all parts will use
every machine in the group. Parts often travel in a jumbled routing and may return to the same
machine for processing several times.
Information
Information is the most critical aspect of such a layout as information is needed to route an
order through the shop, and specify the exact work to be done. Information flow begins with a
job sheet and blueprint is prepared before the job is released to the floor. Once on the
production floor, job sheets are to be followed to ensure that the quality of products are
matched to the standards set. The plan proposes the computerization of information flow in
order to reduce paper work and also increase the production rate.
Scheduling
A part manufacturing is characterized by its route, its processing requirements, and its priority.
Therefore advanced scheduling methods are to be followed to ensure that the parts are
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manufactured on a sequential order. In a job order the mix of products is a key issue in
deciding how and when to schedule jobs. Jobs may not be completed based on their arrival
pattern in order to minimize costly machine set-ups and change-over. Work may also be
scheduled based on processing time, from shortest to longest.
Storage facilities
Along with the above points, another important factor is the storage facilities for both spare
parts and tools. State of art computerized storage system is to be introduced to control the
access of spare parts or tools. Proper racking facility depending on the type of materials
handled is to be provided. The racking system is designed based on ergonomic design
procedure for storage.
The process layout can be fixed by use of Activity Relationship charts. Activity Relationship
Charts are useful graphical means of representing the desirability of locating pairs of
machines/operations near to each other. The following letter codes have been suggested in
literature for determining a “closeness” rating
 A - Absolutely necessary. Because two machines/operations use the same equipment or
facilities, they must be located near each other.
 E - Especially important. The facilities may for example require the same personnel or
records.
 I - Important. The activities may be located in sequence in the normal work flow.
 O- Ordinary importance. It would be convenient to have the facilities near each other, but
it is not essential.
 U - Unimportant. It does not matter whether the facilities are located near each other or
not.
 X - Undesirable.
Based on this rating, the sections in GEG have been clubbed together. The chart below gives
the exact relation between the sections
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1.1.4.9 Material estimation process

The material estimation process is an important process in GEG (Annexure 1.1.4– B). Once
the work order is received by the group, it is checked if necessary drawings are available for
manufacturing and if not available, the necessary drawings are made from the sample product
received. From the drawings, the man-hours and material required for manufacturing is made
as estimate. Once the estimate is made the Die/Tooling if required are produced. Then the
material estimate is then sent to MCO for material procurement and then the job order is
allocated from PP&C and the job order is sent to the GEG for manufacturing. Once the job
order has been received the manufacturing of the spares is carried out based on the work
order. (Annexure 1.1.4-C)
1.1.4.10 Ancillary section

1.1.4.11 Carpentry shop
The process flow for carpentry shop is given in the annexure 1.1.4-D. The work order is
received from method engineering and the required material is checked if available in the
section. If not available, the material is requested from MCO and a sample trial manufacturing
is carried out as per the specification. The required man-hours for the job are booked and then
the final inspection of the product is carried out. If the product after checking matches the
requirement, all the items are handed over to R&I section along with the complete
documentation.
1.1.4.12 Electroplating shop

The process flow for Electroplating shop is given in the annexure 1.1.4-E. The work order is
received from method engineering and the plating feasibility is checked and if the electroplating
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is feasible, the items required is sorted and the electroplating method is allocated. The
electroplating shop consists of the following process
 Zinc plating (Annexure 1.1.4-E-1)
 Copper plating (Annexure 1.1.4-E-2)
 Hard chrome plating (Annexure 1.1.4-E-3)
 Lead plating (Annexure 1.1.4-E-4)
 Nickel plating (Annexure 1.1.4-E-5)
 Oxidizing (Annexure 1.1.4-E-6)
 Phosphating (Annexure 1.1.4-E-7)
 Silver plating (Annexure 1.1.4-E-8)
Before electroplating the chemical solution is sent to the lab for analysis and after analysis, the
solution concentration is maintained and electroplating is carried out. The final inspection of the
product is carried out and if the product after checking matches the requirement, all the items
are handed over to R&I section along with the complete documentation.
1.1.4.13 Moulding shop

The process flowchart for the moulding shop is given in the annexure 1.1.4– F. On the receipt
of the work order from PP&C and the required material, the necessary mould required for the
process is selected and if the mould is unavailable, the necessary moulds and patterns are
produced from GEG. An initial pilot sample is manufactured and a fitment trial is carried out and
once the fitment is finalised, the casting of the jobs is carried out. Then the final product is
checked for any defects and products with defects are sent for rework. The product without any
defects is packed and sent to R&I for issue to the required group.
1.1.4.14 Rubber moulding shop

The process flowchart for the rubber moulding shop is given in the annexure 1.1.4– G. On the
receipt of the work order and the required material, the compounding and mixing of the material
is carried out. Then the necessary mould required for the process is selected and if the mould
is unavailable, the necessary moulds are produced from GEG. With the help of the received
mould, the moulding process is carried out and then the finishing and trimming operation is
done and the final product is checked for any defects and products with defects is sent for
scrap. The product without any defects is packed and sent to R&I for issue to the required
group.
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1.1.4.15 Tool room

The process flow for tool room is given in the annexure 1.1.4 -H. The work order is received
from method engineering and the required material is checked if available in the section. If not
available, the material is requested from MCO and a sample trial manufacturing is carried out
as per the specification. The required man-hours for the job are booked and then the final
inspection of the product is carried out. If the product after checking matches the requirement,
all the items are handed over to R&I section
1.1.4.16 Blacksmith shop

The process flow for blacksmith shop is given in the annexure 1.1.4 -I. The work order is
received from PP&C and the required material is checked if available in the section. If not
available, the material is requested from MCO and a sample trial manufacturing is carried out
as per the specification. The trial product is checked for fitment and if rework is needed it is
carried out. Once the fitment trial is passed, the product is produced for the work order quantity
and the final inspection is carried out and the required man-hours for the job is booked. If the
product after checking matches the requirement, all the items are handed over to R&I section
1.1.4.17 General Engineering Group Machinery Requirement:


1 CNL001 Conventional Lathe - Model 1 2
• Swing over bed 500 mm
• Swing over slide 290 mm
• Bed Length 200 mm
• Width of Bed 380 mm
• Main Motor : 3 HP
• Coolant Motor : 0.1 HP
• Speed Range : 22-1000 RPM
• Main Motor :3 HP
• Coolant Motor : 0.1 HP
• Speed Range : 30-1235 RPM
3 THR001 Thread Rolling Machine 1
• Work piece diameter Ø10 ~ Ø75 mm
• Axial pitch for ISO threads 1.0P ~ 10.0P Mm
• Main power motor 25 HP
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• Distance between spindle center to vertical guide way 175 mm
• Motor 4 KW
6 JBM001 Jig Boring Machine 1
• Max 2500 x 2000 x 1500 mm
• Working surface 1400x1600 / 1600x1800 mm
• T-slot 22x7x200 / 22x7x225 mm
• Y-direction 7000/ 12000 kG
7 CGM001 Centreless Grinding Machine 1
• Max. Grinding dia. 140mm
• Min. grinding dia. 3mm
• Max. job length -infeed 245mm
• Grinding wheel size (ODxWidth) 500x250mm
• Min. grinding wheel dia. 390mm
• Peripheral/cutting speed 33/(45)m/sec
8 SGM001 Surface Grinding Machine - Model 1 2
Surface 400 mm
9 SGM002 Surface Grinding Machine - Model 2 1
• Max. Table grinding W x L: 300mm x 750mm
• Max. Travel: 350mm x 775mm
• Max. Grinding Height under wheel: 275mm
• Grinding wheel Head Motor Speed: 2800 / 1400 RPM
• Grinding wheel Head Motor: 2 HP / 3 Phase
• Grinding wheel Size (D x W x B): 250mm x 20mm x 71mm (Opt.)
• Hydraulic Tank Capacity (Telus - 68): 60 Lit
• Hydraulic pump motor: 1.5 H.P.
• Least Count of Vertical Feed Hand wheel: 0.01mm
• Least Count of Cross Feed Hand Wheel: 0.05mm
• Working Pressure: 12 kgs / cm²
• Net Weight: 1500 Kgs
• Wooden Case Dimension L x D x H (in mm): 1200mm x
1500mm x 1700mm
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10 TCG001 Tool and Cutter Grinding Machine 1
• Swing over table (Dia) 230 mm
• Maximum distance between centres 305 mm
• Table longitudinal traverse 305 mm
• Table Cross traverse 200 mm
12 LPM001 Lapping & Polishing Machine 1
• Wheel OD 720 mm
• Max. Work piece diameter 180 mm
• Max. Work piece thickness 75 mm
• Carrier driver type Pin Drive
• Maximum # of carriers 6
• Drive system 3-Way
13 TAP001 Tapping Machine 1
• Tapping in steel 5 mm
• Tapping in CI and alloy metals 7 mm
• Distance between top to table face 140 mm
• Diameter of column 46.75 mm
• Size of work table 168 X 168 mm
14 SMM001 Spring Manufacturing Machine 1
• Wire Dia. (mm) 0.30mm - 1.60 mm
• Spring OD 60 mm
• Production rate 80 Springs / Min
• Wire Feed Length 1500 mm
15 STM001 Spring Tempering Machine 1
• Max. Temperature 350ºC
• Inner size 60x50x90 mm
• Outer size 96x87x175 mm
• Power 415 Volt, 3 phase
16 SEG001 Spring End Grinding Machine 1
• Wire Capacity 1-6 mm
• Max. Spring OD 35 mm
• Spring Length 5-200 mm
• Daylight 515mm
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18 CKP001 Crank Press – Model 1 1
• Capacity 250T
• Capacity (Above Lower Dead Point) 10 mm
• Stroke 300 mm
• No. Of Stroke 24 SPM
• Die Height 600 mm
ELECTRICAL POWER:
• Main Motor : 25 x 4P
• Slide Adjusting Motor : 3 x 6 P
19 CKP002 Crank Press – Model 2 1
• Die Height 515mm
ELECTRICAL POWER:
• Main Motor : 15HP x 4P
• Slide Adjusting Motor : 1HP x 4P
21 ACM001 Abrasive Cutting Machine 1
Machine Specifications:
Diameter: 400 + 5 mm
- 3 mm
Thickness: 4.0 + 0.25 mm
Bore: 22.23 +0.5 mm
-0 mm
Nominal Size: 400 x 4 x 22.23 mm
Operating speed: 4800 r.p.m. (approximately)
Self life of disc: Min. 02 Years.
22 PBC001 Pipe / Bar Cutting Machine 2
• Speed 10-20000 mm/min
• Input Power 3 Phase, 400 Volt, 50 Phase
23 HSM001 Hydraulic Shearing Machine – Model 1 1
• Cutting Length : 250 mm
• Normal rake angle [M.S]: 13mm
• Maximum rake angle [M.S]: 16mm
• Normal rake angle [S.S]: 10mm
• Maximum rake angle [S.S]: 13mm
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27 MIG001 MIG Welding Machine 1
• Capacity : 250 Amps
• Phase : 3 phase
• Input Supply : 380/415 V0LT
• Efficiency : 50 Hz
28 TIG001 TIG Welding Machine 1
• Standard Voltage 415Volt, 3 Phase
• Protection Class IP23S
• Insulation Class H
• Rated output TIG DC (40▫C) 400@35
29 SPW001 Spot Welding Machine 1
• Capacity : 15 kva
• Input supply : 220/380 volts, 50 cycles
• Phase : single & two phase
• Insulation : f class
30 UGM001 Universal Grinding Machine 1
• Capacity for work piece in mm
Swing: 800mm
Length: 3000mm
• Max. Grinding diameter with new wheel: 700mm approx
• Steady rest capacity mm
Max. : 400mm
Min.: 100mm
• Max. Grinding length: 2600mm
Centre height: 410mm
• Max. Weight of work piece in Kg: Supplier to indicate
• Grinding wheel Dia x Width: 750 x 70 mm approx
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31 VBM001 Vertical Boring Machine 1
• Boring Capacity - 50-200 mm
• Maximum Boring Depth - 508 mm
• Distance between spindle center to column - 400 mm
• Spindle Speed Range - 172-205-258-280-308-420 RPM
• Spindle feeds per revolution - 0.002”, 0.004”, 0.006”
• Rapid movement up & down - 750 mm
• Surface of table - 1890 x 400 mm
• Table traverse (Longitudinal) - 900 mm
• Table traverse (Cross) - 50 mm
• Motor 2 HP - 1440 RPM
• Rapid motor up & down 0.75 HP - 1440 RPM
• Base area ( L x W) - 1650 mm x 1400 mm
• Height - 2400 mm
• Approx. Weight - 2200 Kgs
32 LEG001 Laser Engraving Machine 1
• Type Ytterbium fibre laser
• Power 10/20 W
• Wavelength 1064 nm
• Frequency Range 20-100 kHz
• Fibre Length 5/3 M
• Head 7 kg
• Control Unit 18 kg
33 FGP001 Forging Press 2
• Force capacity 1600 KN
• Power 11 KW
• Tension 400/50 V/HZ
34 PIM001 Plastic Injection Moulding Machine 1
• Screw Diameters 80 mm
• Max. Injection Pressure 1300 kg/cm2
• Swept Volumes 1327 cm3
• Actual Shot Capacity (in Polystyrene) 1219 gm
• Max. Injection Rate 663 cc/sec
35 RBM001 Rubber Moulding And Bakelite Moulding Machine 1
• Screw Diameters 80 mm
• Max. Injection Pressure 1300 kg/cm2
• Swept Volumes 1327 cm3
• Power of Heating Unit 24 kW
• Motor Capacity 37 kW
36 SHM001 Shaper Machine 1
• Length of stroke : 630 mm
• No. of speeds to Ram : To be indicated by the party
• No. of Ram cycles / min : Max.140 strokes/min.
• Motor Power : A.C. 7.5 H.P.
• Vertical Travel of tool post slide : 150 mm
• Power Supply : AC 3-Phase, 415V +10 % / -15%, 50 HZ +/- 3%.
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37 WPM001 Wood Planning Machine 2
• Working width : 450 – 630 mm
• Working thickness : 10-170 mm
• Max. Planning depth : Up 5 /down 3
• Min. working length : 310mm
• Spindle speed : 4800 r/min
38 CSW001 Circular Saw 1

Rated power input 1.400 W
• No-load speed 5.500 rpm
• Weight 4,2 kg
• Saw blade bore diameter 30,0 mm
39 PLM001 Polishing Machine 2
• Overall Length 1220 mm
• No of Bearings 2/4 no
• Spindle Speed 2800 RPM
• Main Motor Power 3 HP
40 PBF001 Buffing Machine 1
• Speed: 3000 rpm
• Mop size: 2 x 150mm – 200 mm (approx) diameter.
• Net Weight (approx.): 102 Kg.
• Admit Between Centre 304 mm
•Diameter 610 to 637 mm
• Height of Centres 254 mm
• Spindle Power 3 KW
42 PCM001 Plasma Cutting Machine 1

• Rated input voltage : 3Ph,380v
• Input frequency :50/60 Hz
• Rated input Power :15.2 Kva
• Output current :20-100A
• Rated Out Voltage :120v
• Power factor :0.93
• Arc – Sarting :Touch
43 IGM001 Internal Grinding Machine 1

• Centre height :180 mm
• Max. grinding length :100 mm
• Max. swivel of table : ± 8 deg
• Wheel head repid approach :50
• Wheel head swivel :± 60 deg
• Work head centrea : 4 MT
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Arm Dimension :
• Flexible segment : Black Flex Sentry, hose, flame-retardant, with
255mm round capture hood
Air Volume :
• CFM Low : 400
• CFM High : 1300
Base Unit :
45 CPM001 Crimping Machine 1

CNC MACHINES
1 HFL001 Heavy Duty Flat Bed CNC Lathe 1
• Swing over bed: 650mm,
• Swing over slide: 360mm,
• Max-turning diameter: 380mm,
• Max-turning length: 1500mm,
2 MSL001 Medium CNC Lathe 1
• Chuck Dia 165 mm
• Maximum Turning Dia 250 mm
• Maximum Turning Length 300 mm
• Spindle Power 5.5/7.5 KW
• Swing Over Bed 450 mm
3 LSL001 Light CNC Lathe 1
• Center distance: 2000 mm
• Center height: 260 mm
• Swing over bed: 520 mm
• Swing over carriage: 460 mm
• Swing over cross slide: 310 mm
4 TRM001 CNC Turn Mill Centre 1
• Chuck Dia 250 mm
• Maximum Turning Dia 370 mm
• Maximum Turning Length 670 mm
• Spindle Power 11/15 KW
5 VMC001 Vertical Machining Centre 1
• Table Size 900X450 mm
• Stroke X/Y/Z 600/450/500 mm
• Rapid Transfer X/Y/Z 50/50/40 m/min
• Spindle Speed Std /Opt 8000/10000 RPM
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6 HMC001 Horizontal Machining Centre 1
• Table/ Pallet Size 650X470 mm
• Stroke X/Y/Z 400/350/350 mm
• Rapid Transfer X/Y/Z 40/40/40 m/min
• Spindle Speed Std /Opt 6000/8000 RPM
Ancillary GroupMachinery Requirement:

• Power 11 KW
2 IQF001 Integral Quench Furnace 1
• Gross capacity KG @ 950º C – 2700 KG
• Oil Quench Tank (KW)3
Warm 54
Hot 118
• Furnace KCAL / HR x 1000 (G) – 500
• Atmosphere consumption - 30 M3 / HR
• Quenchant Volume - 18000 (LT)
3 BSW001 Band Saw 2
• Cutting capacity for round: 300mm
• Cutting capacity for square: 250 x 250mm
• Blade speed: 20-75 m/min
• Blade size: 3760 x 27 x 0.9
• Main motor: 3 HP
4 WTM001 Wood Turning Machine 1
Power Input : 3550W / 230V
Power Output : 2200W
Diameter Over Bed : 610 mm
Center Distance : 1065 mm
Weight : 410 kg
5 IFM001 Induction Furnace 1
Chamber Size - 1200mm Dia x 1200mm D
Application - Nitriding
Max temp - 750° C
Operating Temp - 580° C - 600° C
Type of Sensor - K type.
Control Accuracy - +/- 2° C
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General Engineering Group Testing Equipments

1 CTM001 Coating Thickness Measuring Equipment 1
For all magnetic induction and eddy current probes
Memory for up to 1000 readings
Power : 1.5V AA battery ×4
Measuring methods : Magnetic induction(E) ,Eddy current(H)
Measuring range : 0-2500um(99mils)(E),0-
1200um(40mils)(H)Large, display rich in contrast with 240x160
pixels
2 ECI001 Electronic Comparator 1
A high chrome high carbon ,hardened , ground & lapped Block
is attached to the base at the centre , below Arm holding
electronic probe.
Precision electronic probe is provided with the unit with a
Measuring range of + / - 2.0 mm.
3 MCI001 Mechanical Comparator 1
Accuracy : 0.004 mm
Range 2-300mm
Power: 1 battery, 1.55V, type SR44
Repeatability: 0.01mm (0.0005")
Resolution: 0.001mm
4 TMM001 Tool Maker's Microscope 1
Illumination: It adopts 12V 50W high-brightness halogen lamp
reflect illumination and 10W LED contour illumination unit Fast-
moving Stage range : 200X100mm
Distance : 55-75mm Distance : 95mm
Over size : 900*700*980
Weight : 170kgs Power supplier : 110/240V 50/60Hz
5 IPC001 Industrial Pressure Calibrator 1
Pressure Gauge :
• vacuum to : 30 to 500bar
• vacuum to : 2, to 35bar
Pressure Absolute Ranges :
• 0 to100
Engineering units:
• User defined : One user-definableunit
• User selectable : 20 units
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6 RTC001 Reference Temperature Calibrator 1
Temperature range :
• -57 to 155°C/-71 to 311°F
• -45 to 155°C/-49 to 311°F
• -31 to 155°C/24 to 311°F
Accuracy (model B & C) with external STS ref. sensor:
• F±0.10°C/±0.18°F
7 ITC001 Industrial Temperature Calibrator 1
Power Supply:
230V, 60Hz, 150 to 1150 VA
8 WKT001 WORK TABLE 10
Ancillary Group Testing Equipments
1 UTM001 Universal Testing Machine 2

• Minimum Graduations kN : 0.4
• Maximum capacity kN : 2000
• Clearance between columns mm : 850
• Power HP : 6.5
• Volts : 400-440
• Dimensions -L X W X H (approx.)mm: 3000 x1200 x3600
2 WKT001 WORK TABLE 1
General Engineering Group Material Handling Equipment:

Ancillary Group Material Handling Equipment:

1 Single Girder EOT Crane 1 T x 20m 2
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1.1.5 FABRICATION GROUP(BODY REPAIR SECTION)

The Fabrication group is responsible for fabrication loads like body building of KRAZ, JCB
operator cabin, manufacture of Mock-ups for BMP-II.

Mechanical
 Need of modern body building and fabrication facilities in welding, sheet metal work,
carpentry, upholster and cabin repair works were noted.
 Lack of sufficient space for stores and damaged parts/scrap were noted.
 The machinery currently in use is outdated and insufficient for the load expected. Also
there is a need for advanced machines requirement considering the future role of the
workshop
 The present machine layout needs to be reworked in order to provide a smooth flow of the
product throughout the cycle
 The material handling system in the current workshop needs a complete overhaul so as to
accommodate the future needs of the workshop
 The compressor used at present is old and worn out and needs to be replaced.
 The electrical wiring of the workshop needs a complete overhaul.

The fabrication shop provides body building services to each production group, therefore in
order for the other production groups to achieve their respective vision goals the Fabrication
group needs to cater to their needs with high performance and quality control.
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 The workshop is to have a modern repair and inspection ramps in each shed is to be
 Automotive Spray Booth, Industrial Spray Booth, Sanding Booth, Humidity Control Booth
and Paint Mixing Room are introduced in finishing stage of the body repair / overhauling
process.
 The body repair and alignment system includes the Press System, Tower Pulling System,
Frames Alignment System, Induction Heater and Frames Drill.
1.1.5.5 Recommendation
Operation Layout
The fabrication shop deals with different types of vehicles from Kraz to Engineer Equipment
and the future load may vary to other different types of vehicles. Therefore the group needs to
have a flexible production line in order to handle these loads.
 It is recommended that, the fabrication group can be utilized for chassis, body and cabin
repair activities.
 This section is provided with welding shop, machine shop, sheet metal work, carpentry
shop, Electrical section, upholstery section, fitting section and painting booth.
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 This section provides with raw material stores scrap stores, Consumables store and
spares Store.
 The Chassis Repair work and complete painting process is planned in this shed.
 The cabin repair work, painting, electrical fitment, upholstery fitment and wood work are
planned in this section.
 Mobile battery unit provided in this section for testing purpose of electrical fitments.
 Portable welding trolleys are provided for repair work of chassis, cabin and body.
 A 20T EOT crane is provided in this shed for handling the chassis, body and cabin.
 The existing Kraz overhauling shed is recommended for this fabrication.
 State of art shot blasting machine is provided in this section for paint of the rust removal
process
The most suitable layout for the fabrication group is the cell layout. In cell layout, the materials
and information entering the operation are pre-selected to move to one part of the operation (or
cell) in which all the machines to process these resources are located. After being processed
in the cell, the finished products can move on to another cell. In effect the cell layout brings
some order to the complexity of flow that characterizes process layout. The major advantages
of a cell layout are as follows
 Reduced materials handling – 67% to 90% reductions in distance travelled, since
operations are adjacent within a dedicated area.
 Reduced inventory in process – 50% to 90% reduction, since material is not waiting
ahead of distant processing operations. Also, within the cell, smaller lots or single-piece
flow is used, further reducing the amount of material in process.
 Shorter time in production – from days to hours or minutes, since parts and products can
flow quickly between adjacent operations.
In addition to this primary benefits, quantifiable benefits of cells also include
 Easier production control
 Greater productivity
 Quicker action on quality problems
 Better utilization of personnel
Cells are a compromise between the flexibility of process layout and the simplicity of product
layout. They are best used when a predictable variety of products have to be produced. Since
the fabrication group has a predictable load like Kraz and Engineer Equipment, the cell layout
will be the most advantageous.
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The cell layout proposed in this group is determined based on the following data,
 The exact location of all facilities, plant, equipment and staff that constitute the ‘work
centres’ of the operation
 The space to be devoted to each work centre
 The tasks that will be undertaken by each work centre
The detailed design involves deciding the extent and nature of the cells to be used and which
resources to allocate to which cell.
The cell structure is designed at two levels
 Overall cell Plan
 Detailed cell Plan
1.1.5.6 Overall cell plan

This stage determines the number of cells that will be required for completing the fabrication
process. After the determination of the number of cells, each cell in the layout has to be fixed
with the function of the cell, the machineries are installed in that particular cell based on its
functionality.
The fabrication group is divided into three major divisions based on its activities.
 Body shop – This cell is designed to handle any type of fabrication work. The section is
provided with state of art PMSE to meet its commitments.
 Paint shop – The paint cell is provided with modern painting booth and coating facilities.
The section is designed to handle painting and finishing process of any type of body and
cabin
 Final assay – The final assay cell has the function of assembly of the accessories like
head lamp, cabin seats etc., on to the finished and cabin.
1.1.5.7 Block layout of cells and supporting areas

Once the individual cells have been decided, the location of the cell in the overall layout has to
be finalized along with location of the storage facilities, tool room, scrap facilities etc.,
The layout of the fabrication shop is designed in such way that there is a minimal movement of
men and materials. The proposed layout of the group is provided in the annexure I. The group
is provided with two EOT cranes to move the body & cabin from one cell to another. The first
section of the fabrication shop is designed to be the first cell capable of handling the body
building activities of the group. Once the body building activities are carried out, the body is
moved into middle cell having the automated painting booth in which the required painting
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activity is carried out. The end section is designed as the third call of the group where all the
accessories of the vehicle are assembled onto the vehicle.Separate material handling systems
like fixtures, forklift and EOT crane are to be provided for movement of body, cabin and
material required for the operation of each cell. In addition to this portable welding machines
and portable tools trolley are to be provided to each cell which helps in increasing worker
productivity.
1.1.5.8 Detailed cell plan

The detailed cell plan gives the proper layout of each cell by considering the following points,
 Normal operator work position
 Location of tooling, gauges, controls
 Parts containers, fixtures, and workplace handling devices
 Utility drops and connection points
 Access points on control panels and machinery
The detailed layout plan of each cell is designed based on ergonomic and 5S principle, which
provides the proper working environment for workers and also increases the labour productivity
to a great extent.

• Daylight 515mm

• Drill Capacity in steel 20 Mm
• Tapping capacity in steel M 12 Mm
• Morse taper in spindle MT 12 Mm
• Spindle travels 130 Mm
• Vertical adjustment of spindle head 425 Mm
• Spindle speed 10 (rpm)
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Surface 400 mm
6 RVM001 Riveting Machine 2
• Riveting capacity 6 mm
• Throat-Depth 110 mm
• Shut height 180 mm
• Stroke Adjustable 0-30 mm
7 HSM002 Hydraulic Shearing Machine – Model 2 2
• Cutting Length : 3000mm
• Normal rake angle [M.S]: 13mm
• Maximum rake angle [M.S]: 16mm
• Normal rake angle [S.S]: 10mm
• Maximum rake angle [S.S]: 13mm
• Variable rake angle: 1 – 3º
8 PBM001 Pipe bending machine 1
• Max bending capability 0115 x10 mm
• Max bending radius R520 mm
• Min bending radius R90 mm
• Max effective distance of mandrel 4500 mm
•Diameter: 400 + 5 mm- 3 mm
•Thickness: 4.0 + 0.25 mmBore: 22.23 +0.5 mm
•Nominal Size: 400 x 4 x 22.23 mm
•Operating speed: 4800 r.p.m. (approximately)
•Self life of disc: Min. 02 Years.
10 TIG001 TIG Welding Machine 2
• Standard Voltage 415Volt, 3 Phase
• Protection Class IP23S
• Insulation Class H
11 MIG001 MIG Welding Machine 1
• Capacity : 250 Amps
• Phase : 3 phase
• Input Supply : 380/415 V0LT
• Efficiency : 50 Hz
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• Oxy-Acetylene ratio for Welding 1.1:1
• Oxy-Acetylene ratio for Cutting 1.5:1
13 SPW001 Spot Welding Machine 1
• Capacity : 15 kva
• Input supply : 220/380 volts, 50 cycles
• Phase : single & two phase
• Insulation : f class
• Power 11 KW
16 PUM001 Punching Machine 1
• Max. Material Thickness 6 mm
• Punching force 200 KN
• Axis travel X 1350 mm Y 2600 mm
• Work area without reposition 1250 x 2500 mm
• Speed: 2800 rpm
19 PHA001 Power Hammer 1
• Size : 300 Kgs.
• Space between slides : 360 mm
• Stroke Maximum : 1450 mm
• Maximum weight top die : 100 Kgs
• Tup front to back : 330 mm
• Height : 5000 mm
• Maximum Number of blows per minute
Short Stroke : 95
Full Stroke : 45
• Maximum Weight of Job : ½ Kgs.
• Gross Weight : 10 MT
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20 MCM001 Metal Coating Machine 1
• PC Control with touch screen operator interface.
• Optional Keyboard control or operator interface unit.
• Unlimited recipes and parameter recording.
• Straight, 90 Degree and extension guns.
21 MSM001 Automatic Metal Spraying Machine 1
• Element Disk Size:
Diameter : 550 mm
Thickness : 105 mm
Disk Speed : 15-60 Rpm
• Spray Wire Material : Zinc, Lead, Tin Lead, Tin Copper etc.
• Spray Wire Diameter : 1.6 – 2 mm
• Wire Feeding Speed : 0 – 7000 mm/min.
22 PFC001 Profile Cutting Machine 1
• Plate thickness : 5 to 100mm
• Cutting speed : 50 to 750mm/min
• Max. Square : 500 x 500mm
• Max. Rectangle : 400 x 900mm
• Max. Circle cutting : 600mm
• Max. Line cutting : 1200mm
• Cutting precision: Ellipse < 1.5mm, Square + 1mm/600mm
• Dimension : 1190 x 335 x 800mm
• Weight : 56.5 Kg
Arm Dimension :
• Flexible segment : Black Flex Sentry, hose, flame-retardant,
with 255mm round capture hood
Air Volume :
• CFM Low : 400
• CFM High : 1300
Base Unit :
CARPENTRY & UPHOLSTERY MACHINES
1 SSM001 Seat Inner Sewing Machine 1
• Max. Sewing Speed 1200 s.p.m
• Stitch Length 13mm
• Weight 190 - 140 KGS
2 SEW001 Sewing Machine 2
• Stitch Length 0-9 mm
• Need bar stroke 34 mm
• Presser food lift 16 mm
• Needle size DP7/18/25/18
• Needle gauge 3.4.6.8.10.12 mm
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3 BSW001 Band Saw 2
• Cutting capacity for round: 300mm
• Cutting capacity for square: 250 x 250mm
• Blade speed: 20-75 m/min
• Blade size: 3760 x 27 x 0.9
• Main motor: 3 HP

4 Battery Operated Trolley 1T 2
6 Material Manipulators 0.5Ton 3
1.1.6 Battery charging section

The battery charging station is located in the first floor of the Workshop Expense Store building.
The section consists of the following departments
1. Charging room for battery – electric trucks
2. Charging room for batteries of repairable vehicles
3. Battery revision workshop
4. Repair shop for battery – electric trucks
5. Storage area for batteries
The function of each department is given below
Charging room for battery –electric trucks:

 Charging of lead-acid battery sets which are used in battery – electric trucks, which are
used for transporting material inside the workshop.
 Equalizing charging
Charging room for batteries of repairable vehicles

 Charging of lead-acid battery sets which are used for overhauled vehicles.
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 Equalizing charging does not include new batteries installed in repaired vehicles.
Battery revision workshop

 Regular inspection and measurements of electrolyte density, voltage electrolyte
temperature during charging
 Maintenance of batteries
 Production of distilled water
Repair shop for battery – electric trucks

 Technical servicing
 Maintenance
 Checking for repairs and overhauling
Process and services provided:

The following kinds of servicing will be carried out in the section
 Routine charging of batteries
 Repair work of batteries and trucks
Repair of battery operated trucks:

The scope of work includes
 Daily servicing
 Technical servicing
 Repair works
Daily servicing includes greasing, filter’s cleaning, battery clamps cleaning and greasing and
electrolyte re-filling
Technical servicing includes daily servicing and greasing in accordance to the equipment
instruction, engine’s state checking, fuel and oil filter checking and trouble shooting, inspection
with instruments for the following components
 Sound of the engine
 Revolutions
 Compression pressure
 Tightening up of nuts
 Adjustments of plays
 Checking of parameters according to OEM instruction
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Major repairs to be carried out will be done in Workshop Services Group. The following checks
have to be made by the operator every day for reporting of faults. Every fault noted has to be
sent for repair
 Fuel level checking
 Electrolyte level in batteries checking
 Auditory inspection of engine’s work
 Visual inspection of entire truck
 Checking whether the indicators on the control board are working
 Assemblies work checking
1.1.6.2 Battery charging process:

After each shift, during which the sets of batteries were used, the batteries must be charged
with operating charging. The charging should be done in the stands for charging
The shop’s workers should supervise the charging process. If necessary, the level of electrolyte
in cells should be refilled with distilled water. The operating charging should be carried out with
constant value of voltage.
The equalizing charging used batteries should be carried out every month. The process is to be
carried out during weekends due to long time of the cycle. The charging should be done with
the current intensity equal to 1\6th to 1\5th of maximum admissible battery charging rate. The
charging should be carried out as long as the density of electrolyte and the cell’s voltage will
not change during the last four hours of charging.
1.1.6.3 Industrial safety and fire protection:

The workers in the charging station should follow the rules listed below for safety issues
 For inspection of batteries proper portable lamps should be used
 The section must be kept in order, the floor and the walls must be rinsed with water once
a day
 Hands must be washed when finishing maintenance works
 Splashed electrolyte must be immediately removed using sawdust and the place and the
skin if splashed with electrolyte, should be smeared with ammonia or with soda solution
which should be kept in first-aid kit.
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1.1.7 OTRP
 This section is planned to do wheel dismantling, wheel repair and fitment purposes.
 This section provided with Drum repair section Skimming process of wheel drum.
 The tube repair section is provided to check the condition of the tire and tube
 It is recommended that complete reclamation process for the tube and tire based on
damage level
 No repair process is recommended for tireandtube to meet the reliability of the
overhauling process
 Sufficient Storage for serviceable tire and tube are provided in this section.
 State of the art machine recommended for the wheel fitment section.

1 TDM001 Tyre Dismantling Machine 2
• Clamping Range 355-1422 mm
• Max wheel weight 1600 Kg
• Max.wheel width 1065 mm
• Max diameter of tyre 2300 mm
2 TFM001 Tyre Fitment Machine 2
• Bead Breaker Power @ Shoe 3500 lbs
• Air Pressure 150 PSI
• Weight: 900 lbs
• Torque: 737 ft/lbs
3 WBM001 Wheel Balancing Machine 2
• Pump motor 2 Hp
• Gearbox motor 2 Hp
• Max.Wheelassembly diameter 2299 mm
• Max. wheel assembly width 1067 mm
4 WSK001 Wheel Skimming Machine 2
• Drum diameter : 150 – 800 mm
• Drum depth capacity : 250 mm
• Spindle speeds : 45 & 70 rpm
5 RIM001 RIM Straightening Machine 2
• Gear box : Heavy Duty Reduction Gear Box load.
• Dies Material : EN 8 material for all rollers
• Bearing : SKF
• Motor : 2 H P 1440 rpm (available In 1 phase or 3 phase)
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1.1.8 Electronics Repair Sho

op
The Electronnic repair shhop located in WSG wouuld be responnsible for repairing the electronic
e
PCS’s that would
w be avvailable in sccania and Krraz vehicles.. This would be a basic testing /
repair facilityy in the WSG
G building.
1.1.8.1 Sub-Assemb
S bly Cleaning
g:
An ultrasonicc cleaner is a cleaning deevice that usses ultrasounnd (usually frrom 20–400 kHz) and
an appropriaate cleaning solvent (som
metimes ordinary tap waater) to cleann delicate iteems. The
ultrasound can
c be used with just waater, but usee of a solvent appropriate for the iteem to be
cleaned andd the soiling enhances thhe effect. Cleaning norm
mally lasts beetween threee and six
minutes.
Ultrasonic cleaners are used

u to cleann many differrent types of objects, including tools, industrial
parts and eleectronic equipment etc. They
T are usedd primarily inn electronic reepair workshops.
ULTRASONIC
C CLEANING
G EQUIPMEN
NT
1.1.8.2. Typical ESD

D workstatio
on:
 Removee all extraneous materials from the workstation (food, beverages, combbs, bags,
clothingg etc).
 Test the wrist strap/ooperator dailyy or install constant monittors.
 Inspect the
t ESD grouunding conneections, the mats,
m the EB
BP, weekly.
Clean the suurfaces with purpose-madde antistatic cleaner, do not use com
mmercial prodducts, the
cleaners may leave a ressidue insulative layer.
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1.1.8.3 Grounding
People are the primary source of electrostatic charges.
The elimination of charge build-up is obtained by using conductive and dissipative materials
that have fewer tendencies to generate static charges. Grounding systems shall be used to
ensure that components, personnel and any other conductors are at the same electrical
potential. For proper and safe grounding the ESD ground must be tied directly to and at the
same potential as the building or "green/yellow" ground.
Personnel grounding devices
WRIST- The wrist strap is the most used device to ground personnel, it will safely and effectively
STRAP drain static charges from the body. Someone offers ESD Wrist straps without cord
(cordless), we can assure that are ineffective.
FOOTWEAR In some locations, such as stores and around equipment, conductive shoes or foot
grounders are used. Foot grounders should be worn on both feet to ensure constant
contact to ground floor or floor mat. Foot grounders will not function properly if used on
surfaces which are insulative or improperly grounded.
GARMENTS The main purpose for wearing conductive smocks is to suppress static fields on
employee clothing. The conductive fibers woven into the material provide a Faraday cage
that prevents dangerous fields from extending to and damaging sensitive products. There
shall be electrical conductivity between all parts of the garment.
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GLOVES ESD sensitive device can experience a damaging discharge if touched by a person, even
if that person is properly grounded. Increasing the electrical path's contact resistance is
one way to control the speed of the discharge. A good way to accomplish this is by
wearing static dissipative cots and gloves.
CHAIRS The resistance to ground from any part of the seat which may have contact with
personnel, must be less than 10^10 Ω. At least two castors or feet must provide a path to
ground.
Safety
Before we get to the key issues of ESD control, it is important to note that personnel safety is
paramount. In no way should an ESD control program replace or supersede any requirements
for personnel safety.
In the factory, grounding personnel around the AC power line is a possible hazard. Personal
grounding should not be used when working around voltages greater than 250VAC. Although
personal grounding items must include a 1MΩ resistor to limit current to less than 0.25 mA,
ground fault circuit interrupters should be used.
Where high voltages greater than 250VAC or 500VDC are present, use proper warning signs.
1.1.8.4. Modular BGA/CSA Re-work station:
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It is comprised of a handd held convecction tool, pree-heater andd adjustable ttool holder with
w board
holder to creeate a manuaally assisted rework systeem. A series of nozzles aare targeting a variety
of applications, and light magnifier round out the product
p offerring for this ssystem. With standard
features succh as programmability, a digital displaay, program storage of uup to 50 profiles, this
system is noot only versattile, but also easy and effficient to worrk with. A choice of boardd holders
and accessoories are avvailable that make the system
s capabble of handling multiple sizes of
PCBs.
Features off the system:
 Desktopp sized
 2800W dual
d zone preeheater with 550W top heeater
 208-2400VAC, 50/60H
Hz, 15A-13A,, Single Phasse
 Modularr design allow
wing customeer to customize the unit too meet their nneeds
 A 343mm
m (13.5”) x open-ended PCB w micrometter adjustment
P holder with
 Mechanical X and Z axis movemeent on linear bearings forr long-life andd
 Minimal maintenancee
 Componnent is retractted automatically at the end
e of reflow when removving parts
 Linux-baased integral computer
 Externall USB for file transfer
 SmartPlace Vision System
S is a high definition vision system
s whicch uses Duaal CMOS
sensors toassist in thhe placement of componeents and requuires no calibbration.
 Optionall Precision Placement Heead for ultra fine
f pitch
 Componnents with plaacement accuracy of .0388mm (.0015”))
 Optionall Contactlesss IR Sensor for
f auto start at pre-determ
mined tempeeratures
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1.1.8.5. ESD Re-Work station:

Features of Soldering and De-soldering work station
 Self-contained powerful pump
 2 in 1 ergonomic and flexible hand-piece: pencil or pistol
 Collection chamber with 40% increased capacity
 Innovative collection chamber for quick and easy change
 Dual switchable output
 Compatible with previous Desolder range
System Components and Accessories:
 Switched Dual Output Power Supply with Internal Pump
 Desolder Hand-piece, with selectable grip, and cord
 Solder Cartridge Hand-piece, with cord
 Universal Work stand for Desolder Hand-piece
 Universal Work stand for Solder Hand-piece
 Disposable Collection Chamber
 Fittings and Air Hose Kit
 Replacement Pistol grip
 Coil assembly for Desolder Hand-piece
 Desolder work stand cradle
 Seal Kit Collection Chamber
 Vacuum Port
 ESD Air Hose
 Desoldering Tip Cleaner
 Yellow sponge for Work stand
 Brass pad for Work stand
 Vacuum Port Filter
1.1.8.6. ESD Test Equipments

Combo tester:
Wrist Straps and Foot wears need to be tested regularly in EPAs. It is a convenient instrument
that can be used for this purpose. The instrument allows testing both wrist strap and footwear
simultaneously to save time and lessen the number of operations for testing the personnel
grounding. The instrument is compliant to the standard resistance prescribed in the ANSI ESD
S 20.20 – 1999 standard.
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The instrum
ment consistts of the following sections:
1) Wrist Straap Testing Section:
S Thee instrument displays
d on a PASS or FA
AIL Basis.
PASS: This means that the total resistance of the
t wrist straap system iss in range of
o 0.75 M
Ohms to 10 M ohms andd the wrist strrap is OK to Use.
U [This is indicated by GREEN LED
D]
FAIL: This means
m that thhe wrist strapp worn by opperator is outtside the Accceptable rangge of test
standard. [Thhis is indicateed by RED LED
L with Buzzz]
2) Footwearr Testing Seection: The instrument displays

d the individual Teest result for both the
feet at the same
s time ass per the folllowing. PASS
S: This meanns that the tootal resistance of the
footwear sysstem is in rannge of 0.75 M Ohms to 355 M ohms annd the footweear is OK to use.
u [This
is indicated by
b corresponnding GREEN
N LED] FAIL:: This meanss that the insttrument is ouutside the
acceptable range
r of testt standard. [T
This is indicaated by correesponding RE
ED LED withh Buzz] it
works with 9V
9 DC input (9V DC Adoopter will be supplied aloong with thee instrument) also the
instrument has
h a Normal 9V battery for stand by operation. The
T battery status indicatoor on the
instrument alerts
a the perrsonnel when the batteryy voltage goees less than 7Volts. Thee stand is
curved awayy from the opperator for eaase of use whhile testing.
Note: For Baattery operatiion, the DC Jack
J has to be
b removed frrom the instrrument.
1.1.8.7 ESD
E Work Bench:
B
Basic workttables are standard
s tabbles that aree suitable foor a broad range of taasks and
environmentts when fitted with accesssories: testing, packing,, repairing, innspecting. The
T Basic
table is guarranteed for reegular use wiith weights up to 500 kg.
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1.1.8.8. ESD Chair:

The ESDC Chair
C has beeen made to incorporate thhe Electrical properties off the ESD Chhairs with
the aestheticcs and comfoort of fabric upholstery
u of an office chaair. The speccial ESD Fabbric helps
the skin of persons
p sitting on the chaair to breathee. The seat iss wide and bback rest is a Medium
High Back variety
v which provides lumbar suppport and hennce the chaair is comforrtable for
extended peeriods of workk. The chair is also revolvving type andd height adjuustable throuugh a gas
lift.
1.1.8.9. PCB Storag

ge Racks:
For PCB
B storage
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1.1.8.10. (Inspection
n Systems) Light Magniifier:
The Lighht Magnifier is an integrrated light annd magnifierr. It featuress a 4x magnnification lenss and an
integrateed LED lightiing system foor shadow frree illumination. Configurre it for standdalone operaation with
its own optional
o basee plate.
1.1.8.11. ESD Apron

ns:
Techniccal Specificaations:
SL.NO PARAM
METER ESCRIPTION
DE N
01 Compoosition Polyester 98%
02 Weavinng Structure TW
WILL 2 up/ 1ddown
03 Yarn (D
Denier) Wrrap 75D Weppt 100D
04 Densityy (Thread/Incch) Wrrap 192 Weptt 92
05 Electroo Conductive Yarn Intervaal Wrrap 5mm Wept 5mm
06 Conductive Yarn Tyype Sufffused in to the Surface
07 Weightt 1100 Gm/Sqm
08 Frictionn Charge (V)) 30 V
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SL.NO PARAM
METER DE
ESCRIPTION
N
09 Surface Resistivity 10E
E6-10E9 Ohm
ms/Sq
05 Decay Time < 0.1
0 Sec
06 Particlee Filtration Efficiency 85((%)
07 Air Perrmeability 8.99 Cc/Sqcm/Seec
08 Moisture Permeability 3499 Gm/Sqm/H
Hr
09 Colourr Whhite/Blue/Pinkk/Navy(Subjeect to availabbility)
10 ESD Coats
C available in standarrd sizes S, M, L, XL
1.1.8.12. Anti-static liquids for cleaning

c purpose:
Antistatic Flooor Cleaner is specially designed liqquid cleanerr for the purrpose of wasshing the
Antistatic / Conductive
C P Floors. Floor
PVC F cleanerr is neutral inn PH value w
with no ionic residues
left behind after
a the flooor is cleanedd using the liquid. Antisttatic floor cleeaner has also been
imparted witth disinfectant characterristics for hygienic reasoons. Specialtty of this liquid is its
capabilities to meet the demands of
o the Static Control meeasures in Electronic andd related
applications..
1.1.8.13. Wrist strap

ps:
Wrist straps are the mosst basic form
m of defence against failuure of ESD ssensitive Com
mponents
due to Electtrostatic Disccharge. Theyy are inexpeensive and simple
s to usse. The wristt strap is
adjustable and
a has an elastic wrist band for operator com
mfort. The insside of the elastic
e is
conductive to make goodd contact witth the skin during
d use. The
T wrist bannd can be addjusted to
suit any wrisst comfortabbly. The Coil cord consissts of 1 mega ohm curreent limiting reesistor to
comply with the ESD Association staandards. Thee coil cord alsso has the ooption of banaana jack,
crocodile clipp or lug buttoon connector.
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1.1.8.14. ESD table Mat:

Work suurface are deesigned to provide
p A a homogeeneous polymer mix,
a staatic safe worrk surface. As
productss are alwayss protected by a consisstent, controolled static drain
d with uunsurpassed physical
propertiees.
1.1.8.15. Foot wear::

Anti static slipper is madde of soft andd comfort durrability and fllexibility. Thee sole is thickk enough
to protect baase board froom static andd make sure the static caan conduct too the earth. The anti-
static properrty makes sttatic dischargges to dissippative via the sole for thhose who arre on the
move in factory environm
ment with easse. It is also design
d with base
b that minnimizes dirt trrapping.
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1.1.8.16. ESD glovees:

Features: Gloves
G are made from 100 % polyesteer material with
w 5 mm coonductive yarrn, use in
PCB assembbly.
1.1.8.17. Synthesizeed Signal Geenerator

Analogue siggnal generatoors based onn a sine-wavee oscillator were
w commonn before the inception
of digital electronics, andd are still useed. There waas a sharp disstinction in purpose and design
d of
radio-frequency and audio-frequency signal generrators.
With the advvent of digitaal communicaations system
ms, it is no loonger possibble to adequaately test
these system
ms with traditional analoog signal gennerators. Thiis has led too the development of
vector signaal generators, also knownn as digital siignal generators. These ssignal generrators are
capable of generating
g digitally-modullated radio signals
s that may
m use any of a large number of
digital moduulation formaats such as QAM,
Q QPSK
K, FSK, BPSK, and OFD
DM. In additioon, since
mmercial diggital communnication systems are allmost all baased on well-defined
modern com
industry standards, manny vector siignal generaators can geenerate signnals based on
o these
standards.
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E8663D PSG RF Analog Signal Generator
Necessary specification of Synthesized Signal Generator

 100 kHz to 3.2 or 9 GHz with .001 Hz resolution
 -135 to +24 dBm typical output power with Option 1EU
 AM, FM, ØM, and pulse (may be simultaneously enabled)
 Lowest phase noise available in a commercially-available signal generator
1.1.8.18. MACHINERY REQUIREMENT:

Plant Machinery and Special Equipments
Sl.No Ref.No Name of the Machine Qty
1 DSD001 Digital Soldering and Desoldering Station 5
Soldering Iron
• Output Voltage 24V AC
• Power 60W heat up rating 130W
• Temperature 160°C - 480°C
• Ceramic Heating Element
Desoldering Gun
• Output Voltage 24V AC
• Vacuum Pressure 600mm HG
• Power 80W
• Temperature 160°C - 480°C
2 BGA001 BGA Re-work Station 1
APPLICABLE PCB SIZE
• Max. PCB Size : 430mm x 350 mm
APPLICABLE BGA SIZE
• Max. Size : 55 mm x 55 mm
• Min Size : 7mm x 7 mm
• Max Weight : 80 g
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3 USM001 Ultra-Sonic Cleaning Machine 1

• Four Stage Cleaning Machine
• Water based neutral cleaning media
• Fully interlocked motorized mechanism for up/down motion and
traverse mechanism
4 ASC001 Air Shower Chamber 1
• Stainless Steel SS-304 Grade Construction
• Face Velocity - 6000 ft/min + 20 feet
• HEPA Filters - Glass pleated non woven fabric filter having 99.99%
efficiency
• Multi- Directional Air Flow
• Solid State Air Flow Control Unit
5 ESD001 ESD Work Bench 1
• Frame – Static Dissipative powder coated MS 38 SQ Frame (2mm
thick) dismantling type.
• Table Type – Marine grade water proof ESD laminated post formed
table top with notching-01no and With size-1600W X 870D X 25mm
thick (silver gray colour)
• Top Storage Shelf – Marine grade water proof ESD laminated post
formed storage top with notching-01no.size-1600W X 600D X 25mm
thick. (Silver gray color) fixed shelf.
• MS Power Race – Static dissipative powder coated ms power race
way-1no and is with Size of 1595W X 60D X 100H (Approx.)
6 ESD002 ESD Chair 1
• Seat Upper Layer – Static Dissipative Leather
• Back Rest – Anti Static PP Plastic
• Metal Parts – Chrome Plated Steel
• Gas Cylinder – Chrome Plated Steel
7 PCB001 PCB Storage Rack 5
• Material – Conductive plastic
• Size - External 485 x 175 x 50 mm
• Total No. of slots up to 25
• Width of each slot up to 3.0 mm
• Depth of the slot up to 7.5 mm
• Surface Resistivity of 10E4-10E6 ohms/Sq
8 ALC001 Anti-static liquids for cleaning purpose 5
• Aqueous based liquid supplied as concentrate.
• Diluting medium, preferably hot de-ionized water or hot clean
water.No ionic contaminants
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9 ESD003 ESD Wrist Strap 5

• Band Type – Adjustable Elastic band
• Length of the band – 2m when fully extended
• Material of the band - Made of Elastic & electrical conductive woven
fiber
• Contact with wrist band – 7mm ID & 10mm OD Male button
• Loose end contact – Banana Plug + Crocodile Clip +7mm Lug button
10 ESD004 ESD Table Mat 5
• Length of the mat – 1m
• Material of the band - Made of Elastic & electrical conductive woven
fiber
• Contact with wrist band – 7mm ID & 10mm OD Male button
• Loose end contact – Banana Plug + Crocodile Clip +7mm Lug button
11 ESD005 ESD Foot Wear 5

• Color – Completely White
• Body to Ground resistance - 2.17 E6 Ohms/sq
• Surface Resistance - 10E6 Ohm
• Size - Small, Medium, Large, XL
• Compliant to ANSI ESD S 20.20 and ISO - 9001 standards
12 ESD006 ESD Gloves 5

• Yarn – RFT 50D Denier
• ECF – BASF 22D Carbon Suffused
• Weave – Tricot (Stripes 10 mm)
• Weight – 99 GR/MR SQ
• Surface Resistivity – 10^7 to 10^9 Ohm/sq
• Friction Static Voltage – 50V
Static Decay – 5000V to 500V within 0.10 secs
13 ESD007 ESD Testing Equipments 1
Combo Tester
• Range for Footwear Section – Right: 0.75 To 35 M Ohms Left: 0.75
To 35 M Ohms
• Range for Wrist Strap Section – 0.75 To 10 M Ohms
• Indications – PASS - Green LED, FAIL - Red LED Audible Alarm for
fails mode
Static Sensor
• Power supply – 9V Battery
• Detection method – Charge coupling by field Interception
• Detection sensitivity – 100V
14 LIM001 Light Magnifier 5
Provision of 1.7x zooming, with LED powering and RoHS compilant
15 ESD008 ESD Aprons 10
• Polyester 98%
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• Weight – 110 Gm/Sqm

• Friction Charge (V) – 30 V
• Surface Resistivity – 10E6-10E9 Ohms/Sq
• Air Permeability – 8.9 Cc/Sqcm/Sec
• Moisture Permeability – 349 Gm/Sqm/Hr
Testing Equipments:
S.No. Ref .No Name of Testing Equipments Quantity

1 DRT001 Digital Insulation Resistance Tester 5000VDC 2
• 3 1/2 Digit LCD Display
• Backlight
• Data Hold
• Auto-ranging (0.1M to 200G for 1000V)
• Test Voltage: 1000V
2 AWG001 Arbitrary Waveform Generator, 10 MHZ 2
• 10 MHz sine and square waveforms
• Option 002 provides 14-bit, 50 MSa/s 8 K-point arbitrary
waveform generator
• Ramp, triangle, noise, pulse generation with variable edge, and
DC waveforms
3 DSO001 Digital Storage Oscilloscope 4
• 1 GHz, 2 Analog Plus 16 Digital Channels
• update rate of 1,000,000 waveforms per second
• 8.5-inch WVGA display
1.2 WORKS DEPARTMENT

1.2.1 METHODS ENGINEERING / INDIGENIZATION SECTION
Method Engineering Group is responsible for the methodisation of production work. It
calculates the man-hours, costing, tooling and material requirement for line assembly work.
This group is also the main R&D and design hub for indigenization of the spare parts. It
consists of following departments.
 Method Engineering Section
 Indigenization cell
 CAD/CAM Centre
 Material Testing Laboratory
 Drawing Room
 Tool Room
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IT Infrastructure
 There is no separate IT infrastructure at present for the section. The tools currently in use
are basic and need up gradation
 The setting up of IT infrastructure will bring in the need for Environment controlled rooms
Material testing equipment

 The material testing lab lacks modern testing equipments that will be useful for the Base
workshop and also clean room conditions for any CAM machines that may be installed.
 The material testing facility currently needs a state of art material testing lab capable of
testing physical and chemical properties of any type of material.
Indigenization cell
 The Indigenization cell has got no modern prototyping machines that will help in re-
engineering of parts to facilitate indigenization of parts
 The CAD/CAM centre needs a complete overhaul of its facilities including modern
computer system of higher configuration, along with the latest CAD software like CATIA
V5, Pro-E, and AnSYS etc.
 The furniture in the drawing room needs to be replaced along with a new lighting system
and HVAC system

The purpose of the Method Engineering group is set up methodology for manufacture of spares
and also the indigenization of spares, they play a very important role.
 The division will be provided with state of art material testing lab equipped with modern
gadgets to test physical and chemical properties of all types of materials.
 This division's IT infrastructure is to include the latest technology in Computer Aided
Design (CAD), Computer Aided Method (CAM), and E-CAD.
 The latest high configuration computers, work station, printers, plotters are to be procured
for methods engineering division.
 The proposed High end design and drafting software to be included for the group are Pro-
E, Solid works, CATIA, Auto CAD, CAD Inventor, and UG are proposed.
 In addition to the design and drafting software CAM tools software are also to be included
to enable the division to develop CNC programming for High Speed Machining, that is
being proposed to be installed for all production group.
 CAM tools integrated surfacing modelling and NC programming techniques allows
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generating tool path to run the CNC machines "Safely & Unattended" while providing
unparalleled finish quality.
 The Indigenization cell has to be equipped with the latest technologies like Rapid
Prototyping machines, 3D Scanner, 3D printer, Wire Cut EDM machines and Co-Ordinate
Measuring Machines (CMM)
 The material testing lab is to be modernized by installing both Destructive and Non-
Destructive testing methods. The machines Up-gradation of training and skill to handle
and equipments selected here are of high technology and sophisticated ones required for
repairs and calibration.
1.2.1.4 Recommendation:
1.2.1.5 ReverseEngineering:
Reverse engineering is a copy process. Sometimes, a design without any engineering data but
sample model, such as shoes or golf club, must be production. Reverse engineering can copy
3D data from the sample model. Traditionally, a 3D mimic milling machine copy the shape of
sample and produce a full scale mold than make mass production. This kind of copy process is
Analog type copy. It cannot rebuild engineering data nor revise shape. The new digital
reverseengineering system with 3D digitizer measures surface profiles to get 3D digital data
quickly and precisely. From 3D digital data, engineers can rebuild, edit, and revise surfaces to
get 3D models which can import to CAD/CAM system. With 3D models, engineers can create
NC tooling path in CAM system. Finally, CNC machine make the mold to mass produce
product. From 3D models, engineering can also get STL data. Rapid Prototyping system
makes a sample model. These processes are reverse engineering.
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Improving industrial technology brings products diversified, complicated and shorter product life
cycle. Therefore, it is important to design and produce products in time and to get market
share. But not all of products have original engineering data. Some shapes of products are
sculpted in clay with hands by designer or model maker. Traditionally, engineers made
approximated mold with complex mimic procedures still without 3D digital data. Reversed
engineering can conquer these difficulties easily. Reversed engineering can quickly accomplish
product design and manufacture. It can be applied to various field include auto parts, exercise
accessories, medical accessories, home appliances, glass wares, shoe molds, golf clubs,
ceramic wares and rapid prototyping.
Firstly, Reverse engineering uses 3D digitizer to get digitized profile coordinates of model.
These digital coordinates can be reconstructed into surface model. After editing and revising,
the surface model transfers to general CAD/CAM systems. From CAD/CAM systems, we can
get NC tooling path for CNC machine to produce mold or get SLA file format for rapid
prototyping machine to produce sample.
Rapid prototyping technology uses CAD/CAM system to get solid model and transfer to STL
format which is polygon mesh to approximate the surfaces of solid model. Complex model
needs more triangular mesh to simulate model surfaces. Rapid prototyping computer gets STL
Editor (Slicing Software) which can slice polygon mesh model and analyzed cross section of
each layer. Rapid prototyping machine solidified each layer material either liquid or power than
stack together to make a sample.
Companies, from OEM, ODM to brand, use Reversed engineering as main procedure to
develop, design and manufacture products. Reversed engineering helps companies to develop
ideas, improve quality and ability of product design. By way of shortening product development
cycle, product meets time to market. Company gets more market share and global competition
advantages.
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1.2.1.6 Machinery list:

A ) REVERSE ENGINEERING SECTION
1 SPA001 Spectra Analyser 1

• Power supply: AC 100,230/240V, 50/60Hz
• Interface: SCSI-2
• Mirror scanning speed: 2.5, 5, 12.5, 25mm/sec
• Resolution(cm-1): 1, 2, 4, 8, 16
2 MTM001 Metallurgical Microscope 1
• Eyepiece tube: inverted tri-ocular eyepiece tube
• Leaning degree of tube 30°
• Mechanical tube length: 160mm
• Specification: 200x152mm Moving range: 15x15mm
• Illumination unit: KELE Illumination: 60V/20W halogen
lamp, adjustable brightness.
• Power: 220V/50Hz, Filter: yellow, blue, green 1each
6V/20W halogen lamp 1pc
3 MPM001 Metallurgical Polishing Machine 1
• Base Unit with large 0.75HP Motor
• Variable wheel speed 50-600 rpm
• Automatic Head, Large LCD screen
• LED lighting
4 SEM001 Scanning Electron Microscope 1
• SmartSCANstrategy
• Up to 4096 x 3536 pixels(~14Megapixel)
• File type: TIFF (8 or16 bit), BMP orJPEG
• 256 frame average orintegration
Accelerating voltage : 200 V - 30 kV
• Probe current : up to 2 µA, continuously adjustable
• Magnification : 13 to 1000000
5 PHT001 Portable Hardness Tester 1
• Measuring Hardness Range : HRC 0 - 70,HRB 0 – 120,
HB 30 – 700,N/mm2
• Detector : carbide ball
• Display Unit : LCD display, maximum 3 digits
• Function Conversions : HL,HV, HB, HRC, HRB, HS, HTN
• Indentation Direction : Any Direction
• Offsetting Memory : 1,800 data
• Output : RS 232C, SPC
• Power supply : Alkaline AA battery
• Power Output : 100 hours approximately
• Dimensions : Detector: (Dia. X H) 1.10” x 6.89” (28 x 175
6 WKT001 Worktable 5
7 PTK001 Power tool kit 5
8 STR001 Storage racks 5
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B) MEASUREMENT LAB
Quantit
S.No. Ref. No. Name of Testing Equipment
y
1 RCM001 Roundness And Cylindricity Measurement 1
• Mechanism / system : Porous static pressure air bearing
system / table rotation type
• Rotation accuracy: (0.04 + 0.0006H) μm H: height from table
surface (mm)
• Max. measuring diameter : φ220 mm both inner and outer
diameters
• Z traverse range : 280 mm (at the use of b-type stylus arm)
Supplied with fine or coarse adjustment function (memory: 0.1
mm)
2 SRM001 Surface Roughness Measurement 1
2D Roughness:
• Standards : JIS(2001/94/82), DIN, ISO, ASME, etc
• Measuring range : Z: 600 μm X: 100 mm
• Measuring magnification : Z: 50-500,000 X: 1-5,000
• Recording : Recordable in free layout
3D Roughness:
• Measuring range : Z: 600 μm X: 100 mm Y: 50 mm
• Minimum sampling pitch : 1 μm for X and Y
• Recording : Color recording (bird's eye view, differential
contour, etc.), particle analysis, 3D roughness parameter
analysis, etc
3 OPJ001 Optical Profile Projector 1
Working table:
• Working table size(mm) 400*150
• X-axis travel(mm) 200
• Z-axis travel(mm) 100
• Y-axis travel(mm) 75(for focus)
• Turning range ±15°
• Resolution(X-axis,Z-axis) 0.001mm
• The indication error of coordinate(µm) <=(4+L/25)
Dimension:
• L*W*H(mm) 1090*830*1010
Weight:
• Unit:(kg) 160
• Power 110V/220V(AC);50/60HZ; Total power=400W
4 WKT001 Worktable 10
5 PTK001 Power tool kit 5
6 STR001 Storage racks 2
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CNC Equipments:

A) REVERSE ENGINEERING SECTION
1 3DP001 3 D Printer 1
• Basic System : Including Nitrogen generator, Exchangable
frame system, Software licence EOS Desktop PSW plus an
offline version of PSW
• IPCM : SM P3 - Sieving Machine Atex Version
• Software :
EOS RP Tools 5.07 (32Bit)
Magics RP base single license (32Bit)
• Powder Material : 40 Kg Precision polyamide PA 2200
2 RPT001 Rapid Proto Type 1
• Base System 36” x 24” x 36”
Choice of Material:
• ABS-M30
• ABS-M30i
• ABS-ESD7
• PC-ABS
• Polycarbonate (PC)
B) MEASUREMENT LAB
1 CMM001 Co Ordinate Measuring Machine 1
• Operating Mode : DCC
• Measuring Range X axis mm :1200
• Measuring Range Y axis mm :3000
• Measuring Range Z axis mm :1000
• Clearance range Bridge mm :1230
• Length :4250
• Width :2130
• Height :3800
• MPEE :3+L/200
• MPEP :3.0
2 3DS001 3 D Scanner 1
• Single Scan Range : 400 x 300 x 150 mm
• Scanning Type : Non-Contact
• Degitization : 1280 x 1024/1.3 Mega Pixels
• Feature accuracy : 0.04 mm - 0.015 mm
• Object Size : Grater than 200 mm ~ 1500 mm
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Testing Equipments:
A) MATERIAL TESTING LAB

1 MPM001 Melting Point Tester 1
• Base Unit with large 0.75HP Motor
• Variable wheel speed 50-600 rpm
• Automatic Head, Large LCD screen
• LED lighting
2 HRM001 High Resolution Microscope 1
• Hard mask surface of the coating, corrosion, wear, area
140X135mm stroke 76X50mm crude micro-coaxial. Investigation
focal stroke 30mm, Fine Division
• 0.002mm, to ensure adequate operating distance.
• X,Y,Z axis resolution: 0.5um
• 24V/20W Halogen lamp
• Dimension : 540X667X850mm
3 WQA001 Water Quality Analyser 1
Display easy to understand value and functions menus
• Switch between digital real time graphs or analogue displays
during measurement with just
the flick of a finger.
• Full on-screen support on the meter via an electronic user guide
with colour pictures that
can be called up at any time, featuring problem solver guide for
calibration or measurement
4 ABT001 Abrasion Testers 1
• can be called up at any time, featuring problem solver guide for
calibration or measurement
5 HTR001 Hardness Tester For Rubber 1
• Measurement range : 0-100HA (HD)
• Measurement target : Soft Rubber,felt,hardfoam,winder
• Measurement deviation : 0 ＜1%H
• Resolution : 0.1
6 LTM001 Leather Testing Machine 1
• Flexing Frequency : 100 + 5 cycles per minute
• Angle of oscillation of grips : 22.5 + 050
• Dimension of the test specimen : 70 x 45 mm
7 FEL001 Hardness Tester For Felt 1
• Display specification :Digital
• Measurement target : Soft Rubber,felt,hardfoam,winder
• Shaft Diameter :1.25 ± 0.15 mm
• Tip Shape : Semi - Sphere
• Tip Diameter :5 ±0.04
• Pressure surface shape : 44 x18 mm
• Protrusion of press needle from :2.5mm
8 STM001 SPRING TESTING MACHINE
Digital load indicator on the machine will be connected to a load cell.
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The machine will have one load cell (capacity: 150 kgf.).
Non-memory resident digital length/ displacement indicator having
resolution 0.1mm and accuracy + 0.2mm using rotary optical
encoder.
Power supply: 220V, single phase, AC supply
Loading Capacity: 150 kgf max.
B) CHEMICAL TESTING LAB
1 CHA001 Chemical Analyser 1

• The minimum sample capacity should be 30 at a time.
• Multi-monitoring with one unit of up to 4 types of chemical solutions
or ranges possible.
• Measurement principle : Absorption spectrometry
• The through put should be 150 tests or more per hour.
2 CSA001 Carbon And Sulphur Analyser 1
• Automation system of EMIA Mid-process measurement: Editing of
measurement order Main unit: (W) 619 x (D) 928 x (H) 953 mm;
approx. 170 kg,
• Voltage: Main unit: Specify 200 V
• Power: Main unit: 5 kVA, PC: 0.5 kVA, Cleaner: 1 kVA
• Supply pressure: 0.35 MPa
3 SOA001 Sodium Analyser 1
• Range, pH : 0 -14 pH, reagent conditioned sample
• Range, temperature : 0-100 ° C
• Ambient operating temperature : 5-50 °C (41-122 °F)
• Dimensions HWD Enclosures: 900 x 450 x 190 mm
4 PTT001 Ph Tester 2
• pH : -2.000 to 19.999
• mV (rel. mV) : -1999 to130.0 °C
• Resolution : 0.001
• Accuracy :0.002
5 MPM001 Melting Point Tester 1
Base Unit with large 0.75HP Motor
Variable wheel speed 50-600 rpm
Automatic Head, Large LCD screen
LED lighting
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1.2.2 WORKSHOP SERVICE GROUP

Workshop Service Group is responsible for formulating the perspective plans of the workshop
services, installation of new machines, repairs and maintenance of all technical infrastructure
and PSMEs, initiate MES works for buildings, electrical power, water and allied facilities like
compressed air and environment control and housekeeping. The group also maintains
machinery folders consisting of receipt inspection, periodic inspection, machinery card,
machinery usage card and machine wise annual repair cost.

Mechanical
 Insufficient space for machineries & equipments were studied.
 Need of modern plant & machineries were discussed.
 Need of space for stores, record room and spares were discussed.

The Workshop Services Group provides the support and maintenance of all production groups
and all allied activities in the Army Base. For other production groups to maintain their
efficiency and modernization goals the Workshop Services Group needs to be up-to date on
equipments and technologies. The scope of work to be undertaken will fulfil these
requirements.
 The unsafe buildings will be demolished and will be newly constructed with better shop
 The proposed buildings are of RCC framed and steel construction with profile sheeting
and the floors are provided with proper cable trenches. The flooring will be ironite and with
hardener topping.
 The new buildings will be integrated and orientated to minimize energy consumption as
per the functional aspects. The electrical wiring will be modernized to improve the
 The buildings which are to refurbished will be upgraded or revamped for columns and
 The columns with RWP will be integrated with proper drain. And the cable trenches will be
covered with proper cover plates.
 The modern heavy duty portable ramp is included.
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 Advanced optical line network connection for internet and intra-net facilities are also
considered.
 New building and infrastructure facilities will be provided for storing tools and spares
required to maintain the Base Workshop.
 Material handling systems helps in automating the possible processes in the workshop.
 Advanced welding and brazing machines will be used for manufacturing of spares.
Room conditions
1.2.2.4 Recommendation
The workshop services group provides two kinds of maintenance process (Annexure 1.2.2 -A)
 Preventive Maintenance
 Breakdown Maintenance
In this part of the group the following maintenance sections are located
 Machine shop maintenance section
 Motor repair /maintenance section
 HVAC repair / maintenance section
 Fork left & Crane maintenance section
 Carpentry & upholstery section
 House Keeping Equipment Maintenance section
 Painting section
 Raw material store
 Machine shop
 Welding shop
1.2.2.5 Tasks
 Repair & maintenance of machine tools in shop floor
 Repair & maintenance of machine handling equipments
 Repair & maintenance of House Keeping equipments
 Repair and maintenance of HVAC equipments
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 Repair and maintenance of motor and pump equipments

 Repair and maintenance of buildings
 Repair and maintenance of rolling shutters & windows
 Repair and maintenance of fire fighting equipments
 Repair and maintenance of ventilation and electrical items
 Supply of tool for rooms in the shop floor area
 Maintenance of electrical lines
 Maintenance of intranet lines
 Maintenance of piping & pumping lines
 Maintenance of ETP & STP equipments
 Maintenance of RO Plant equipments
 Maintenance of Slat conveyor System
 Refilling of oil tanks
 Periodical oil change joined with flushing & cleaning of oil tanks
 Lubricator refilling
 Machine coolant refilling
 Maintenance of washing & blasting units.

1 CNL001 Conventional Lathe – Model 1 1
• Width of Bed 380 mm
2 PDM001 Pillar Drilling Machine 1
• Drill Capacity in steel 20 Mm
• Tapping capacity in steel M 12 Mm
• Morse taper in spindle MT 12 Mm
• Spindle travels 130 Mm
• Vertical adjustment of spindle head 425 Mm
• Spindle speed 10 (rpm)
• Speed: 2800 rpm
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• Oxy-Acetylene ratio for Welding 1.1:1
• Oxy-Acetylene ratio for Cutting 1.5:1
• Cutting Capacity 45º • Stroke (approx) 60 – 75 mm
Diameter: 400 + 5 mm- 3 mm
Thickness: 4.0 + 0.25 mm
Bore: 22.23 +0.5 mm -0 mm
Nominal Size: 400 x 4 x 22.23 mm
Operating speed: 4800 r.p.m. (approximately)
8 PBM001 Pipe bending Machine 1
• Max bending capability 0115 x10 mm
• Max bending radius R520 mm
• Min bending radius R90 mm
• Max effective distance of mandrel 4500 mm
9 CRM001 Coil Rewinding Machine 1
• Maximum torque load : 350Nm
• Motor Power : 3.0kw
• Winding Speed : 400 rpm
• Maximum No. of Parallel Wires : 25 x 1.32 mm
• Coil Diameter : 50 to 1060 mm
• Coil Circumference : 160 to 3330
10 ILM001 Industrial Laundry Machine 2
• Capacity : 250 Kg.
• Drum Size : 1200 x 2800 mm
• Motor power : 7.5 Kw
• Rotate speed : 29 rpm
• Water consumption : 1750 kg
11 MDM001 Magnetic Drill Machine 1
• Diameter : 52 mm
• Depth : 52 mm
• Twist Drills : # 2 Morse Taper 23mm
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1.2.3 OSS
1.2.3.1 Introduction
The functions of OSS broadly are:-
(a) Demanding, stocking and issuing stores of ordnance origin required for repair
equipment by the Army Base Workshops.
(b) Carrying out provision review as per instructions.
(c) Receiving, taking on charge and reissuing stores locally purchased, manufactured,
retrieved, reclaimed by Workshops.
(d) Receiving serviceable surplus stores if any, from the Workshops after the repair
commitment is over.
(e) Back loading stores on longer required to concerned CODs.
(f) Demanding, stocking and issuing in bulk, expendable stores, required by the
Workshops as well as for use in OSS.
Traffic
Trafficsection will be responsible for receiving the stores consigned to OSS and handing
them to the receipt section. Stores will be received by rail/road or post. The broad functions of
this section can be sub-divided into:-
(a) Action before the arrival of stores.
(b) Action on receipt of stores.
(c) Disposal of stores and documents.
(d) Discrepancies.
Action before Arrival of Stores
(a) Railway receipts (RRs) will be received from receipt section of OSS.
(b) RRs will be kept in a separate file one for each consignee station.
(c) These RRs and file will be regularly examined to expedite the railway authorities or
ot raise claim in case of RRs are outstanding over the normal time allowed for transit.
(a) By Rail-Full Wagon.
The seals will be checked and if intact the stores will be off-loaded under supervision of
Traffic representative. If not intact, open delivery will be taken after Officer Commanding
OSS has been informed.
(b) By Rail Piece
Consignments:-
(i) Delivery of piece consignments will be taken at Railway Station.
(ii) The delivery will be taken on relevant RRs. If RR is not available delivery will
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be taken on indemnity bonding case there is a sign of packages having been

tampered, open delivery will be taken.
(c) By Road or Post If stores are received by post/road the particular of such
receipts will be entered in a Register of Receipts.
(a) Daily Receipt Sheet (DRS) will be prepared in duplicate for all receipts.
(b) Daily receipt sheet will be slotted serial number which will be maintained by
Traffic Section.
(i) Suffix F - Full wagon
(ii) Suffix P - Piece Wagon
(iii) Suffix PP - Postal Parcels
Disposal of Stores and documents
(a) Stores will be handed over to the receipt section on Number 1 and 2 copies of DRS.
(b) The In-Charge Receipts will sign number 1 copy as token of having received
correct number of packages.
(c) The traffic rep shall hand over number 1 copy of DRS to receipt Sub Section and
obtain acknowledgement in the Traffic Register.
Stores Received from Ordnance Agencies
Whenever stores have been received through depots the traffic section will hand these to the
receipt section along with 2 copy of DRS. The stores will be checked for correctness and
disposed of the normal manner.
Locally Purchased Stores

Whenever stores have been purchased locally, these will be inspected by a board of
officers of which the Officer Commanding OSS or his rep shall be a member., stores after
inspection will be handed over to OSS, with 3 copies of Inspection action taken . Two Notes
will be taken as RV and normal receipt requirement of LP stores will be directly issued to the
section concerned. The Officer Commanding OSS shall bring to the notice of the Comdt&
MD if LP stores are not consumed within a reasonable time.
Locally Manufactured Stores.

Locally manufactured stores will be received from the Workshops along with 2 copies of WCN.
After checking for correctness, these will be handed over to stores on WCN duly controlled,
and issue to Workshops in a normal way. In case of urgency physical movement of stores
need take place and only documentation will be carried out.
Return of Surplus Stores from Workshops.
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Immediately on completion of a repair programme, intimation will be given by the Workshops

to OSS in return voucher.
Expendable Stores.
All expendable material will be issued to ESS in bulk against demands prepared on IAFO-
2183 in quadruplicate, These demands will also be controlled by issue Control Clerk before
issue.
Accounting of Stores
Account Cards will be maintained for all items including expendable stores on IAFO-2630. The
stores of the OSS can be divided into the following categories:-
(a) Items peculiar to an equipment.
(b) Items common to more than one equipment.
(c) Expendable stores.
The following system has been incorporated in the stores
1.2.3.2 ASRS
An automated storage and retrieval system (ASRS or AS/RS) consists of a variety of
computer-controlled methods for automatically placing and retrieving loads from specific
storage locations. Automated Storage and Retrieval Systems (AS/RS) are typically used in
applications where: there is a very high volume of loads being moved into and out of storage;
storage density is important because of space constraints; no value adding content is present
in this process; accuracy is critical because of potential expensive damages to the load. AS/RS
can be used with standard loads as well as nonstandard load.
1.2.3.3 Overview
AS/RS systems are devices designed for automated storage and retrieval of parts and items in
manufacturing, distribution, retail, wholesale and institutions. They were invented in the 1980's.
They are compact units that utilize the unused overhead space of a plant or warehouse, and
convert to live storage of product. Items can be placed on trays or hang from bars, which are
attached to chains/drives in order to move up and down. They focus on bringing "goods to the
man"rather than manual walking and searching. Space savings, increased productivity/reduced
labor, increased accuracy and reduced inventory levels are some of the primary benefits. Ideal
for lean manufacturing, sustainability, six sigma, Kanban, JITand other value added
methodologies and processes. The equipment required for an AS/RS include a Storage &
Retrieval Machine, or SRM, that is used for rapid storage and retrieval of material. SRM are
used to move loads vertically or horizontally. SRM can also move laterally to place objects in
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correct storage location. The trend towards just in time production often requires sub-pallet
level availability of production inputs, and AS/RS is a much faster way of organizing the storage
of smaller items next to production lines. Traditional high bay warehousesare designed with
pallet storage in mind, and if goods are being delivered in sub pallet quantities, high bay
warehouses are problematic.
Material Handling Institute of America (MHIA), the non-profit trade association for the material
handling world, and its members have broken AS/RS into two primary segments: Fixed Aisle
and Carousels/Vertical Lift Modules (VLMs). Both sets of technologies provide automated
storage and retrieval for parts and items, but use different technologies. Each technology has
its unique set of benefits and disadvantages (like everything in the world). Fixed Aisle systems
are characteristically larger systems whereas carousels and Vertical Lift Modules are used
individually or grouped, but in small to medium-sized applications.
Fixed-aisle AS/RS is categorized into three main types: single-masted, double masted, and
man-aboard. Most are supported on a track and ceiling guided at the top by guide rails or
channels to ensure accurate vertical alignment, although some are suspended from the ceiling.
The 'shuttles' that make up the system travel between fixed storage shelves to deposit or
retrieve a requested load (ranging from a single book in a library system to a several ton pallet
of goods in a warehouse system). As well as moving along the ground, the shuttles are able to
telescope up to the necessary height to reach the load, and can store or retrieve loads that are
several positions deep in the shelving. A semi-automated system can be achieved by utilizing
only specialized shuttles within an existing rack system. To provide a method for
accomplishing throughput to and from the AS/RS and the supporting transportation system,
stations are provided to precisely position inbound and outbound loads for pickup and delivery
by the crane.
In addition, there are five types of AS/RS devices called Unit-load AS/RS, Mini-load AS/RS,
Vertical Lift Modules (VLMs), Horizontal Carousels and Vertical Carousels. These systems are
used either as stand-alone units or in integrated workstations called pods or systems. These
units are usually integrated with various types of pick to light systems and use either a
microprocessor controller for basic usage or inventory management software. These systems
are ideal for increasing space utilization up to 90%, productivity levels by 90%, accuracy to
99.9%+ levels and throughput up to 750 lines per hour/per operator or more depending on the
configuration of the system.
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1.2.3.4 AS/RS Components and terminology

An AS/RS consists of one or more storage aisles that are serviced by a storage/retrieval (S/R)
machine. The stored materials are held by storage racks of aisles. The S/R machines are
used to deliver and retrieve materials in and out of inventory. There are one or more
input/output stations in each AS/RS aisle for delivering the material into the storage system or
moving it out of the system. In AS/RS terminology, the input/output stations are called pickup-
and-deposit (P&D) stations
Storage Space
It is the three-dimensional space in the storage racks used to store a single load unit of
material.
Storage Racks
This structural entity comprises storage locations, bays and rows.
Storage Structure
It is the rack framework, made of fabricated steel that supports the loads contained in the
AS/RS and is used to store inventory items.
Storage/Retrieval Machine
It is used to move items in and out of inventory. An S/R machine is capable of both horizontal
and vertical movement. A rail system along the floor guides the machine and a parallel rail at
the top of the storage structure is used to maintain its alignment.
Storage Modules
These are the unit load containers used to hold the inventory items. These include pallets, steel
wire baskets and containers, pans and special drawers. These modules are generally made to
a standard base size capable of being stored in the structure and moved by the S/R machines.
Pickup and Deposit (P/D) Stations

P/D stations are where inventory are transferred into and out of the AS/RS. They are generally
located at the end of the aisles to facilitate easy access by the S/R machines from the external
material-handling system. The location and number of P/D stations depends upon the
origination point of incoming loads and the destination of output loads.
1.2.3.5 Types of AS/RS

Several important categories of AS/RS can be distinguished based on certain features and
applications. The following are the principle types:
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Unit Load AS/RS

The unit load AS/RS is used to store and retrieve loads that are palletized or stored in
standard-sized containers. The system is computer controlled. The S/R machines are
automated and designed to handle the unit load containers. Usually, a mechanical clamp
mechanism on the S/R machine handles the load. However, there are other mechanisms such
as a vacuum or a magnet-based mechanism for handling sheet metal. The loads are generally
over 500 lb per unit. The unit load system is the generic AS/RS.
Mini Load AS/RS

This system is designed to handle small loads such as individual parts, tools, and supplies that
are contained in bins or drawers in the storage system. Such a system is applicable where the
availability of space is limited. It also finds its use where the volume is too low for a full-scale
unit load system and too high for a manual system. A mini load AS/RS is generally smaller than
a unit load AS/RS and is often enclosed for security of items stored.
Deep-lane AS/RS
This is a high-density unit load storage system that is appropriate for storing large quantities of
stock. The items are stored in multi deep storage with up to 10 items in a single rack, one load
behind the next. Each rack is designed for flow-through, with input and output on the opposite
side. Machine is used on the entry side of the rack for input load and loads are retrieved from
other side by an S/R- type machine. The S/R machines are similar to unit load S/R machine
except that it has specialized functions such as controlling rack-entry vehicles.
Man-on-board AS/RS
This system allows storage of items in less than unit load quantities. Human operator rides on
the carriage of the S/R machine to pick up individual items from a bin or drawer. The system
permits individual items to be picked directly at their storage locations. This provides an
opportunity to increase system throughput. The operator can select the items and place them
in a module. It is then carried by the S/R machine to the end of the aisle or to a conveyor to
reach its destination.
Automated Item Retrieval System
This system is designed for retrieval of individual items or small product cartoons. The items
are stored in lanes rather than bins or drawers. When an item is retrieved from the front by use
of a rear-mounted pusher bar, it is delivered to the pickup station by pushing it from its lane and
dropping onto a conveyor. The supply of items in each lane is periodically replenished and thus
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permitting first-in/first-out inventory rotation. After moving itself to the correct lane, the picking
head activates the pusher mechanism to release the required number of units from storage
1.2.3.6 Recommendations
We recommend a automatic storage and retrieval system by using specialized shuttles and a
storage rack system. The system will enable easy identification and tracking of spares,
maximize space utilization, reduce labour and increase productivity.
The semi-automatic storage system will consist of the following.

a. Storage and Retrieval Machines
b. Storage bays with adjustable dividing shelves
c. Pallets
d. Modular rack system for storage of tyre wheels, batteries and oversized parts
e. Multi-tier installation with mezzanines
f. Storage bins
g. Computer with software & Bar code readers
1.2.4 Material Control Group

1.2.4.1 MCO
The function of MCO is to ensure that the spares/materials required by the workshops for
smooth execution of the preplanned schedule against repair/manufacture commitments allotted
by Army HQ are positioned at the right time in correct range and depth and at the right time so
that there are no bottlenecks during overhaul.
In order to coordinate its functions efficiently it is considered desirable that the Material Control
organization including OSS should be so located that close liaison may be possible between
the various sections.
Activities
The broad activities of the Material Control Organisation which have been explained to
detail in succeeding paragraphs will be as under :-
(a) Initial and supplementary provision of spares/materials as per ISG/Overhaul scales
and supplementary demands.
(b) Preparation and updating of overhaul scales and ‘O’ column of ISG.
(c) Progressing and procurement of inabilities.
(d) Progressing of manufacture of spares on MOS work orders.
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(e) Local manufacture for progress of commitments.

(f) Local purchase of items declared NA.
(g) Repair by Local Contract.
(h) Central Demand Section.
(j) Planned retrieval from class VI equipments.
(k) Workshop Store Section for Engineer Equipment and non-Ordnance origin spares.
(l) Expense Store Section for expendable materials and raw materials.
Provisioning procedure
The form provisioning implies advance provision of spares and material from “ordnance’
required by Workshops for various commitments, such as Army HQ repair commitments,
deposit repairs, manufacture commitments, repairs of class ‘B’ stored, maintenance of unit
vehicle/equipment and WOs. The provisioning will be the responsibility of the OSS, WSS
attached to Workshops, whereas the necessary data will be supplies by DY GM (M). This
section deals with the detailed activities of the OPS of the material control organization.
Spares / Materials for Maintenance of Unit Vehicles and Equipment.
(a) Workshops may obtain their requirement from OSS provided the same is readily
available such issue will automatically be replenished by OSS if considered essential in
accordance with Army HQ letter number 06084/OS-II dated 8/22 Jun 62.
(b) Since OSSs are not permitted to stock maintenance spares certain OSSs may nor hold
such spares. Depending upon the type of load on the Workshops. WSS will demanded
maintenance stores such as contact points, wheel and master cups., fuel pump gasket
etc., as per maintenance scales for field Workshops, direct from depots and stock then
against ledger charge in order to avoid sudden hold ups.
(c) Repairable / UNSV stores accrued during course of repairs will be disposed off in
situation by concerned CODs as per latest direction issue vide Army HQ letter number
A/93623/OS-10 dated 14 Sep 88.
Provision Data
The basis for advance or initial provision so far as Army HQ Repair Commitments and
Repair of Class ‘B’ Stores are concerned will be as follows:-
(a) ISG/SSO/Overhaul Scale issued by Army HQ/HQ Tech GP EME
(b) Where the existing scales are considered to be inadequate draft amendments to the
current scales duly approved by Comdt& MD Workshops.
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Initial Demands
(a) Initial demands are those which are placed on the depots before commencement of any
Army HQ serial or repair of repair commitment are based either on the basis of scale
/draft amendments to the scales of draft scales. Such demands will be initiated annually
based on the repair schedule.
(b) Dy GM (M)/MPO will fwd scales (not held by OSS/WSS) and draft amendments to the
scales in quadruplicate or draft scales to OSS/WSS in reference to the repair schedules
three months in advance of the date by which a particular schedule is due to be taken in
hand.
(c) In case, where repair schedules have to be made on an anticipated arising of the
repairable equipment or repairs to certain equipment have to be undertaken on priority to
meet changing needs of the GS requirements, or repair schedules have be revised due
to unsatisfactory supply position of spares against certain Army HQ serials, the advance
provision of 9 months ahead may not be possible. In such cases OSS/WSS will be
advised to place priority demands on deposit and to position the spares as early as
possible. Simultaneously, action will be taken to fwd demand details to HQ Base
Workshops GP EME in order to arrange expeditious issue of spares/materials.
Supplementary Demands
(a) Supplementary demands are those which are placed subsequently during progress
of commitments. These may be either due to the items not demanded initially being not
covered in scale/never required in the past or due to increased requirements. In such
cases, issue of draft amendments to the scales, will be necessary.
(b) Supplementary requirement will be assessed as a result of review carried out at 25%.
50% & 75% stages keeping in view the quantity issued/dues out recorded against
number of the equipment in reference to the total equipment scheduled for repairs. This
will however, be demanded by OSS/WSS in consultation with GM(M)/MPO.
(c) Though responsibility for assessing supplementary requirement devolves on OSS/WSS.
MPO will be responsible to keep watch on the trend requirement through the media of
the SRB for taking appropriate actions when called. It will be ensured that the
supplementary demands are placed to cover the actual requirement in relation to
physical consumption.
Intimation of Demand Particulars
Supplementary demands will be placed by OSS on concerned depots in the following
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cases :-
(a) Initial Deficiencies.
(b) Non scaled items.
(c) Items required over and above the scales.
OSS will feed the demand particulars (whether initial or supplementary to Dy GM (M)).
Receipt of Inability List and Actions
The time schedule from the time of preparation of Advance Provisioning (AP)
Demands for the formulation of Consolidated Vital inability List (CVIL) will be as follows :-
(a) AP demands to be placed by - 30 Jun
(b) Receipt of Initial Inability List (ILL) from COD - 31 Aug
(c) Vetting of IIL and return to COD - 15 Oct
(d) Receipt of CVIL from COD - 31 Dec
(e) Issue of Spares by COD - 31 Dec- 31 Mar
(f) Launching of Commitments - 01 Apr
(g) OSS will receive a CVIL from CODs in respect of each Army HQ serial as per the
timing enumerated above, One copy of such list will be fwd to DyGM(M) by OSS.
These lists will indicate ‘PDS’ or other suitable remarks about the supply position of
the different items.
(h) Above lists on receipt, will be thoroughly studied and cross checked against
demands in order to observe any items left over for further reference to depot
concerned.
(j) This list will be filed separately against each Army HQ serial wise. Further list of
inabilities received against supplementary demands, will also be filed along with the
initial inability lists. Each sheet of the inability list will be pasted with another sheet of
blank paper for the purpose of recording further progress intimated by depot of as to
how such inabilities had been overcome during progress till the final conclusion of
the commitment.
Periodical Review and Stock Replenishment

Material Control Organization is overall responsibility to ensure regular flow of
spares/materials at the right time and in correct range,. It is therefore vital for by Dy GM (M)
to have info about stock held, trend of issue, anticipated bottlenecks for smooth execution of
pre-planned schedules. Reviewing of stock shall be continuous and will comprise of the
following:-
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(a) Determination of stock position.

(b) Provision action for depleted stocks.
(c) Progressing of outstanding demands.
(d) Initiate actions for LM/LP
The CILs received from depot will be put on computer and this list shall be updated regularly.
OSS shall be responsible to give supply position of spares listed in CIL on weekly basis to
update the information; OSS shall be also responsible to intimate the DY GM (M) for items
which are being consumed over and above the scales. Dy GM (M) will initiate draft
amendment to scales and also initial LP/LM for such items.
Analysis of the Items
There is a need to analyse the scaled items into three categories as under :-
(a) Critical items without which production will be paralyzed.
(b) Critical items which could be managed within Workshops resources such as retrieval,
rolling over for sometime, reclamation, local manufacture.
(c) Items non availability of which, may not affect production very much i.e. easily
procurable by LP/LM as and when required.
Action on Items Declared NA
MPO will analyse the reasons of non-availability and take following actions:-
(a) Procurement through LP/LM will is expedited, where action has been initiated.
(b) Fresh LP/LM actions will be initiated to avoid immediate bottlenecks.
(c) ‘DUEs-IN’ where existing will be expedited or supplementary demands initiated.
(d) ‘Signal demands to cover immediate requirement for vital hold ups will be preferred
where necessary.
(e) Items which cannot be made available from any source will be retrieved through a
team of production group tradesmen where possible from Cl-VI equipment earmarked
for retrieval or through class ‘B’ stores held in the Workshops. In order to account for
these items, MPO will prepare CRVs in triplicate and will forward copy number 1 and 2
along with covering demand (IAFO-2672) against jobs on which the retrieved stores
are intending or have been used, to enable OSS to take the items on charge and
charge off against the demands. OSS will return copy number 2 of the ‘CRV’ duly
receipted which will be linked with copy number 3 of the CRV already held. Copy
number 2 of the ‘CRV’ will then be forwarded to P&P for filling in the job folder
concerned. Items so retrieved and the requirement having been met will be reflected in
the SRB through the media of the ‘CRV’ copy number 3.
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(f) OSS/WSS will be advised to reduce/cancel the ‘DUES-IN’ where the requirement
has been met with by incidental manufacture under ISRs or through retrieval. Where
the items procured in this manner are not taken on charge by OSS.
Central demand section
The Central Demand Section (Known as CDS) will be controlled by the MPO. Its
broad functions will be as under:-
(a) Preparation of demands on the basis of overhaul scales/SSG/ISG as per TS and their
submission to OSS.
(b) Collection of serviceable stores from OSS/WSS and their delivery to the groups/sections.
(c) Arranging local manufacture, retrieval, local purchase.
Preparation and Submission of Demands
(a) Demands will be prepared on IAFO-2672 in quintuplicate on the basis of the following:-
(i) Based on overhaul scales/ISG/SSG and as per TSS where the Workshops are
unable to stock the stores drawn in the CDS store and sufficient equipment cannot
be bulked in one job for obvious reason.
(ii) Based on the rate of advance provision, where the Workshops are able to keep
stores job wise in CDS stores and sufficient equipment can be batched in one
WO. In such cases, equipment on receipt will be examined for deficiencies by
inspectors and details provided to CDS for the purpose of demanding from OSS
against deficiencies.
(b) The spares required under each group/sub-group will be listed in the demand on the
order of COS/CMTS section. For this purpose, MT1 to MR15 and LV/NEW will be
treated as one CMTS section. Similar sections A to Z will be treated as one COS
section. LV7 items peculiar to each make will form separate CMTS section. Hence, in
practice, the spares required to be demanded from OSS will fall under 3 or 4 separate
section. Separate demands will be prepared for each job number.
(c) Separate demand will be placed for each composite COS Section.
(d) A demand will not consist of more than one sheet of IAFO-2672, large or small. (e) It
will be ensured that the following particulars are correctly filled in :-
(i) Part Number and Designation of the items.
(ii) Army HQ serial number, commitment reference, job number, number of
equipment covered in the job, number of total of equipment so far covered
inclusive of the equipment for which the spares have been demanded.
(III) Minor items demanded to make of deficiencies, will be clearly indicated by
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insertion of the word ‘Def’ against such items on the demands.

(iv) Demands after preparation will be allotted a serial control number and date
with prefix of the Workshops groups for whom the spares are being demanded
for examples, demands prepared for EOG (Engine Overhaul Group) or VOG
(Vehicle Overhaul Group) will be allotted a serial number with date as under :-
EOG/1/MCO dated.......................
VOG/1/MCO dated.......................
EOG/2/MCO dated.......................
VOG/2/MCO dated.......................
(f) All demands will be scrutinized and signed by the Dy GM (M)/MPO. In case any other
officer is authorized by the Comdt& MD to sign demands the same will be routed
through the material control organization.
Demand Control Register
All demands before submission to OSS will be recorded in the demand control register as per
Appendix ‘CO’ which will be maintained centrally in CDS.
Collection of Stores from OSS/WSS
(a) All copies of the demands will be handed over to the issue Control section of the
OSS/WSS and stores will be collected during fixed hours (mutually decided). The CDS
representative authorized for collection of stores from OSS/WSS will check the stores in
regards to the quantity and carry out visual inspection at the Issue counter and will sign
number 4 copy of IAFO-2672 as a token of temporary receipt. The CDS
representative will also suggest ‘issue in low’ part numbers if any provided the
suggested part numbers fall within the composite COS sections of the demands and
obtain the stores.
(b) The stores after issue to CDS will accompany copy number 1 & 2 of IAFO-
2672. The stores will be issued to Workshops groups/sections concerned as per
the overhaul scale and as TSs against clean exchange with INSV ones. Disposal of
copy number 1 to 2 of IAFO-2672 will be as under:-
Copy Number 1 - To be retained by CDS
Copy number 2 - To OSS duly receipted.
(c) Demand Control Register will be kept upto date and prompt disposal of the copies of
IAFO-2672 ensured.
(d) When stores after receipt from OSS/WSS are found defective, damaged/UNSV or of the
wrong type, the MPO will intimate such cases to works inspector for detailed
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investigation Works inspector will inspect the stock held in OSS/WSS for further action
as under:-
(i) Defect report in respect of defective stores will be initiated by works Inspector under
advice to Dy GM (M) who will further progress the case.
(ii) Stores rendered unfit for issue owing to deterioration in stock, will be dealt
(iii) Correct identification of the stores found to be ‘Wrong Type’ will be carried out by
worker inspector and results intimated to OSS/WSS, under advice to Dy GM (M)
for adjustment action.
(e) Items/stocks falling under above categories will be inspected/segregated pending
disposal orders from the depots. Action will be taken to re-demand the affected
requirements from the depots concerned. Pending receipt of fresh supplies, immediate
requirement, will continue to be met through LM/LP retrieval and reclamation as the
case may be.
Action on Items Declared NA by OSS
Items declared NA by OSS may be recorded on a register as per Appendix ‘CO’ maintained
separately for each group and sub sections of the Workshops. MPO will analyze the reason
for their NA from OSS and take suitable actions as per the instructions contained in Section III
Para 7.32 in consultation with Dy GM (M) The stores, on materialization in OSS, will be re-
demanded against job concerned, endorsed on all copies of the IAFO-2672.
When Components to Repaired an Assembly are Not Available

When components to repair the assemblies are not available from the OSS or through LM/LP,
such assemblies will be deposited with R&I either for eventual repairs at a later date under
‘Class ‘B’ stores commitment or for returning to depots as ‘repairable’. In such cases
assemblies if available in OSS will be drawn against jobs concerned. Reasons necessitating
use of assemblies will, however, be endorsed at the back of IAFO-2672 k for information of
OSS/WSS and depots expedited for immediate provision and issue of the components in
question.
1.2.4.2 Local purchase procedure
Initiation of Local Purchase Requisition
LPRs could be initiated by In-Charge Group where considered feasible Workshops may
use Registers in view of Appendix ‘CT’ where considered practicable. The intentionis
to obtain latest supply position from OSS/WSS before any purchase is effected. Disposal will
be as under.
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(a) Original and - To OSS/WSS who will return original copy of

Duplicate copy LPO after verification.
(b) Triplicate copy - To LPO as an advance copy in order to float
LP enquiries.
Registration of LPRs in LP Office
All LPRs received in the LP office will be registered in LPR Control Register as per Appendix
‘CD’. Each entry in the register will be cross linked with the supply order number and date so
as to trace the further progress when required.
Floating of LP Enquiries
(a) Where is not required to invite ‘Tenders’ but quotations from at least 3 reputed firms or
even more will be obtained before resorting to Local Purchase. These may be obtained
personally by LPO or by floating official LP enquiries.
(b) On receipt of an advance copy of the LPR, reference will be made to the respective ‘Rate
Card’ which would indicate the acceptable trade brands and the names of the likely
suppliers for the purpose of floating LP enquiries. LP enquiries will be floated to three or
more firm atleast but the last supplier as per ‘Rate Card’ should invariably be addressed.
While floating LP enquiries, it will be ensured that one or two new firms are always
included in order to encourage new firms and create conditions for fare competition.
(c) When the stores are of proprietary nature and obtainable from only one firm, calling of
three quotations is not necessary.
Receipt of Quotations
Quotations will be obtained in sealed covers. They may be received as under:-
(a) By post.
(b) Personal collection by the LPO or JCO/Supervisor Technical specially detailed for the
purpose.
(c) Personal delivery by the firm. These will be collected in a box placed at the gate office.
Opening of the Quotation

The sealed quotation will be opened on due dates by a Board which should be headed by an
Officer. All Quotations opened will bear a unit stamp, date and initials of the members of the
board.
Verification of Rates and Preparation of Comparative Statements
(a) LPO, on receipt of quotations, will an endorsement on the office copy of the ‘Enquiry
Form’ about the firms who have responded of otherwise. He will also verify the lowest
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rate received against the past rates. In case, the lowest rate received is considered
exorbitant, the firm concerned will be asked to furnish reasons in writing before the rate
is accepted. Such reasons will be kept in record for future reference if needed.
(b) When the GMW(R)/LPO is satisfied that the items beings offered at the lowest rates
are consistent with the Workshops requirements., the LPO will ascertain the supply
position of the items intended to be purchased once again from OSS if a considerable
time has elapsed from the original intimation from OSS and if satisfied, a
comparative of the available quotations including those firms who not quoted against
enquiry, will be prepared in duplicate on form IAFZ-2125 (as modified) shown at
Appendix ‘CW’. LP enquiry number and date where initiated, will be mentioned on the
IAFZ-2125.
(c) When items offered at the lowest rate are not acceptable due to the poor/ inferior
quality known from experience or after feasible examination/test, next higher quotation
will be accepted. In such cases, suitable endorsement will be made on IAFA-2125.
(d) Comparative statement in duplicate, supported with the original quotations, rate card of
the item affected, will be put up to Comdt& MD for his approval GMW (R).
Preparation of Supply Orders
(a) Supply order specimen shown at Appendix ‘CX’ indications the term involving financial
aspects accepted, will be prepared in quadruplicate and disposed off as under:-
(i) Original Copy. This will be retained in the LP docket for submission to CDA
concerned after finalization of the transaction.
(ii) Duplicate Copy. To be dispatched to the firm concerned.
(iii) Triplicate Copy. To be issued to the receipt section of the LP office duly
indicated with the OSS control number and date of the LPR in question, for
progressing receipt of stores from the firm and preparation of inspection notes.
(b) All supply orders issued during a financial year i.e. from 01 April to 31 Mar, will be
allotted a serial number date-wise will prefix of the year concerned. The serial number
date-wise will be allotted from the supply order register
Signing of Supply Orders
Supply orders will be signed by Dy GM (M) whose three specimen signatures will be
forwarded to the CDA concerned, and will be authorised through the media of the unit Daily
Part I orders.
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Local manufacture
This section deals with the procedure to be followed in regard to the incidental
manufacture, manufacture on planned basis and manufacture of A-in-U stores and
component in Army Base Workshops. Incidental manufacture would imply the stores
manufactured to meet day- to- day requirements when the commitments are in progress.
Manufacture on plan basis in undertaking against anticipated requirements before
commencement of the commitments.
Incidental Manufacture to Meet Day-to -Day Requirement
(a) The manufacture of stores to meet day-to-day requirement may be undertaken
when:-
(i) A demand for these stores cannot be meet in time from the normal sources of
supply i.e. items against which no ‘DUES IN’ exist or supply position regarding
their availability or otherwise is no known.
(ii) The items have been reported not available from the normal sources by
reasons of their being not provided items (i.e. items declared not provided,
dead. No further provisioning) and it is necessary to fit them.
(iii) Items of ‘NIV’ natures i.e. not included in the vocabulary of ordnance stores.
(b) Scope
(i) The items will be manufactured only to the extent to meet immediate
requirement of the jobs in hand.
(ii) The items will be manufactured against the main equipment WO.
Manufacture of Planned Basis
(a) Army Base Workshops are permitted to undertake manufacture of stores in
anticipation before commencement of a commitment when:-
(i) The items are of ‘Provided’ status.
(ii) The items have been demanded and the same have been reported not
available from the source of supply.
(iii) The expenditure involved falls within the financial powers of the Comdt& MD.
(b) Scope
(i) The quantity proposed to be undertaken for manufacture will be decided in
economical batches keeping in view the ‘PDS’ intimated by the depots.
(ii) The items manufactured will be physically taken on charge by OSS and issued
against jobs concerned. Such manufactured items will be accounted for as if
issued by the supplying depots.
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(iii) Surpluses arising from the planned manufacture i.e. Unconsumed stores left
over either in full or in part in OSS after conclusion of the commitment,
provided the same are not required for equipments likely to be scheduled in a
near future, will be back loaded to the depots concerned for merging them into
depot’s working stocks.
(iv) ION order to avoid surpluses and to ensure correct utilization of available
manufacturing capacity, items and quantity decided for manufacture, will be
related to the past requirement data.
Manufacture of A-in-U stores
These WOs will be initiated by the group/section requiring these stores. On receipt of the
material estimate requisition the group/section which is responsible to manufacture these
stores will demand the raw material from ESS and complete the WO. LP action will be
initiate the ESS in case the required material is not available in the stores.
After vetting the list of inabilities received from OSS/WSS, the MPO/CPS will initiate LMRs,
keeping in view the availability of the raw material in expense stores and in
consultation with LPO regarding availability of the required in the market, as per
Appendix‘DJ’ in duplicate. LMRs will be forwarded to P&P along with the scales
samples/drawings or sketches of the items concerned, provided by Works Inspector. Where
the samples are not readily available, action will be taken to call in a sample equipment.
Actions by Planning and Progress Branch on LMRs
(a) P&P will ensure that the capacity/facilities to undertake manufacture is available
and the expenditure involved does not exceed the Comdt& MDs financial powers,
before job number are allotted on the duplicate copies of LMRs. Where cost of
manufacture against any items is likely to exceed Comdt& MD’s power,
DGEME’s/Cdr HQ BWG powers will be invoked before manufacture is undertaken.
Cases where manufacture in Workshops is not possible suitable endorsement will be
made against items concerned on the LMRs to enable CPS to explore other avenues
for procure
(b) Material estimate requisition of items to be manufactured in the Workshops, will be
prepared in triplicate by Method Engineering Cell with the help of Material Testing
laboratory where in existence otherwise by, an experienced supervisor trained for the
purpose. Disposal of Material Estimate Requisition will be as under:-
(i) Original. The Workshops section responsible to execute the job,
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together with sample/drawing, OPS pending issue of work

order IAFO-1370.
(ii) Duplicate. To MPO/CPS alongwith the copy of the LMR.
(iii) Triplicate. To be retained by P&P in the manufacture job folder.
Action by CPS
(a) CPS on receipt of duplicate copy of the LMR will transfer job numbers where allotted
on the ‘PRCs’ for future progressing reference.
(b) CPS will ensure issue of required material from the Expense store, on demand by the
manufacturing group. Where raw material is not available, immediate action will be
taken by Expense Stores to get the same purchased. This coordination will be
responsibility of the MPO/CPS so as to ensure that the manufacture as per schedule is
not handicapped due to non-availability of materials.
(c) Items which have not been approved by the GM(P&P) for manufacture in Workshops
due to capacity/facilities being not available/in adequate, will be reviewed in the light of
their past usage and remedial actions such as LP/LM. Retrieval taken as
recommended in the procedure.
Inspection of manufactured Stores
(a) Group will manufacture raw samples in the first instant before resorting to bulk
manufacture and will get the same approved/inspected by stage inspection, which
carries out.
(i) Material test
(ii) Dimensional checks
(iii) Functional tests where necessary
Note: Bulk manufacture will be progressed based on the results of the sample tests.
(b) Stores after manufacture in suitable batches will be tendered for inspection to the stage
inspector on inspection notes prepared in duplicate. Correct job number, part number
and nomenclature will be indicated on these inspection notes by the groups.
Preparation of WCN
(a) The groups will hand over the accepted stores to R&I section in full or in part
convenient batches accompanied with both the copies of the inspection notes. R&I will
return duplicate copy of the inspection notes as receipted to the group.
(b) R&I will link the original copy of the inspection note to the copy of the WO already held
with him and will prepare WCN (IAF (EME)W-28) in centuplicate duly allotted with a
serial control number and date. These will be prepared separately against each job
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number.
1.2.4.3 Expense stores
The provisioning responsibility ie, preparation and submission of demands on depots
concerned devolves on OSS/ESS based on the data furnished by the GM (M) (Officer-in-
charge expense Stores). Whereas stocking, and the retail issue functions will be carried out by
the Workshops.
Provision
(a) The requirements of expendable materials/stores will be furnished to OSS by Expense
stores in a draft form. These will be calculated on the basis of MMF (Monthly
Maintenance Figure) or as per scales/known requirements, which be fixed so as to
represent the average monthly requirement, necessary to carry out normal functions of
the Workshops. The initial ‘MMF” will be fixed by adding up past 12 months normal
issue and dividing the result by 12. The ‘MMF’ may be decreased or increased as
necessary to conform to the trend of issues.
(b) During normal function of retail issue, it may at times become necessary to issue an
alternative material or an alternative size (when an original item OSS not available in
stock) which may be useable but not uneconomical. Such contingencies will be kept in
view while calculating ‘MMF” in order to obtain ‘original items’ for further use’ as far as
possible.
(c) Special provision action to cater for the requirements of expendable stores which may
be peculiar to certain commitments, may be initiated irrespective of their past issue
records. The quantity will be restricted to actual requirement recommended through
‘WPLs’ or Job Circulars or assessed requirement.
(d) The ‘MSP’ (Maximum Stock Potential) will constitute 4 MMS while working out‘draft
requirements’.
.
Demand on CODs
The demands on depots will be prepared and submitted by OSS/WSS after vetting the
requirements provided by Expense Stores. One copy of the demand will, however, is received
from OSS.
Demand of Stores from OSS
Immediately, on receipt of (Receipt Notification) of any item from OSS/WSS. Expense Stores
will arrange to draw the stores in bulk from OSS on IAFZ-2183A prepared in
quadruplicate. These demands will be serially numbered.
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Accounting of Stores
The stores on receipt from OSS/WSS will be taken on charge on IAFZ-3056. The ledgers will
be maintained separately for each vocabulary section and the pages will be serially numbered.
These ledgers will be auditable.
Retail Issues
The retail issues of the expendable materials are divided into following categories:-
(a) Stores when required against manufacture/payment WOs will be charged to specific
WOs (job numbers) against demands received from the shops.
(b) Stores and materials such as coal smithy, brushes, oils, fuel, sheeting, abrasives,
cotton waste, soda ash, soda caustic, spray painting materials, welding rods, electrodes,
fluxes, chemicals, acids, electroplating and deposition materials, degreasing materials,
solder, metalizing wires, insulation tapes, spirits, etc. which cannot be charged to a
specific jobs (WOs) will be debited to respective SWOs.
(c) Items such as units, bolts, screws, washers, spring washers, nails, sand papers,
emery papers, glue, cotton thread balls, etc. will also be charged to appropriate
SWos under the provision of para 194 of RAOS (I) Regulations Para IV in order to
eliminate paper work entailed in accounting for small issues to different Workshops.
(d) In order to minimise paper work, a monthly scale for usage of such expendable materials
chargeable monthly in respect of various Workshops groups and sections, will be worked
out and issues effected during the month will be charged off from the ledger on 1st of
each month against IAFZ-2183A which will be signed by the GM(P).
Monthly reviews of the holding and trend of issue will be carried out from the ledgers in order to
expedite ‘DUES-IN’ or to place supplementary demands.
1.2.5 TECHNICAL TRAINING CELL

 The technical training of civilians conducting trade tests for different trades for promotion
and ACP scheme including recruitment and supervisory tests.
 The technical training of Combatants conducting trade test for HMT & MT drivers.
 The technical training of Apprentice conducting Screening test, All India trade test and
conducting RI Classes of Apprentices on all working days.
 Component and base level training by original equipment manufacturers of various
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equipment is also organized in the workshop under the aegis of TT cell

 There is a lack of proper classrooms that will be needed to train both Army and civilian
operators regarding the latest equipment that will be installed during the course of the
modernization.
 Currently the training cell does not have proper training machineries available
 There is also an absence of a proper library for students of the Training cell to study and
learn about latest technologies.

 Adequate number of Sophisticated and modern classrooms are to be designed
considering the training load the TT cell will have after the modernization of the Base
Workshop.
 The class rooms will be provided with modern and comfortable furniture, facilities, cabins
and storage keeping in mind the comfort of the students.
 Modern teaching and training aides like multimedia projector, DLP projector, LCD display
products, etc will be installed in each classroom to ensure proper parting of knowledge.
 A modern technical library will be provided along with computer and internet facilities to
enrich the TT cell's students on future technologies. A provision will be made to have a
digital library consisting of relevant technical literatures and books.
EQUIPMENTS FOR OTHER SECTIONS:

Plant Machinery and Special Equipments
TRAFFIC STORES
1 WEM001 Weighing Machine– Model 1 2
• Size : 500 x 500mm
MEASURING TOOL KIT
1 MMT001 Digital Micrometer - Model 1 2
Range : 0-25mm
Accuracy : +/-0.001mm
Graduation : 0.001mm
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Range : 25-50mm
3 DIG001 Digital Dial Gauge 2
• Display : Dual (Combined analogue and numerical) LC
Display
• Display Range : 6-decade LC Display.
• Display Size (H x L) : 10x5 mm
• Resolution
0.01mm : ± 0.25mm
0.001mm : ± 0.025mm
• Conversion : MI or MIE Type (Metric / Inch Conversion)
• Battery : 3V Lithium Battery
• Weight : 150G.
4 DPG001 Digital Depth Gauge 2
• Measuring Range : 0-150 mm
• Resolution : 0.01mm
• Limit Error : ±0.03mm
5 DVC001 Digital Vernier Caliper 2
• Measuring range : 0 to 150 Mm
• Resolution : 0.01 Mm
• Accuracy : ±0.02 Mm
• Max measuring speed : 1.5m
6 DHG001 Digital Height Gauge 2
• Measuring Range : 0-1000mm
• Resolution : Switchable between 0.01 and 0.005mm•Display : 7-
Digit LCD, Character Height : 11 mm
• Accuracy : ± 0.06mm
• Repeatability : 0.01mm
• Weight : 15.7 Kg
7 SGS001 Slip gauge set 1
Square block set:
No of Set - 122
• Nominal Length (1 Block) - 1.0005 mm
• Nominal Length (9 Block) - 1.001 thru 1.009 mm
• Nominal Length (4Block) - 25 thru 100 mm
Rectangular block set:
No of Set - 122
• Nominal Length (1 Block) - 1.0005 mm
• Nominal Length (8Block) - 30 thru 100 mm
• Nominal Length (2Block) - 25, 75 mm
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8 FGS001 Feeler Gauge Set 1

Quantity of Leaves : 32 No's
Range :0.03 - 1.00mm
Testing Equipments:
S.No. Ref .No Name of Testing Equipment Quantity
A) COMMON TESTING EQUIPMENTS

1 UET001 Universal Electrical Test Stand 1
• Effective stroke:220mm
• Max. load :30000 N
• Testing speed : 15 to 240mm / min
• Weight : 90 kG
2 IMT001 Impact Tester 1
• Pendulum drop angle :90°
• Pendulum effective Wt :21.300 kg
• Striking velocity of pendulum :3.857 m/sec
• Pendulum impact energy :168 j
• Min scale graduation :2 J
• Distance of axis of pendulum rotation from center of specimen to
specimum hit by pendulum :815 mm
• Max permissible by friction &windageetc :0.50% of impact energy
3 FLM001 Flow Meter 1
Nominal Meter Size : 10 to 1000mm
• Liquid Pressure (MPa) : 1 to 25
• Accuracy : ±0.5%, ±1%
• Type : Fluid
• Minimum Conductivity : 5μs/cm
• Electrode Material :
SST 316L (standard), Hastelloy, Tantalun, titanium, Tungsten Carbide.
4 VIS001 Viscosity Meter 1
• Measurement range : 1 ~2 x106 m Pa•s
• Rotor types : 1# to 4# rotors
• Rotor velocity : 0.3 to 60 rpm
• Operation modes : Manually or Automatically select the rotor types and
velocity.
• Measurement error : ±2% (Newton liquid)
• Dimensions : 370 x 325 x 280 mm
• Net weight :6.8 Kg
• Ambient temperature : 5°C~ 35°C
• Relative Humidity(RH) : not greater than 80% Power supply
• Voltage : 220 V±10%
• Frequency : 50 Hz±10%
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5 CWA001 Computerized Wheel Allignment Tester 1
Toe Measurement Range : 5 Degrees
Caster Measurement Range : 10 Degrees
Camber Measurement Range : 10 Degrees
KPI Measurement Range : 20 Degrees
Maximum Steering Range : 90 Degrees
Operating time with fully charged batteries: Greter than 10 H,Frequency
: 433 MHz
Operating Voltage : 240V, 1 Ph, 60 Hz
6 LBM001 Laser Bore Measurment Set 2
Housing Material: Anodized aluminiumOperating Temp: 0 to 50°C
Storage Temp: -20 to 70°C Relative humidity: 10 – 90%Weight: 110 g
7 FIR001 Fluid Impurity Remover 2
Purification : Heat Transfer oil, Thermal fluid.
Filter Element: Stainless steel and innocuous
8 BGC001 Bore Gauge Calibration Set 1
Display : LCD
Range
1.8-4"/45-100mm
System of Measurement
Inch and Metric
Accuracy
+/-0.00012"/0.003mm
Graduation
0.00005"/0.001mm
9 PIT001 Portable Insulation Tester 2
Power supply: AC220V±10%, 50Hz
Output voltage: 0~80KV(60KV---80KV)
Capacity: 1.2KVA(1.6KVA --2.0KVA)
Speed of pressure rise: about 2KV/S
Voltage test precision: ±3%
Breakdown sensitivity: <2KV
Wave difference: <=3% 8. Time of breakdown: <=10ms
10 COT001 Continuity Tester 2

Voltage LED: On at between 70% and 100% of marked voltage
Continuity threshold: Beeper on at <20,000Ω
Input impedance: 750 kΩ nominal
AC frequency response: 45 Hz to 66 Hz
Battery: (2) AA Life: 250 hours
11 PFM001 P.F. Meter 1
Accuracy of measurement:power factor : 0.5
Signal input : 1 Phase, AC380V, AC 5A, 65Hz
Auxiliary power supply : AC\DC, AC380V , DC48V
Power consumption: Greater than 4VA
Environment:Working temperature:-10°C ~+55°C
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12 BCS001 Battery Charging Set 1
Power source voltage :220 v
Rated Frequency :50 Hz
Rated input capacity : 480/960 kva
Charging voltage :12\24 DCV
Rated output current : 50 A
The capacity of battery pack : 40-400 Ah
Machine dimension : 315x280x240 mm
Weight : 10.4 Kg
13 PBC001 Portable Battery Charging Set 2
• Power voltage(V) 230
• Frequency(HZ) 50/60
• rated input capacity(w) 1400
• charging voltage(v) 12/24
• reference capacity(ah) 20-700
• effective charging current(A) 60
• weight(kg) 22
• Dimensions(cm) 32.5x25x57.5
14 LUX001 Lux Meter 1
Display :
3 1/2 digits 18mm LCD
Range: 0.1~200, 000Lux/0.01~20, 000FC
Over-input: Indication of "1"
Accuracy:
≤ 20, 000Lux, ± (3%rdg+10digit)
>20, 000Lux, ± (5%rdg+10digit)
Resolution: 0.1Lux
Repeatability: ± 2%
15 CRO001 Cathode Ray Oscilloscope 1
BandWidth
AC 10Hz ~ 30MHz (-3dB)
DC ~ 30MHz (-3dB)
Y Deflection 5mV / div ~ 20V / div
Sweep Rate
0.1μs/div ～ 0.2s/div l—2—5 20 steps,
error ±5％
16 MTU001 Managetic Test Unit To Check Plunger & Solenoid 1
Materials of construction MLI :316/316L or 304/304L stainless steel.
Materials of construction – Float : Varies per application
Pressure class ratings:ANSI 150# to2500 #
Process connection sizes :13 to 205 mm
Measuring range :12 to 600
17 BAG001 Beam Aligner 1
• Laser Diode : 635 nm
• Alignmaster : Yes
• Battery Pack : 30 hours
• Battery Type : NiMH
• Dimensions (Length x Diameter) : 310 x 135 mm
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18 DET001 Decibel Tester 1
Measurement Ranges: 30 to 100 and 60 to 130 dB
Noise Floor : Greater than 33dB(A)
Time Weightings : Fast, Slow, Impulse
Freq.Weightings : A and C
Battery Power : 3xa4 alkaline
External Power : 5V via USB Mini B Socket
19 PHA001 Portable Hardness Tester 2
• Measuring Hardness Range :
HRC 0 - 70 N/mm2
HRB 0 – 120 N/mm2
HB 30 – 700 N/mm2
• Detector : Carbide ball
• Display Unit : LCD display, maximum 3 digits
• Function Conversions : HL,HV, HB, HRC, HRB, HS,
• Indentation Direction : Any Direction
• Offsetting Memory : 1,800 data
• Output : RS 232C, SPC
• Power supply : Alkaline AA battery
• Power Output : 100 hours approximately
• Dimensions (D x H): 28x175 mm
20 HMS001 Humidity Measurment Set 1
Display Dot matrix
Storage temperature : -30 to +50 °C
Operating temperature : -20 to +50 °C
Probe type Type K
Measuring Range : -50 to +600 °C
Accuracy : ±(-0.5 °C +0.5% of mv)
Resolution : 0.1 °C
Weight : 527 g
Dimensions : 193 x 166 x 63 mm
21 ACC001 Accelerometer Tester 1
• Display: 4 digits, 18 mm LCD
• Transducer : Piezoelectric accelerometer
• Parameters measured: Velocity, Acceleration, Displacement, RPM and
Frequency
• Measuring range Velocity : 0.1-400 m/s2 true RMS
Acceleration : 0.1-400.0m/s equivalent peak
Displacement : 0.001-4.000mm equivalent pk-pk
RPM : 60-99,990 r/min
Readings should be multiplied by 10, if the display show '10'.
Frequency: 1-10 kHz
22 CEA001 Computerized Engine Analyser 1
Power : 50wParameter Range Precision : 0-8000 rpmIgnition ADV : 0-
60°±1°Ignition Voltage : 0-40 KVSpark Voltage : 0-4000VIgnition
duration : 0-04 - 9.99msCranking current : 0-900A
507 ABW 195

Part-A DPR

23 IWR001 Impact Wrench 2
• Voltage: 12V DC
• Amperage draw: 8A
• Max torque: 271 ft-lbs
• Power cord length: 13 ft
• 1/2" Drive
• Weight: 3lbs
• Speed: 0 to 2100 rpm
Range : 0-25mm
Range : 25-50mm
26 DPG001 Digital Depth Gauge 2
• Measuring Range : 0-150 mm
• Resolution : 0.01mm
• Limit Error : ±0.03mm
27 DVC001 Digital Vernier Caliper 3
• Measuring range : 0 to 150 Mm
• Resolution : 0.01 Mm
• Accuracy : ±0.02 Mm
• Max measuring speed : 1.5m
28 LSA001 Laser Shaft Alignment 1
System : Relative humidity 10–95%
Weight (complete system) 10 kg [22 lbs]
Display unit : Displayed resolution 0.001 mm / 0.05 thou
Rods : Material Stainless steel
29 ALC001 Alcohol Tester 1
B) MECHANICAL GAUGE CALIBRATION DEVICE

1 LOA001 Load Cell 1
Connector or Cable length : Side mount connector
Rated Output : 2 ±0.2
Maximum excitation : 15 VDC
Bridge resistance : 350Ω ± 2Ω
Overload without zero shift (% FS) : 300%
Minimum ultimate safety factor (% FS) : 500%
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2 MAN001 Manometer 1
Service: Air and compatible gases.
Wetted Parts: Consult factory.
Accuracy: ±0.10%
Pressure Hysteresis: ±0.1% of full scale.
Pressure Limits: See chart.
Temperature Limits: 32 to 104°F
Storage Temperature Limits: -4 to 176°F
Display: 4-digit LCD
Power Requirements: 9 volt
3 MAG001 Magnetic Gauge 1
Materials of constructionMLI :316/316L or 304/304L stainless steel,
Materials of construction – Float : Varies per application
Pressure class ratings:ANSI 150# to2500 #
Process connection sizes :1⁄2" to 8"
Measuring range :12 to 600
4 PRT001 Pressure Transducer 1
Accuracy: ±0.4% fs (bfsl)
Hysteresis: ±0.2% fs
Repeatability: ±0.07% fs
Zero balance: ±1% fs
Storage temperature: –65° to 250°f(–53° to 121°c)
5 VAG001 Vacuum Gauge 1

Measurement Range :
• 1.0 X 10-11 to 20,000 Torr
• 1.0 X 10-11 to 2.7 X 104 mbar
• 1.0 X 10-9 to 2.7 X 106 Pascal
• 1.0 X 10-8 to 1.0 X 107 microns
Operating Temperature : 5° to 40° C (41° to 104°F)
Storage Temperature : -10° to 55°C (14° to 131°F)
Weight : 8 lbs (3.6 kg)
Controls : Power on-off switch, setup and operational commands can be
accessed via the keypad
Material Handling Equipment:

CAUSTIC SODA WASH
1 EOT Crane 20 T x5m 2
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COMMON MATERIAL HANDLING EQUIPEMENT TO WORKSHOP

1 Mobi Lift (EQUIPMENT LOAD / UNLOAD) 22Ton 1
2 Mobicon Material Handling Equipment 20Ton 1
3 Equipment loading/unloading ramp 14 ton 1
4 Utility Truck 3Ton 2
5 Utility Truck 10Ton 2
6 Utility Truck ( tipper Type) 10 Ton 1
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Part-A DPR
1.3 Work study

“Work study is a generic term for those techniques, method study and work measurement
which are used in the examination of human work in all its contexts. And which lead
systematically to the investigation of all the factors which affect the efficiency and economy of
the situation being reviewed, in order to effect improvement.” Work study is a means of
enhancing the production efficiency (productivity) of the firm by elimination of waste and
unnecessary operations. It is a technique to identify non-value adding operations by
investigation of all the factors affecting the job. It is the only accurate and systematic procedure
oriented technique to establish time standards. It is going to contribute to the profit as the
savings will start immediately and continue throughout the life of the product.
Work study has become one of the important methods in improving production operation
system and production efficiency. During the implement of work study, all kinds of factor which
may affect the production efficiency were investigated and analyzed. Work Study is the generic
name of Methods Study and Work Measurement. The most obvious character is using less
investment or no investment to increase the production efficiency and benefit , reduce the cost
and to strengthen the competition ability through improving the operating process and method,
implementing the advanced and reasonable working quota, fully utilizing the human resources,
material resources and financial resources inner the workshop. Method study is based mainly
on searching efficient working method, whereas work measurement is to determine the
scientific and reasonable working time quota of each operation in overhauling and
manufacturing process.
The main analysis tools in method study are 5W1H (What, Where, When, Who, Why and How)
question-asking method, the four principles of ECRS (Eliminate, Combine, Rearrange and
Simplify) and the principles of motion economy. Work measurement is to work out a time
standard for fulfilling a job with economical and rational methods. The main methods under
work measurement are stopwatch time study, work sampling, predetermined time system and
standard data method. Among them, the predetermined time system is simply called PTS
method. It is used to determine the time required for different operations on basis of the time
standard predetermined for various motions instead of direct observation or measurement.
Under PTS method, there are a few methods for determination of standard working hours.
 Processing tasks: a processing task is an indivisible working unit which has associated
processing time. The total work required to overhaul a vehicle in an assembly line is
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Part-A DPR
divided into a set off (n) tasks.

 Workstations: are the line com
mponent wheere a task are processed, and involves an
operatoor, certain eqquipment andd some specialized processsing mechaanisms.
 Cycle time (Ct): is the time availlable in eachh workstation to completee the tasks reequired to
processs a unit of product
p -the production raate is equal to 1/Ct unitss of product per time
unit. Thhe cycle timee is also deffined as the time intervaal between thhe processinng of two
conseccutive units.
 Workstation load Sj: is the subseet of tasks asssigned to woorkstation j.
 Workstation time t(S
Sj): is the sum
m of the timees ti of all taskks assigned to workstatioon j.
 Workstation idle tim
me I tj: is thee difference between thee cycle timee and the woorkstation
load.
( Ct- t(S
Sj))
1.3.1 Line balanccing:

Line balancing is the proocess of disttributing the n tasks amoong the m w
workstations in such a
way that preecedence coonstraints annd other connstraints are satisfied; aiming at optiimizing a
given efficiency measuree. Classical objectives
o seeek to minimize m for a ddesired cyclee time Ct,
or to minimizze Ct.
There existss a great variety of configurations invoolving assem
mbly lines, whhich are charaacterized
according too diverse criteria. Amongst others, these include the layout and shape off the line,
the number of products and models being processed in the line, types off workstationn and the
variability of the task proccessing times.
1.3.2 Pro
oductivity Im
mprovementt Techniquees
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Part-A DPR
1.3.2.1 Technology based:

Computer Aided Design (CAD), Computer Aided Manufacturing (CAM), and Computer
Integrated Manufacturing Systems (CIMS).
 CAD refers to design of products, processes or systems with the help of computers. The
impact of CAD on human productivity is significant for the advantages of CAD are:
(a) Speed of evaluation of alternative designs,
(b) Minimization of risk of functioning, and
(c) Error reduction.
 CAM is very much useful to design and control the manufacturing. It helps to achieve the
effectiveness in production system by line balancing.
(a) Production Planning and Control
(b) Capacity Requirements Planning (CRP), Manufacturing Resources Planning (MRP II)
and Materials Requirement Planning (MRP)
(c) Automated Inspection.
 Computer integrated manufacturing: Computer integrated manufacturing is characterized
by automatic line balancing, machine loading (scheduling and sequencing), automatic
inventory control and inspection.
(a) Robotics
(b) Laser technology
(c) Modern maintenance techniques
(d) Energy technology
(e) Flexible Manufacturing System (FMS)
1.3.2.2 Employee based:

 Financial and non-financial incentives at individual and group level.
 Employee promotion.
 Job design, job enlargement, job enrichment and job rotation.
 Worker participation in decision-making
 Quality Circles (QC), Small Group Activities (SGA)
 Personal development.
1.3.2.3 Material based:

 Material planning and control
 Purchasing, logistics
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Part-A DPR
 Material storage and retrieval

 Source selection and procurement of quality material
 Waste elimination.
1.3.2.4 Process based:

 Methods engineering and work simplification
 Job design evaluation, job safety
 Human factors engineering.
1.3.2.5 Product based:

 Value analysis and value engineering
 Product diversification
 Standardization and simplification
 Reliability engineering
 Product mix and promotion.
1.3.2.6 Task based:

 Management style
 Communication in the organization
 Work culture
 Motivation
 Promotion group activity.
1.3.2.7 Principles of manufacturing:

Lean manufacturing is the implementation of the concept that anything that does not create
value in the product is to be eliminated. It is the concept of more value for less work. As waste
is reduced, quality improves, production times are reduced and cost is minimized. Various
methodologies are used as tools to achieve this including Value Stream Mapping, 5S, Kanban
(pull systems) and error-proofing.
The steps to developing a lean culture

1. Senior management needs to agree on a lean vision.
2. Identify the project leader and set objectives for the leader.
3. Communicate the plan and vision to the workforce
4. Solicit volunteers to form the Lean Implementation Team. Five to seven people with varied
backgrounds seems to work best.
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Part-A DPR
5. Appoint the Lean Manufacturing Implementation Team

6. Train the team in various lean tools. 5S is often a good starting point.
7. Select a pilot project for implementation.
8. Implement the pilot. Evaluate the results, review and learn from mistakes made.
9. Roll out the next project(s).
10. Train supervisors how to teach and train their employees.
11. Continue adding and training in additional lean manufacturing tools.
1.3.2.8 Lean Building Blocks

In order to reduce or eliminate the wastes, Lean practitioners utilize many tools or Lean
Building Blocks. Successful practitioners recognize that, although most of these may be
implemented as stand-alone programs, few have significant impact when used alone.
Additionally, the sequence of implementation affects the overall impact, and implementing
some out of order may actually produce negative results (for example, you should address
quick changeover and quality before reducing batch sizes). The more common building blocks
are listed below. Note that some are used only in manufacturing organizations, but most apply
equally to service industries.
 Pull System – The technique for producing parts on demand. Service organizations
operate this way by their very nature. Manufacturers, on the other hand, have historically
operated by a Push System, building products to stock (per sales forecast), without firm
customer orders.
 Kanban – A method for maintaining an orderly flow of material. Kanban cards are used to
indicate material order points, how much material is needed, from where the material is
ordered, and to where it should be delivered.
 Work Cells – The technique of arranging operations and/or people in a cell (U-shaped,
etc.) rather than in a traditional straight assembly line. Among other things, the cellular
concept allows for better utilization of people and improves communication.
 Total Productive Maintenance – TPM capitalizes on proactive and progressive
maintenance methodologies and calls upon the knowledge and cooperation of operators,
equipment vendors, engineering, and support personnel to optimize machine
performance. Results of this optimized performance include; elimination of breakdowns,
reduction of unscheduled and scheduled downtime, improved utilization, higher
throughput, and better product quality. Bottom-line results include; lower operating costs,
longer equipment life, and lower overall maintenance costs.
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Part-A DPR
 Total Quality Management – Total Quality Management is a management system used

to continuously improve all areas of a company's operation. TQM is applicable to every
operation in the company and recognizes the strength of employee involvement.
 Quick Changeover (Set up Reduction and Single Minute Exchange of Dies) – The
technique of reducing the amount of time to change a process from running one specific
type of product to another. The purpose for reducing changeover time is not for increasing
production capacity, but to allow for more frequent changeovers in order to increase
production flexibility. Quicker changeovers allow for smaller batch sizes.
 Batch Size Reduction – Historically, manufacturing companies have operated with large
batch sizes in order to maximize machine utilization, assuming that changeover times
were “fixed” and could not be reduced. Because Lean calls for the production of parts to
customer demand, the ideal batch size is ONE.
However, a batch size of one is not always practical, so the goal is to practice continuous
improvement to reduce the batch size as low as possible. Reducing batch sizes reduces
the amount of work-in-process inventory (WIP). Not only does this reduce inventory-
carrying costs, but also production lead-time or cycle time is approximately directly
proportional to the amount of WIP. Therefore, smaller batch sizes shorten the overall
production cycle, enabling companies to deliver more. Shorter production cycles
increases inventory turns and allows the company to operate profitably at lower margins,
which enables price reductions, which increases sales and market share.
 5S or Workplace Organization – This tool is a systematic method for organizing and
standardizing the workplace. It’s one of the simplest Lean tools to implement, provides
immediate return on investment, crosses all industry boundaries, and is applicable to
every function with an organization.
 Visual Controls – These are simple signals that provide an immediate and readily
apparent understanding of a condition or situation. Visual controls enable someone to
walk into the workplace and know within a short period of time (usually thirty seconds)
what’s happening with regards to production schedule, backlog, workflow, inventory
levels, resource utilization, and quality. These controls should be efficient, self-regulating,
and worker managed, and include kanban cards, lights, color-coded tools, lines
delineating work areas and product flow, etc.
 Concurrent Engineering – This is a technique of using cross-functional teams (rather
than sequential departmental assignments) to develop and bring new products to market.
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Part-A DPR
The benefits of implementing Lean can be broken down into two broad categories;
 Operational
 Administrative
Some of Lean’s benefits are summarized below.
1.3.2.9 Operational Improvements

Typical operational improvements are as follows:
 Lead Time (Cycle Time) reduced by 90%
 Productivity increased by 50%
 Work-In-Process Inventory reduced by 80%
 Quality improved by 80%
 Space Utilization reduced by 75%
1.3.2.10 Administrative Improvements

 Reduction in order processing errors
 Streamlining of customer service functions so that customers are no longer placed on hold
 Reduction of paperwork in office areas
 Reduced staffing demands, allowing the same number of office staff to handle larger
numbers of orders Documentation and streamlining of processing steps enables the out-
sourcing of non-critical functions, allowing the company to focus their efforts on
customers’ needs
 Reduction of turnover and the resulting attrition costs
1.3.2.11 5S or Workplace Organization
One definition of the Visual Workplace is ‘an environment where, within 5 minutes, a stranger
can recognize the area’s vision, their mission, and the key performance measures critical to
their success.’ All this is determined without the need for a conversation of any kind. In
addition, the visible measures – or ‘dashboard indicators’ – clearly show at a glance how
successful the process owners are in achieving their vision. Joint selection of the right
indicators is essential to ensure true ownership.
Such an environment begins with the discipline of “5-S” which is wrapped in management’s
envelope of support. Every employee plays a role in presenting an image of organization,
order, and cleanliness to potential customers. What’s more, employees find this new order
produces a better workplace.
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Part-A DPR
KAIZEN
5S
SEIRI SEITON SEISO SEIKETSU SHITSUKE

Sort Order Clean Standardize Self-discipline
The definitions and significance of the five words are given below:
• SEIRI – Sorting.
• SEITON – Ordering/Arrangement.
• SEISO – Cleaning and disturbance detection.
• SEIKETSU – Standardizing.
• SHITSUKE – Disciplining.
Sorting
Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and so
forth in the plant and work area. Keep only essential items and eliminate what is not required,
prioritizing things per requirements and keeping them in easily-accessible places. Everything
else is stored or discarded.
Straightening or Setting in Order
Arranging tools, parts, and instructions in such a way that the most frequently used items are
the easiest and quickest to locate. The purpose of this step is to eliminate time wasted in
obtaining the necessary items for an operation.
Sweeping or Shining
Clean the workspace and all equipment, and keep it clean, tidy and organized. At the end of
each shift, clean the work area and be sure everything is restored to its place. This makes it
easy to know what goes where and ensures that everything is where it belongs.
Standardizing
All work stations for a particular job should be identical. All employees doing the same job
should be able to work in any station with the same tools that are in the same location in every
station. Everyone should know exactly what his or her responsibilities are for adhering to the
first 3 S's.
Sustaining the Practice
Maintain and review standards. Once the previous 4 S's have been established, they become
the new way to operate. Maintain focus on this new way and do not allow a gradual decline
back to the old ways. While thinking about the new way, also be thinking about yet better ways.
When an issue arises such as a suggested improvement, a new way of working, a new tool or
507 ABW 206

Part-A DPR
a new output requirement, review the first 4 S's and make changes as appropriate. It should be
made as a habit and be continually improved.
1.3.2.12 Recommendation for ABW 507

An essential step required for waste elimination in ABW 507 is to attain lean-site manufacturing
and in order to attain this, the integral part is the implementation of 5S principle. An excellence
model for 5S performance is given below
Systematic Organization
Improved Quality
Improved Safety
Customer Expectations
Reduced costs
Consistent Deliveries
Standardizing Improved Product/ Service Options
Control
Self-Discipline-
Control
Sorting Visual
Placement
Scrubbing clean
The building blocks of Lean manufacturing the workshop should follow includes the following
Evaluate
 Baseline Process Performance
 Establish Target
Decide
 Compare solutions
 Choose
Act
 Communicate
 Implement improvement
 Control
Measure
 Validate improvement
507 ABW 207

Part-A DPR
 Standardize
 Update Procedures
Focus
 Eliminate Waste 5S
 Seek Incremental Process Changes
The wastes that occur in a workshop form a major bottleneck for the implementation of lean
principles. The types of wastes include the following
 Overproduction
 Delays (waiting time)
 Transportation
 Process
 Inventories
 Motions
 Defective products
 Untapped resources
 Mis-used resources
These wastes can be greatly reduced by implementing the 5S principle. The 5S principle
implementation will involve the following 5 stages
 Establishment of 5S team
 Development of specific implementation plan
 Development of communication plan
 Development of 5S training plan
 Implementation of 5S
 Verification of effectiveness
The best method of implementing the 5S principle is through Visual Colour System
Implementation. The following actions are to be carried out
 Develop a map identifying the “access ways” (aisles, entrances, walkways etc.) and the
“action” areas.
 Perform any necessary realignment of walkways, isles, entrances.
 Assign an address to each of the major action areas.
 Mark off the Walkways, Aisles & entrances from the action areas
 Apply flow-direction arrows to aisles & walkways
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Part-A DPR
 Perform any necessary realignment of action areas.

 Mark-off the inventory locations
 Mark-off equipment/machine locations
 Mark-off storage locations( Cabinets, shelves, tables)
 Colour-code the floors and respective action areas
1.3.3 Mathematical modeling:
Based on the work study conducted, mathematical modeling was carried out for calculating
the major parameters as follows
 Mathematical modelling of FAV assembly process
 Mathematical modelling of complete overhauling process of FAV
 Mathematical modelling to calculate equipment capacity
The mathematical models are given below

1.3.3.1 Mathematical modeling of FAV assembly process
Target output of overhauled vehicle per year = Nt
Number of days for one vehicle output = Dv
Number of available Assembly lines in the workshop =L
Number of available working days per month = Dw
Dw
The number of vehicles overhauled per month per Assembly line =
Dv
Dw
The number of vehicles overhauled per month = La× 
Dv
Dw
The number of vehicles overhauled per year  12 La×  1
Dv
Now,
Number of vehicles overhauled per year, No = Nt , Where Nt is the Target output per year
Dw
 12 La ×
Dv
Dw NT Dw ×La
  ⇒Dv
Dv Na t
The maximum number of days within which one vehicle output
Dw ×La
Dv  2
This Dvis fixed as target days for each workstation in the assembly line to attain the target

Part-A DPR
Calculation to find the number of days for unit vehicle output:

Target output of overhauled vehicle per year = 156
Number of days for one vehicle output = Dv
Number of available Assy lines in the workshop =3
Number of available working days per month = 20, 5 days a week
From Equation -2
The maximum number of days within which one vehicle should be overhauled =
Dw ×La
Dv
20×3
Dv
156
46days 5days
Therefore to meet a output target of 156 vehicles per year with 3 assembly lines, the maximum
number of days within which one vehicle output should be less than or equal to 5 days.
During the work study in the workshop, the various stages in the assembly line were noted and
after work analysis, five workstations were fixed. Each workstation was designed to deliver an
output once in every 5 days. Therefore certain activities were clubbed together.
Keeping a delivery time of 5 days a vehicle, the number of vehicles that can be overhauled in a
year is given by
Dw ×La 20×3
N   156vehicles
4.6
This shows that the target set for Kankinara is achieved.
Calculation to find the number of assembly lines required for increased target:
If the output of the workshop has to be increased, the numbers of assy lines are to be
increased
From equation - 2
Dw ×La
Dv
Dv
⇒ La   3
Dw
Therefore if the target output is increased to 350 vehicles a year, then the number of lines
required will be
La = = 5 Lines
20

Part-A DPR
If an extra line is added in the current FAV group, an additional 48 vehicles a year can
overhauled.
1.3.3.2 Mathematical modeling of complete overhauling process of FAV

List of activities in overhauling of a vehicle
 Stripping inclusive of washing
 Overhaul of sub-assy
 Assembly of tank
 Integration & Testing
 Final Testing & Defect Rectification
Complete O/H process time for a vehicle = Dov

The number of days to perform each process is given by
Number of days for Stripping = Ds
Number of days for Overhauling of sub-assy = Do
Number of days for assembly = Da
Number of days for Integration & Testing = Dt
Number of days for Final testing & Defect Rectification = Dr
Process time in days to overhaul a vehicle, Dov is given by

Dov= Ds + Do + Da + Dt + Dr
Now to attain a target of Nt per year, the number of days for one vehicle output is Dv
Now based on Just-In-Time principle, the maximum number of days for each overhauling
activities (like stripping, O/H of sub-assy, assembly, testing and rectification) should be lees or
equal to Dv
Dv should be constant for each process stages. The number of stages in each overhauling
stage may vary depending on the overhauling stage.
Ds = Ns Dv
Do = No Dv
Da = Na Dv
Dt= Nt Dv
Dr= Nr Dv
Dw La
Where Dv , Ns = 2, No = 3, Na = 8, Nt= 2, Nr = 1

Part-A DPR
From Eqquation -2
The maximuum number off days within which one WPV
W should come
c out of aassembly line =
 
12 x 20 x 3
    156
   days days
o = Ds + Do + Da + Dt + Dr
Since Dov
   Dov (4x5)
o  + (3x5)
+ 3)
(5x5)( + (2x5)
+ (5 + (1x5)
3) + (2 3)
3 + (1 3)
20++915+ +1525+6++3
= 12 10 + 5
75 days
= 45 Days
1.3.3.3 To calculatee equipmentt capacity

Let the macchines in an overhaul
o secttion be M
Let the sub--assemblies in overhaul ssection be X1, X2, X3 ……
The machinnes in each sub-assemblyy overhaulingg section = MX , MX , MX ….
Let the num
mber of same sub-assembblies in one vehicle
v =n
The number of each sub-assemblies in one vehicle = nX1, nX2, nX3 …..
Let the num
mber of days required
r to ooverhaul eachh sub-assemblies = DX , DX , DX ….
N one MX can overhaaul one X1 suub-assembliees in DX dayys
Now
n MX ccan overhaull nX1 sub-assemblies in DO days
Here DO dayys is the targeet days baseed on Just-In--Time approaach
Machiness Statioons Days
M
MX = X1 = DX
nMX = nX1 = DO
Based on dirrect proportioonality theoreem
MX nX DO
= = , Where MX = X1 = 1 unit
MX X D
MX nX DO
⇒ = =
1 1 D
D nX
n X 
⇒ nM
DO
D nX
X1 = nMX 
The numberr of machiness required too overhaul nX
DO
Here DO is fixed and equual to DV baseed on JIT principles

Part-A DPR
1.3.4 Manpower analysis:

The manpower calculation indicated below is only for study purpose and the actual man power
requirement is to be carried out during implementation.
1.3.4.1 Manpower Estimation for FAV OH Process
Man power Estimation for Overhaul of FAV Vehicle (3 FAV Vehicles)
Man power Estimation for FAV
S/No Process Type No of Man Total No SU Production

Stations Power Man of rate
in each Power Days
Stations
I. Stripping
Gang
I Stripping 12 vehs
Type 3 3 9 3 1.89
II. Assembly
1 Assembly Process Inline-1 5 3 15 5 5.25 4 vehs
III. Sub - assembly Repair
1 Caustic Washing - 2 2 4 5 1.4 12 vehs
2 Shot blasting - 2 2 4 5 1.4
3 Gear box section - 1 6 6 5 2.1 12 vehs
Transfer Gear box
4 Section - 1 6 6 5 2.1
Steering Gear box
5 Section - 1 2 2 5 0.7

Part-A DPR
6 Axle Section - 3 5 15 5 5.25 12 vehs
7 Winch & Torsion bar 1 2 2 5 0.7 12 vehs
8 Painting Shop - 1 2 2 5 0.7
9 Clutch Plate - 1 2 2 5 0.7
10 Propellor Shaft - 1 2 2 5 0.7
Hydraulic/ Pneumatic
11 section - 1 3 3 5 1.05
12 Electrical Section - 1 6 6 5 2.1
13 Crane operator - 1 5 0.35
14 Fork Lift Operator - 1 5 0.35
15 Trolly Operator - 1 5 0.35
IV. Body Repair Section
1 Welding Section - 2 3 6 5 2.1
2 Sheet Metal Section - 1 3 3 5 1.05
3 painting Section - 1 2 2 5 0.7
4 Carpentry - 1 3 3 5 1.05
5 Upholstery - 1 2 2 5 0.7
6 Cabin Fabrication - 3 6 18 5 6.3 12 vehs
7 Body Fabrication Gang 3 2 6 5 2.1 12 Vehs
8 Fork Lift Operator - 1 2 2 5 0.7
9 Utility Truck Operator - 1 2 2 5 0.7
10 Trolly Operator - 1 1 1 5 0.35
V. Tyre Repair
Wheel Stripping
1 3 2 6 5 2.1 12 vehs
Process Gang

Part-A DPR
VI. Washing & Paint Removal
1 Cleaner - 1 2 2 5 0.7
2 Helper - 1 2 2 5 0.7
VII. Painting Shed
1 Painter - 3 3 9 5 3.15
VIII. Battery Charging
1 Electrical - 1 2 2 5 0.7 12 vehs
IX. Trial & Reclamation
Chassis Dynanometer
1 - 1 2 2 3 0.42
Section
2 Repair Section - 3 2 6 5 2.1
Total 185 63.21
Proposed Man power increase for FAV
X.Other sections
1 Tool room 1 1 1 5 0.35
2 Expendable store 1 2 2 5 0.7
3 OSS store 1 2 2 5 0.7
4 QA 5 1 5 5 1.75
5 QC 5 1 5 5 1.75
XI.Repair Section
1 Suspension 2 2 4 5 1.4 12 vehs
2 Brake repair sec 3 2 6 5 2.1 12 vehs

Part-A DPR
25 8.75
Total Manpower 210
Total SU for 3 vehicles 71.96
SU for one vehicles 23.9867
Field Articulated Vehicle Group :
Total number of SU for 5 days = 63.21
Number of effective working days per month = 22
Number of SU per month = 278.124
Number of Su per year = 3337.48
Number of vehicles overhauled in 5 days = 3
Number of vehicles overhauled in a month = 13
Number of vehicles overhauled in a year = 156
Productivity of FAV group =21.39 + 7.88(ENG)=29.27 SU per vehicle
1.3.4.2 Manpower Estimation for Engineer Equipment Group
Man power Estimation for Overhaul of EEG
S/No Process Type No of Man Power Total Man No of SU

Stations in each Power Days
Stations
1 Assembly Gang 14 5 70 66 323.4
2 Hot Ancillary Gang 1 4 4 66 18.48
3 Cold Ancillary Gang 1 3 3 66 13.86

Part-A DPR
4 Hyd Lab Gang 1 4 4 66 18.48
5 Mtrl Handling Gang 1 4 4 66 18.48
6 Store Gang 1 2 2 66 9.24
7 Office Gang 1 2 2 66 9.24
8 OBM Gang 1 3 3 66 13.86
TOTAL 92 425.04
Total SU 425
EEG
Total number of SU for 66 days = 425 Existing Man Power In EEG = 70 + 39 = 109
Number of Su per year = 1699.99
Number of equipment overhauled in 66 days = 14
Number of equipment overhauled in a month = 4.66
Number of equipment overhauled in a year = 56
Productivity of EEG group = 30.35 SU per equipment

Part-A DPR
1.3.4.3 Manpower Estimation for Engine Repair Group
Man power Estimation for Overhaul of Engines
Man Power Total

No of No of
S/No Process Type in each Man SU
Stations Days
Stations Power
I. Stripping
1 Stripping Gang 1 5 5 5 1.75
II. Washing
1 Orion and Kerosene Washing Gang 1 3 3 5 1.05
III. Sub - assembly Repair
1 Engine Block section Gang 3 2 6 5 2.1
2 FIP Gang 6 1 6 5 2.1
3 Oil Pump Gang 1 3 3 5 1.05
4 Cylinder Head Gang 2 2 4 5 1.4
5 Crank Shaft Gang 2 2 4 5 1.4
6 Injector Gang 2 2 4 5 1.4
7 Air compressor Gang 2 2 4 5 1.4
8 Welding & brazing Gang 1 2 2 5 0.7
9 Starter and Alternator Gang 2 2 4 5 1.4
10 Cam Shaft Gang 2 2 4 5 1.4
IV. Assembly & Testing
1 Engine Assembly process Gang 4 3 12 5 4.2
2 Engine Test House Gang 4 3 12 5 4.2
16 Tool room 0 0 0 5 0

Part-A DPR
V.Other sections
1 OSS Store 1 2 2 5 0.7
18 Storage of Repaired eng comp 0 0 0 5 0
19 QA 0 0 0 5 0
20 QC 0 0 0 5 0
21 Crane Operator - 0 0 0 5 0
2 Fork Lift Operator - 1 2 2 5 0.7
3 Trolly Operator - 1 2 2 5 0.7
4 Helper - 2 2 4 5 1.4
5 House Keeping - 1 2 2 5 0.7
6 Office & Docu/spare supply 1 2 2 5 0.7
Total 87 30.45
Eng Repair Gp
Total number of SU for 5 days = 30.45
Number of SU per year = 1607.76
Number of engines overhauled in 5 days = 4
Number of engines overhauled in a month = 17
Number of engines overhauled in a year = 204
Productivity of ERG group = 7.88 SU per eng
* excl 3 x persons for turbo repair,2 for flywheel and 1 for pick up van
Manpower for Fat engines = 68, for EEG=19

Part-A DPR
1.3.5 Existing Machinery

The tabulation below gives the list of existing machinery for the workshop along with details of
machines that are to be retained in the workshop.
Discarded Criteria:
All Machines having a residual life of less than 49% have been recommended to be discarded.
Also machines whole residual life is not known but vintage has than 1985, have been
recommended to be discarded
W/S YR
S.No DGEMENO NOMENCLATURE LOCATION Remarks
No INSTALL
1 19 12922 Lathe Reed Prentice Precision GEG 1948 Discarded
2 24 13783 Lathe Broad Bent GEG 1948 Discarded
3 28 13784 Lathe Turret Combination No 7 GEG 1948 Discarded
4 29 13853 Lathe Regal Geared Head GEG 1948 Discarded
5 50 12933 Drill Machine-Radial GEG 1948 Discarded
6 51 13789 Drill Machine Radial GEG 1948 Discarded
7 60 12936 Boring Machine Vertical ENG(GDG) 1948 Discarded
8 63 13795 Boring Machine Cylinder Block ENG(GDG) 1948 Discarded
9 67 12938 Crankshaft Grinder, Landis ENG 1948 Discarded
10 71 12940 Milling Machine GEG 1948 Discarded
11 73 12941 Grinder Universal, Landis ENG(Gdg) 1948 Discarded
12 86 12952 Lathe, Reed Prentice precision GEG 1948 Discarded
13 87 12953 Grinder Pedestal, twist drill GEG 1948 Discarded
14 94 12957 Shaping machine. Town GEG 1948 Discarded
15 107 12963 Blower KRAZ(B/S) 1948 Discarded
16 113 13808 Welding Transformer GEG 1948 Discarded
17 114 12966 Surface Grinder GEG 1948 Discarded
18 115 12967 Grinder Union GEG 1948 Discarded
GEG(CARP Discarded
191 121 13809 Lathe Wood Worker 1948
)
20 122 12971 Wood Worker Surface GEG(Carp) 1948 Discarded

Part-A DPR
W/S YR
No INSTALL
21 125 13810 Planner Wood Surface GEG(Carp) 1948 Discarded
22 126 1297 Grinder Planner Knife GEG 1948 Discarded
23 128 13812 Saw Circular GEG 1948 Discarded
24 133 12975 Grinder Saw Blade GEG. 1948 Discarded
25 151 12986 Grinder Wet & Dry GEG 1948 Discarded
26 178 13000 Press Hydraulic ENG 1948 Discarded
27 187 13814 Punching & Shearing machine GEG(Ftr) 1948 Discarded
28 194 13815 Grinder Wet & Dry GEG 1948 Discarded
29 243 13736 Forge GEG(B/S) 1948 Discarded
31 245 13819 Forge : GEG(B/S) 1948 Discarded
33 286 14067 Honing machine Cylinder Block ENG(Gdg) 1950 Discarded
GEG(MOUL Discarded
34 288 14065 Furnace Crucible Tilting 150 lbs 1950
D)
35 295 15267 Grinding m/cTool Tungsten Carbide GEG 1953 Discarded
36 321 16268 Milling Universal Horizontal GEG 1956 Discarded
37 322 16269 Milling Universal Horizontal GEG 1956 Discarded
38 325 16376 Lathe 12" centre SS&SC 12" Bed GEG 1956 Discarded
39 338 1700 Lathe 9-1/4" centre SS&SC 92" BC ENG(Met) 1958 Discarded
40 355 W00582 Forge Transportable collapsible GEG{B/S) 1962 Discarded
41 357 W00584 Hammer machine Forge vertical GEG(B/S) 1962 Discarded
42 361 W01137 Dynamometer Hydraulic DPX4 ETH 1962 Discarded
43 363 W027653 Planner Metal cutting double housing GEG(T/R) 1962 Discarded
Shape metal cutting vertical swivel Discarded
44 370 W01327 GEG 1962
head
Crankshaft Grinding machine 18" Discarded
45 373 WO 1144 ENG 1963
swing
46 383 W01331 Buffing and Polishing machine GEG(T/R) 1963 Discarded
507 ABW 221

Part-A DPR
W/S YR
No INSTALL
pedestal
47 385 W026196 Thermal Drying Electric 2 kw WSG(M) 1964 Discarded
ELECT Discarded
48 386 W026195 Electrode Drying over 1964
SHOP
49 415 W025682 Lathe 8'-8-l/2" centre SS&SC 49" BC WSG(TUR) 1964 Discarded
Lathe Engine gap 20" dia Discarded
50 399 W02196 GEG 1965
(500mm)SOB
51 410 W027104 Lathe 10" centre SS&SC 120" BC GEG 1965 Discarded
54 423 W026199 Surface Grinder Hydraulic horizontal GEG 1966 Discarded
55 436 W025761 Grinding m/c Universal Hyd Precision ENG(Gdg) 1967 Discarded
Lathe SS&SC 12" centre 24"-26" dia Discarded
56 440 W026895 GEG 1968
SOB
57 445 W026201 Lathe 7-1/2" centre SS&SC 30" BC GEG 1968 Discarded
58 448 W026893 Grinding machine Tool & cutter GEG 1968 Discarded
59 460 W027603 Welding Arc, Oil cooled transformer ENG 1968 Discarded
60 454 W027109 Lathe Bombay gap bed SS&SC GEG 1969 Discarded
61 455 W027110 Lathe Bombay gap bed SS&SC GEG 1969 Discarded
62 456 W027101 Milling Universal GEG 1969 Discarded
63 459 W027604 Press Arbor 16 ton, Hand operated ENG 1969 Discarded
Forge Transportable pan 26'X20", Discarded
64 463 NYA KRAZ(B/S) 1970
L/duty
Furnace Metal melting oil brining 150 GEG(MOUL Discarded
65 464 W027606 1970
lbs D)
66 476 W027610 Boring machine. Universal Line ENG(GDG) 1971 Discarded
Grinding machine double ended Discarded
67 486 W027789 GEG 1973
pedestal
Grinding machine double ended Discarded
68 487 W027788 GEG 1973
pedestal
507 ABW 222

Part-A DPR
W/S YR
No INSTALL
69 492 W027787 Grinding machine plain Cylindrical hyd ENG(Gdg) 1973 Discarded
70 493 W027785 Hacksaw machine power, Hy duty GEG 1973 Discarded
71 494 W027873 Plating outfit GEG 1973 Discarded
72 495 W027874 Welding machine Arc Transformer, FAB 1973 Discarded
73 497 W027877 Silicon Rectifier Transformer GEG(OCB) 1973 Discarded
Test stand mobile for testing of Discarded
74 499 W027674 FIP(ENG) 1973
Cummins PT Fuel p
Lathe SS&SC 225mm (8- Discarded
75 502 W027878 GEG 1973
l/2")X1500mmBC
76 503 W025216 Press Power Vertical, Cap 5 ton GEG 1974 Discarded
77 505 W027994 PT Fuel Injector comparator FiP(ENG) 1974 Discarded
Lathe Capstan 1-1/2" dia bar cap 13" Discarded
78 512 W027927 GEG 1975
dia
Milling Universal M/duty 30"X8" Discarded
79 515 W027990 GEG 1975
table.w.s.
Lathe Engine gap SS&SC 9"-10" dia Discarded
80 518 W027991 GEG 1975
SOB
81 523 WQ28059 Dynamometer Hydraulic DPX4 ETH 1976 Discarded
Welding transformer,24KW 30 to 300 Discarded
82 527 W028078 GEG 1977
amps
83 531 W02813S Crankshaft Grinding machine ENG 1977 Discarded
84 532 W028145 Test Bench FIP FIP 1077 Discarded
Grinding machine pedestal. Double Discarded
85 539 W028148 KRAZ 1978
ended
Welding Transformer,24KW 30 to 300 Discarded
86 546 W028141 KRAZ 1978
amps
87 548 W027898 Saw Circular, 36" GEG 1978 Discarded
88 549 W028224 Lathe SS&SC 225mmX1000mmBC GEG 1978 Discarded
89 550 W028222 Welding machine Arc Transformer, FAB 1978 Discarded
90 551 W028221 Welding machine, Arc Transformer, FAB 1978 Discarded
507 ABW 223

Part-A DPR
W/S YR
No INSTALL
300 ST
Grinding machine, double ended, Discarded
91 562 W026918 KRAZ 1979
H/duty
92 567 W028272 Shearing machine, Guillotine FAB 1979 Discarded
93 577 W01983 FAB 1980
H/duty
Lathe Engine Gap SS&SC,12" dia Discarded
94 581 W028351 GEG 1980
SOB
95 582 W028354 GEG 1980
H/duty
96 584 W028233 Press Power 40 ton FAB 1980 Discarded
Grinding machine d/ended, Stdmtd. Discarded
97 586 W0284S5 FAB 1981
L/duty
98 593 W028430 Milling machine Universal GEG 1981 Discarded
99 594 W028431 Milling machine Universal GEG 1981 Discarded
100 607 W028533 Lathe Engine Gap SS&SC 12" dia BC GEG 1982 Discarded
101 608 W028600 Pentograph Engraving machine GEG(T/R) 1982 Discarded
102 583 W028350 Furnace Elect, heat Treatment GEG(H/T) 1983 Discarded
103 590 W028617 Dynamometer Hydraulic 90 KW ETH 1983 Discarded
104 598 W028618 Drill Radial, Capacity 50mm FAB 1983 Discarded
Pneumatic Power Hammer, 100 Discarded
105 613 W028637 GEG{B/S) 1983
kg(2cwt)
106 614 W028619 Saw Circular, rise & fall table, hy duty KRAZ 1983 Discarded
107 623 W02S664 Welding Transformer, Oil cooled ,S/O FAB 1983 Discarded
108 624 W028663 Metallizing Gun ENG(Met) 1983 Discarded
109 589 W028616 Brake Press 80 ton capacity FAB 1983 Discarded
110 621 W028789 Surface Grinder, Vertical Spindle GEG 1984 Discarded
111 627 W028689 Welding Transformer, KRAZ 1984 Discarded
112 Discarded
629 W028792 Drill Radial, MT-4 Spindle GEG 1984
629
507 ABW 224

Part-A DPR
W/S YR
No INSTALL
113 631 W028894 Drill Radial, Mt-4 Spindle GEG 1985 Discarded
114 632 W028895 Drill Radial, Mt-4 Spindle KRAZ 1985 Discarded
115 648 W028942 Welding Generator, Arc Motor, S/O EEG 1985 Discarded
116 650 W028949 Boring machine Connecting Rod ENG(GDG) 1985 Discarded
117 615 W029002 Tool & Cutter Grinder GEG 1986 Discarded
Grinding machine d/e Bench, 8" dia Discarded
118 654 W029006 WSG(M) 1986
wheel
119 659 W029922 Press Brake, 80 Ton FAB 1986 Discarded
120 661 W029009 Profile Cutting machine GEG 1986 Discarded
121 663 W029066 Boring machine, line ENG(GDG) 1986 Discarded
Lathe "DSB" Gde-I,H/S SS&SC, Discarded
122 664 W029064 GEG 1986
Super-17
Press Power 100 ton, inclinable Discarded
123 660 W029919 FAB 1987
geared
-@ 672 W029967 Milling Machine Ran Type, HMT GEG 1987 Discarded
Surface Grinder for Cylinder head & Discarded
125 673 W029968 ENG(Gdg) 1987
Block
126 674 W029969 Lathe Capstan , No 4 GEG 1987 Discarded
Grinder for Engine Fly wheel & Clutch Discarded
127 675 W030009 KRAZ 1988
Plate
Electric heated Hyd Press (Rubber Discarded
128 677 W030042 FAB 1988
Moulding)
129 681 W030192 Hammer Forging 5 cwt KRAZ 1988 Discarded
130 682 W030044 Lathe Centre, HMT: VIKRAM GEG 1988 Discarded
131 683 W030116 Lathe Precision, SS&SC, 2215C/2000 GEG 1988 Discarded
Degreaser Thylene, 1800 X 600 X Discarded
132 685 W030092 KRAZ 1988
750mm
133 686 W030013 Lathe Precision, SS&SC, 2215C/2000 GEG 1988 Discarded
134 689 W028886 Air Compressor, 500 rpm WSG 1989 Discarded
135 690 WO30094 FIP Test bench, 8 Cylinder FIP(ENG) 1989 Discarded
507 ABW 225

Part-A DPR
W/S YR
No INSTALL
Shaper Metal cutting vertical 12" Discarded
136 692 W030193 GEG 1989
stroke
Test stand automotive generator and ELECT(EE Discarded
137 694 W030126 1989
starter G)
138 715 W030231 Valve Refacer GEG 1989 Discarded
139 716 W031229 Welding Arc rectifier, Air Cooled WSG(M) 1989 Discarded
Lathe SS&SC, "DSB" Gde- Discarded
140 699 W030197 GEG 1990
1,1650C/1000
141 700 W030198 GEG 1990
1,1650C/1000
142 709 W030224 Drill Bench Model, Med duty 20mm GEG 1990 Discarded
Shaper Metal cutting Discarded
143 717 W031393 GEG 1992
Horizontal,630mm stroke
144 719 W031415 Boring Cylinder, Special Vertical, HMT ENG(GDG) 1992 Discarded
145 720 W031465 Dynamometer Hydraulic 90 KW ETH 1992 Discarded
Hacksaw power, Hyd Control, Size - Discarded
146 722 W031673 FAB 1996
10"
Metallizing Outfit, Oxy Acetylene, CH- Discarded
147 724 W031675 ENG(Met) 1996
5
148 725 W031734 ME 1996
1,1650C/1000
149 727 NYA Drill Bench, 1/2" Capacity WSG(M) 1997 Discarded
150 728 NYA Drill Bench, 1/2" Capacity GEG 1997 Discarded
151 729 NYA Drill Bench, 1/2" Capacity FAB 1997 Discarded
Lathe, High speed Precision
152 730 W031829 GEG 1999 Retained
NH22/1500mm
153 732 NYA Drill Bench, 1/2" Capacity ENG 1999 Retained
Crankshaft Grinding machine, GCS-
154 733 W031828 ENG 1999 Retained
500(S)
155 734 W031827 Crankshaft Grinding machine, GCS- ENG 1999 Retained
507 ABW 226

Part-A DPR
W/S YR
No INSTALL
SOO(S)
156 735 NYA Air Compressor 1 HP, Cap 45 Itrs FIP(Eng) 1999 Retained
157 736 W031835 Universal Nibbling machine GEG(B/S) 2000 Retained
158 738 NYA Metallizing Gun, 'OWE' Brand ENG(Met) 2000 Retained
Grinding machine, Pedestal, Heavy
159 739 NYA EEG 2000 Retained
duty
160 740 W031875 Milling Vertical, Med duty, "SIGMA" GEG 2000 Retained
161 741 W031874 Milling Vertical, Med duty, "SIGMA" GEG 2000 Retained
Air Compressor 5 HP, W/Pressure 175
162 742 W031901 KRAZ 2000 Retained
lbs PSI
Lathe SS&SC 400mm SOB X
163 743 !MA GEG 2002 Retained
1000mm BC
Lathe SS&SC 400mm SOB X
164 744 NA GEG 2002 Retained
1000mm BC
165 745 NA Hammer Forging vertical, Pneumatic GEG(B/S) 2002 Retained
166 748 NA Universal Too! & Cutter Grinder GEG(T/R) 2004 Retained
Mod of DigitalizedMicroprocessor Control
167 749 FAB 2005 Retained
5xABW Invertised Weld
Modof5xAB Shearing machine 6mm, Model Mo
W Rolling Key
169 751 FC Dynamometer Hydraulic 90 KW ETH 2005 Retained
Mod of Three phase invertised welding
5xABW equipment
ModofSxAB Three phase invertised welding
W equipment
ModofSxAB Thermal Press platen size
172 754 KRAZ 2006 Retained
W 400x400mm
Surface Grinding machine, Model
173 755 WO31994 GEG 2006 Retained
BHU-1024
174 756 WO32000 AC Reciprocatingwihout Motor (air FAB 2007 Retained
507 ABW 227

Part-A DPR
W/S YR
No INSTALL
compressor)
175 757 WO32001 Air Compressor, ModeI-TS-10120NH KRAZ(Fab) 2007 Retained
Digital Tyre Inflator, Model- TICP140
176 758 WO32002 KRAZ(Fab) 2007 Retained
SNX
ModofSxAB
177 759 Valve Face Grinding Machine ENG(Gdg) 2006 Retained
W
178 760 W032020 Drill Machine Pedestal GEG(FTR) 2007 Retained
179 761 W032021 Drill Machine Pedestal FAB 2007 Retained
Hydraulic Control Power Optd
ISO 762 W032022 FAB 2007 Retained
Hacksaw Machine
Digital Tyre Inflator with 7.5 HP Air Kraz({New
181 763 WO32026 2007 Retained
Compressor WSG)
Digital Tyre Inflator with 7.5 HP Air Central Air
182 764 WO32027 2007 Retained
Compressor Comp room
1S3 765 WO32029 Co-ordinate Drilling machine GEG(FTR) 2007 Retained
Crank Type Power operated shearing
184 766 WO32020 GEG(B/S} 2007 Retained
machine
Hydraulic Control Power Optd GEG{store
185 767 WO32031 2007 Retained
Hacksaw Machine area)
ModofSxAB
186 768 Air Plasma Cutting machine GEG(FTR) 2007 Retained
W
187 769 WO32037 Spot Projection Welding machine FAB 2008 Retained
1S8 770 WO32038 F!P Test Bench FIP(Eng) 2008 Retained
Air Compressor 10 HP, Model TS
189 771 WO32036 GEG(FTR) 2008 Retained
1012H, 420 Itrs 1
190 772 WO32034 Hydraulic Control Hacksaw Machine . ME(T/R) 2008 Retained
191 773 WO32035 C Type Power Press, Capacity 10 Ton FAB 2008 Retained
192 774 WO-32041 Muffle Furnace GEG(B/S) 2008 Retained
Welding machine. Model -TORNADO-
193 775 WO-32052 FAB 2008 Retained
401
507 ABW 228

Part-A DPR
W/S YR
No INSTALL
194 776 WO-32051 Tool Room Centre Lathe machine WSG(M) 2008 Retained
Spot Projection Welding machine, 40
195 777 WO-32053 FAB 2008 Retained
KVA
Circumferential Press type Seam
196 778 WO-32058 FAB 2008 Retained
Welding machine
Three Phase Inverter Based 600A
197 779 WO-32065 EEG 2009 Retained
Welding Machine
198 780 WO-32066 Crank Type Power Press 50 Ton GEG(FTR) 2009 Retained
Welding Machine CO2 Based Mig/Mag
199 781 WO-32067 FAB 2009 Retained
out fit of 2!
Modof5xAB Electrostatic Liquid Cleaner, Model-
200 782 M.Shop 2009 Retained
W ELC-50C
201 783 ModofSxABW Low Vacuum Dehydration Plant M Shop 2009 Retained
202 784 WO27673 F1P Test Bench ENG (FIP) 1982 Discarded
Compressor Reciprocating Power Eng(WSG
203 785 NA 2009 Retained
Driven 22M3 Bldg)
Compressor Reciprocating Power
204 786 NA ENG 2009 Retained
Driven 22M4
205 787 WO32077 Heat Treatment Furnace GEG(h/t) 2010 Retained
High Speed Precision Lathe, NH-
206 788 WO32079 GEG(TUR) 2010 Retained
22/1500
ModofSxAB
207 789 Motorised Hydraulic Press EEG 2010 Retained
W
KRAZ(ptg
208 790 WO32097 Airless Painting Machine 2011 Retained
booth)
EEG(Elect
209 791 WO32095 Auto Electric Test Bench 2011 Retained
Shop)
Profile Cutting Machine, Model -
210 792 WO32096 GEG(FTR) 2011 Retained
Flamingo
WSG(Centr
211 793 ModofSxABW Air Compressor 2012 Retained
al Air Com
507 ABW 229

Part-A DPR
W/S YR
No INSTALL
Roon
WSG(Centr
212 794 ModofSxABW Air Compressor 2012 Retained
al Air Com
213 795 ModofSxABW CNC Vertical Milling Machine ME 2012 Retained
214 796 WO32113 Hydraulic Oil Cleaner EEG 2012 Retained
215 TS-01 NA Piller Drill machine CARP 2007 Retained
Pyramid Type Plate/Sheet Bending
216 TS-02 NA FAB 2006 Retained
machine
217 TS-03 NA Piller Drill machine FAB 2007 Retained
218 TS-04 NA Piller Drill machine EEG 2007 Retained
219 TS-05 NA Muffle Furnace GEG(B/S) 2007 Retained
220 TS-06 NA Padestal Grinding machine, D/E EEG 2007 Retained
221 TS-07 NA Padestai Grinding machine, D/E MSHOP 2008 Retained
222 TS-08 NA Piller Drill machine MSHOP 2008 Retained
223 TS-09 NA Padestal Grinding machine GEG 2008 Retained
224 TS-10 NA Bench Drill Machine GEG(FTR) 2008 Retained
225 TS-11 NA Bench Drill Machine GEG(FTR) 2008 Retained
Inverter based DC Welding machine of
200 amps cap
227 TS-13 NA Piller Drill machine GEG(ME) 2008 Retained
228 TS-14 NA Rotary Hammer with Drill bit MSHOP 2008 Retained
229 TS-15 NA Padestal Grinding machine,D/E FAB 2008 Retained
WARPP make Inverter Based Welding
power sources
WARPP make Inverter Based DC
Welding machine
TOTAL HOLDING: 231
Retained: 79
Discarded: 152
507 ABW 230

Process Buildings
Part-A DPR
PART A – VOLUME – 1
2.0 Process Buildings - New Buildings To Be Constructed
Detailed Project Report has been separated into Part A and Part B in which Part A deals with particulars
about the Process buildings of 507 Army Base Workshop and includes their requirements such as
PMSEs, Testing Equipments, Material Handling Equipments, Repair Bays / Process Buildings,Internal
Electrical works, Internal water supply & sanitary works and other allied services like firefighting system,
HVACs, Manufacturing Execution System and support facilities, Storage systems etc. for the Process
buildings and Part B covers the particulars about the Non-Process buildings and it requirements.
This Chapter includes the particulars of civil works about the Process Buildings.
 Engineer Equipment Assembly Group
 Field Articulated Vehicle Assembly Group
 Field Articulated Vehicle Sub Assembly Group
 Engine Repair Group
 General Engineering Group
 Ancillary Shed
 Workshop Expenses Store / Battery Charging Station
 Body Repair Group
 Engine Test House
 Caustic Soda Washing
 OSS, MCO & KRAZ Stores
 Vehicle Stripping Shed
 Engineer Equipment Stripping / Sub Assembly Group
 Outer Traffic Stores
 ETP
 Scrap Yard
 UG Sump - 1 & 2
 Compressor Room – 1& 2
 Overhauled Vehicle Parking – 1 (11 Nos)
 Chassis Dynamometer
507 ABW 231

Part-A DPR
 Repairable Vehicle Parking – 1 (15 Nos)
 Repairable Vehicle Parking – 2 (15 Nos)

Note:
1. Specifications for Each Building has been enclosed at the end of this Volume
2. Individual Floor Plan, Section and Elevation for all the Buildings are enclosed in Part - A / Volume –
1 / Annexure – IIA
3. Electrical, Water Supply & Sanitary Lines and Fire Fighting Drawings for each building are enclosed
in Part - A / Volume – 1 / Annexure – IIB
2.1 Engineer Equipment Assembly Group
Engineer Equipment Assembly Groupwith abuilt up area of about 4197.00 Sq.m. with the height
of 10.5 m up to the Truss bottom level of the building has been located centrally with respect to
the Technical Process of the workshop.
Entrance Door is made by Manually Operated Sliding Doorfor easy access which is usuallykept
closed when there’s no movement of vehicles. The door will be kept open depends on the
requirements such as wider for access of vehicles and it also can be kept narrow for access of
officials and employees.
Roof of the building is designed as double skin roofing of Galvalume sheet with proper
ventilations arrangements using polycarbonate sheets. This will ensure maximum natural light
enters in to the building. Additionally, Ridge ventilators and turbo ventilators are also provided to
achieve moreventilation / air circulation. Turbo ventilators are powered by the wind to create
effective ventilation for workshop buildings. Turbo ventilators are round metal vents with fins in
them. Even the slightest breeze can be enough for the turbo ventilator to rotate. Rotation causes
a centrifugal force on the tip of the fins which suck out the stale hot air from inside of the
workshop building. The faster the wind, the faster the turbine will rotate and exhaust the heat,
smoke, fumes, humidity, etc.
Screed Flooring with 2mm thick epoxy coating has been designed for main shop floor areas such
as Machine Shop, Spares Store, Gear Box Section, Dust Free room, Scrap store & Hydraulic
Testing Section etc.
Vitrified tiles are planned to all office rooms like supervisor room, Q.A / QC Team Room, office
room, document room etc,.andNon-skid ceramic flooring tiles has been designed for toilet area
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Part-A DPR
Facilities Provided in this Building

Ground Floor
 EOT Cranes
 20 Tons - 2 Nos.
 10 Tons - 2 Nos.
 5 Tons - 2 Nos.
 Machine Shop
 Spares Store
 Consumables store
 Gear Box Section
 OBM Facility (Dust Free room)
 Space for Retained machines
 Tools Room
 Scrap store
 Hydraulic Testing Section with AC facility
 Lunch room
 Paint Booth
 Locker / Change Room
 Parking area for MHE
 Common toilets at 2 corners
Mezzanine Floor
 Officer Room with A/C Facility - 2 Nos.
 Foreman Room
 Supervisor Room
 Discussion Room with A/C Facility
 Discussion Room
 Q.C Team Room
 Q.A Team Room
 Document Room
 Electrical Accessories
 Locker Change Room
 Lunch Room
 Other Rooms – 3 nos
 Toilets
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Part-A DPR
2.2 Field Articulated Vehicle Assembly Group
Field Articulated Vehicle Assembly Group having a built up area of about 6410.00 Sq.m. with the
height of 8.0m up to Crane bottom level. The building is planned with mezzanine floor for the
accommodation of officers room, supervisor room etc.
In the ground floor, two number of sound proof room having an area of 96.00 Sq.m. each has
been planned and the process is of lining type where the overhaul of specialist 'B' Vehicles would
be taken care in line one after the other where 15 numbers of vehicles would be overhauled at
once. The passage of 5m has been provided in between the overhauling sections and the same
passage width of 5m provided between the stores and repair sections. Adequate storage space
has been planned for kit storage for each assembly station.
Entrance Door is made by Manually Operated Sliding Doorfor easy access which is usually kept
enters in to the building. Additionally, Ridge ventilators and turbo ventilators are also provided for
better air circulation.
as assembly station, sound proof room & Scrap store etc. Vitrified tiles are planned to all office
rooms like supervisor room, Q.A / QC Team Room, office room etc,.andNon-skid ceramic
flooring tiles has been designed for toilet area
The space allotment for man passage, tool line, and equipment conveyor, working space, kit
storage and utility passage is as follows
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Part-A DPR
Area statement for the Field Articulated Vehicle Assembly Group as follows,
Ground floor – 5750.00Sq.m.

Mezzanine floor –660.00Sq.m.
The following Amenities have been proposed in the group

Ground Floor
 Assembly Stations – 15nos
 EOT Cranes
 20 Tons - 2 Nos.
 10 Tons - 4 Nos.
 Sound Proof Room – 2 Nos
 Scrap Room– 2 Nos
 Locker Room– 2 Nos
 Lunch Room– 2 Nos
 Air Shower – 2 Nos
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Part-A DPR
 Kits / Spares Storage Area.

 Toilets
Mezzanine Floor Plan
 QA Team Room
 QC Team Room
 Officer Room – 2 Nos
 Supervisor Room
 Foreman Room
 Other Rooms – 8 Nos
2.3 Field Articulated Vehicle Sub Assembly Group
Field Articulated Vehicle Sub Assembly Group with a built uparea of about 3662.00 Sq.m. has
been planned with ground & Mezzanine floor.
Entrance Door is made by Manually Operated Sliding Doorfor easy accesswhich is usually kept
better air circulation.
as Shot Blasting, Paint booth, Clutch Assembly section, Gear box section, Transfer Gear Box
Section etc. Vitrified tiles are planned to all office rooms like supervisor room, Q.A / QC Team
Room, office room etc,.andNon-skid ceramic flooring tiles has been designed for toilet area
Area statement for the Field Articulated Vehicle sub Assembly is as follows,
Ground floor– 2875.00Sq.m.
Mezzanine floor– 787.00Sq.m.
The following Amenities has been proposed in the group

Ground Floor
 EOT Cranes
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Part-A DPR
 10 Tons - 1 No.
 5 Tons - 1 No.
 Gear Box Section
 Clutch Assembly Section
 Caustic Washing Booth
 Shot Blasting
 Paint Booth
 Welding Section
 Testing Section
 Steering Gear Box Section
 Transfer Gear Box Section
 Axle Section
 Winch Gear Box Section
 Machine Shop
 Hot & Cold Ancillary Section
 Scrap Stores
 Tool Room
 Expandable Store
 OSS Stores
 Lift
 Toilet
Mezzanine Floor Plan
 Break Value & Houses Section
 Electrical Section
 Officer Room
 Foreman Room
 Supervisor Room
 Discussion Room
 QA Team Room
 Future Expansion
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Part-A DPR
2.4 Engine Repair Group
Engine Repair Group is proposed with a built up area of about 2493.00 Sq.m. planned with
Ground floor &Mezzanine floor. Centralized air conditioning system is provided for this building to
keep required temperature & dust free environment
Entrance Door is made by Manually Operated Sliding Door for easy access which is usually kept
better air circulation. Turbo ventilators are powered by the wind to create effective ventilation for
workshop buildings. Turbo ventilators are round metal vents with fins in them. Even the slightest
breeze can be enough for the turbo ventilator to rotate. Rotation causes a centrifugal force on the
tip of the fins which suck out the stale hot air from inside of the workshop building. The faster the
wind, the faster the turbine will rotate and exhaust the heat, smoke, fumes, humidity, etc.
as Water wash, Caustic soda wash, Orion solution bath, Kerosene & Vibrator, Scrap store, Oil
pump & Water pump OH Section, Cylinder head OH Section, Painting shop, Accessories Drop
OH Section, Fume Extraction system, Engine block OH Section, Repairable Engine Storage,
Stripping Area, Welding section etc. Vitrified tiles are planned to all office rooms like supervisor
room, Q.A / QC Team Room, office room etc,.andNon-skid ceramic flooring tiles has been
designed for toilet area
Area details for the Engine Repair Group is as follows,
Mezzanine floor – 93.00Sq.m.

Ground Floor
 EOTCranes
 5 Tons - 3 Nos.
 QC Team Room
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Part-A DPR
 Assay 1 to 6 with 2 Ton Jib Crane each

 Repaired Engine Storage
 Storage Area for Repaired Engine Components – at two places
 OSS Store
 FIP & injector Calibration Section
 Repairable Engine Storage
 Stripping Area
 Welding Section
 Water wash
 Caustic soda bath
 Orion solution wash
 Kerosene & vibrator
 Scrap store
 Oil Pump & Water Pump OH Section
 Retained machine
 Cylinder Head OH Section with crane ( 2 ton )
 Crankshaft OH Section
 Paint Shop
 Accessories drop OH Section
 Oil Sump OH Section
 Starter & Alternator OH Section
 Camshaft Connecting Rod &Valves
 Tool Room
 Engine Block OH Section with jib crane ( 2 ton )
 QA Team Room
 Supervisor Room
 Lunch Room
 Change Room
 Conference Hall
 Locker Room
 Toilets
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Part-A DPR
Mezzanine Floor
 Supervisor room
 Foreman's room
 Officer Room
2.5 General Engineering Group
General Engineering Group has been planned with a built up area of about 2588.00 Sq.m. and
with the height of 7.5 m up to the truss bottom level.
closed when there’s no movement of vehicles. The door will be kept open depending on the
requirement such as wider for access for vehicles and it also can be kept narrow for access of
officials and employees alone.
better air circulation. This will improve the ventilation of the building considerably and the lighting
as well.
The area details of the General engineering Group is as follows,


Ground floor
 EOTCranes
 3 Tons - 2 Nos.
 Grinding Section - 2 Nos.
 Drilling Section
 Furnace Section
 Lathe Section - 2 Nos.
 Press Section
 Boring Section
 Moulding Section
 Cutting Section
 Raw Material Store
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Part-A DPR
 Tool Room
 Consumable Store
 Special Machine Section
 Space for Storage of Manufacturing Spares
 Milling Section
 Retained Machines
 Welding section
 Wood Section
 Lunch Room
 Toilet
Mezzanine floor
 Conference hall (A/C)
 Officer room with attached toilet (A/C)
 Computer room (A/C)
 Supervisor room with attached toilet
 Foreman's room with attached toilet
 Toilets
2.6 Ancillary shed
Ancillary shed is a steel structure that has been planned with an area of 1760.00 Sq.m.Entrance
Doorsareof Manually Operated Sliding Door typefor easy access which is usually kept closed
when there’s no movement of vehicles. The door will be kept open depending on the requirement
such as wider access for vehicles and narrow access for officials and employees alone.
The Roof of the building is designed as double skin roofing of Galvalume sheet with proper
ventilation arrangements using polycarbonate sheets. This will ensure maximum natural light
better air circulation. This will ensure proper ventilation and lighting as well.

Ground floor
 EOTCranes
 5 Tons - 1 No.
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Part-A DPR
 2 Tons - 1 No.
 1 Ton - 2 Nos. (Single Girder)
 ElectroplatingShop
 Supervisor Room (Electroplating Shop)
 Store for Electroplating Shop
 Testing Section
 Machine Shop
 Store
 Officer In-charge Room (A/C)
 Retained Machinery
 Centre of Excellence (Plastic & Rubber)
 Heat Treatment & Moulding Section
 Carpentry
 Store
 Locker Room
 Lunch Room
 Toilets
2.7 Workshop Expense Stores / Battery Charging Section
Workshop Expense store is planned with Ground & first floor. Ground floor is mainly
accommodated for workshop expense store & First floor is catered for Battery charging section,
Officer Room etc., Staircase is provided for vertical travel of people and Lift facility is provided for
easy access of batteries to the battery charging shop.
The area details of the Workshop Expense store / Battery charging is as follows,
First floor – 300.00Sq.m.
507 ABW 242

Part-A DPR

Ground floor
 Workshop Expense store
 Office room
 R & I Officer room with attached toilet
 Lobby
 Lift
First Floor
 Battery Charging shop
 Officer room with attached toilet
 Supervisor room with attached toilet
 Spare store
 Consumable store
 Lift
 Lobby
2.8 Body Repair Group
Body repair Group is planned with a built up area of about 2125.00 Sq.m. with the floor height of
10.5 m up to the truss bottom level had been planned near the Engine Repair Group.Entrance
Doors are of Manually Operated Sliding Door typefor easy access which is usually kept closed
when there’s no movement of vehicles. The door will be kept open depending on the requirement
such as wider access for vehicles and narrow access for officials and employees alone.
The Roof of the building is designed as double skin roofing of Galvalume sheet with proper
ventilation arrangements using polycarbonate sheets. This will ensure maximum natural light
better air circulation. This will ensure proper ventilation and lighting as well.
The area details of the Body Repair Group is as follows,

507 ABW 243

Part-A DPR

Ground floor
 EOTCranes
 20 Tons - 1 No.
 10 Tons - 1 No.
 Electrical Section
 Upholstery Section
 Carpentry Section
 Welding Shop – 2 Nos
 Machine Shop - 2 Nos.
 Sheet Metal Work
 Raw Material Store
 Scrap Store
 Painting Booth
 Fitting & Testing Section
 OSS Stores
 Tool Room
 Consumable Store
 Locker/change room
 Common Toilet
Mezzanine floor
 Dinning Hall
 Supervisor Room with attached toilet
 Foreman Room with attached toilet
 Officer Room with attached toilet
2.9 Engine Test House
The Engine Test House is a R.C.C. Building (G+1) planned fairly close to the General
Engineering Group with a built up area of about 2882.00 Sq.m. The Ground floor is provided with
a height of about 7m and first floor is of about 3.6m. There are totally8 sound proof Engine Test
Beds with sound proof doors along with fume extraction systems to cater the heat evolved during
the testing process. Adequate ventilation is provided in the ground floor and industrial grade
exhaust fans are provided on the first floor. Ducts are provided for electrical and other service
lines at many points in the building.
507 ABW 244

Part-A DPR
Area statement of the engine Test House is as follows,

Ground floor – 1758.00 Sq.m.
First floor – 1098.00Sq.m.
Terrace Floor - 26.00 Sq.m.

Ground floor
 EOTCranes
 Single Girder 5 Tons - 8 Nos.
 Double Girder 5 Tons - 1 No.
 Engine Test Beds - 8 Nos.
 Cabins for Engine Test Beds - 8 Nos. (A/C)
 Engine Preservation Area
 Supervisor Room with attached toilet
 QA Staff Room
 Fuel Oil Store
 Tools Store
 Common Toilet
2.10 Caustic Soda Wash

Caustic soda washis a steel structure planned with an area of about 200.00Sq.m. of height 10.5
m up to the truss bottom level. Ramp is provided for easy access to the shed.
4EOT cranes are proposed in this building.
Outof 4 EOT cranes, 2 Nos 20 Ton Capacity and 2 Nos 10 Ton Capacity are provided. This
group is planned near the Vehicle stripping shed as per requirements.Ridge Ventilator has been
provided at the roof top and the roofing is of Single skin roofing of 1 in 10 slopes.
2.11 OSS store / MCO store / KRAZ stores

OSS store / MCO store / KRAZ store isa steel structure planned with an area of 3200.00 Sq.m
near Ancillary Shed.
Closed when there’s no movement of vehicles. The door will be kept open depends on the
507 ABW 245

Part-A DPR

Ground floor is accommodated for both the conventional system & ASRS, Staircase has been
provided for the future requirement.

Ground floor
 OSS I/C Room(AC)
 OSS Office Staff room
 MCO I/C Room
 Locker / Change room
 Lunch Rooms
 Lift
 Toilets
2.12 Vehicle Stripping Shed
Vehicle stripping shed planned is a steel structure having an area of 750.00 Sq.m.of height 10.5
up to the truss bottom level. The roof of this building is designed with double skin roofing of
Galvalume sheet with polycarbonate sheets with the slope of 1 in 10. This will ensure maximum
natural light enters the building.
Additionally, Ridge ventilators and turbo ventilators are also provided for better air circulation.
Turbo ventilators are powered by the wind to create effective ventilation for workshop buildings.
Turbo ventilators are round metal vents with fins in them. Even the slightest breeze can be
enough for the turbo ventilator to rotate. Rotation causes a centrifugal force on the tip of the fins
which suck out the stale hot air from inside of the workshop building. The faster the wind, the
faster the turbine will rotate and exhaust the heat, smoke, fumes, humidity, etc.
507 ABW 246

Part-A DPR
It is planned near the existing vehicle washing booth as per requirement. Wide space is
assigned for stripping in ground floor and facility of EOT crane having the capacity of 20 T & 10 T,
tool room, supervisor room and locker room is provided.

Ground floor
 EOTCranes
 20 Tons - 1 No.
 10 Tons - 1 No.
 Stripping area
 Tool room
 Supervisor room
 Locker room
 Common Toilet
2.13 Engineer Equipment Stripping / Sub assembly Group
Engineer Equipment Stripping / Sub assembly Group having aground floor area of 2000.00
Sq.m. & Mezzanine floor are 262.00 Sq.m had been planned near the existing vehicle washing
booth as per requirement. The height of the shed is about 10.5 m. Up to truss bottom level.
507 ABW 247

Part-A DPR

Ground floor
 EOTCranes
 20 Tons - 1 No.
 10 Tons - 1 No.
 05 Tons - 1 No.
 Stripping Area
 Tools room
 Scraps stores
 Shot blasting
 Spares Store
 Caustic Wash
 Hydraulic section
 Welding Section
 Fuel oil lubricant section
 Lunch room
 Locker Room
 Common toilet
Mezzanine floor
 QA / QC Room
 Document room
 Officer room with attached toilet
 Staff room
 Lunch room
 Locker Room
 Rooms for Future Expansion - 2 nos.
2.14 Outer Traffic Store
Outer traffic store is a RCC building planned with ground floor &open terrace having a built up
area of about 103.20 Sq.m. and is facilitated with space for LPO Room with sample library,
Tender dropping box & attached toilet & Store room
507 ABW 248

Part-A DPR
2.15 Effluent Treatment Plant
The treatment of effluents accrued after the various technical processes in the workshopswill be
carried out using Effluent Treatment Plant. Based on quantity of waste water, existingsystem,
land requirements, Effluent treatment system shall be designed.
ETP is planned with an area of 150.00 Sq.m. near the Caustic Soda Washing Booth. In ETP,
waste-water is allowed to enter into aeration chamber; it is mixed with an activebiomass in rolling
action which results in adequate mixing. Chambers are filleted on each sidealong the bottom to
enhance rolling motion of water which is provided with oxygen by passing diffused air through
waste-water. In addition to this, after the process of aeration waste-waterflows to clarifiers which
has a hopper bottom configuration where solids settle down during thesettling period.These
solids are returned by airlift pumps to the aeration chamber to maintain maximumefficiency of the
biological process.
Finally, a skimmer airlift pump is used to return float-ablesolids and scum to the aeration
chamber for further processing. Now, the treated water is madeto flow from the clarifier to a
disinfections chamber for treatment prior to discharge in order tocomplete the treatment process.
2.16 UG sump – 1 & 2
UG sump- 1 of capacity 1.50 Lakhs litres with OHT (Over Head Tank) capacity of 1.00 Lakh
Litres near Engine Test house and UG sump- 2of capacity 3.00 Lakhs litres with OHT (Over
Head Tank) capacity of 1.50 Lakh Litres near Caustic Soda Washing area has been planned to
meet the water required for the technical process of the workshop.
2.17 Scrap Yard
An area of 400.00 Sq.m had been planned for Scrap Yard for dumping purposes with brick wall
around the perimeter and divided into four sheds with the height of about 5.0m up to truss bottom
level with Sheet roofing of 1 in 10 slope and ridge ventilator has planned for better ventilation.
This yard has been planned near Painting Area.
2.18 Compressor room 1 & 2
Compressor Room (1&2) is a RCC structure with an area of 83.34 Sq.m each that has been
planned near the Power house and OTRP shed for ease in workability and maintenance with the
floor height of 5.6m. This room functions as a source of supply of air at high pressure as per
requirements. Ducts for Electrical and other services are provided have been provided in this
building. At open terrace, weathering tiles with leak proof coat is provided.
507 ABW 249

Part-A DPR

 DG Set 1 & 2
 HT Panel
 Transformer 1 & 2
 MV Panel 1 & 2
 Separate cable trench for LT and HT cables
 Compressor room
 Ramps with Rolling shutters
2.19 Over Hauled Vehicle Parking - 1(11 Nos.)
Over Hauled Vehicle parking is planned with an area of 540.00Sq.m. and height of 5 m. It is
planned nearer to the existing Dust proof painting booth. Totally 11 Nos of Overhauled vehicles
can be accommodated in this parking shed.
2.20 Chassis Dynamometer
An area of 224.00 Sq.m. with sound proof facility has been planned for this Chassis
Dynamometer. Two number of vehicles can accommodate space in this shed and control panel /
monitoring cabins & office room also has been planned in this section.
2.21 Repairable Vehicle Parking – 1 (15 Nos.)
Repairable Vehicle parking is planned with an area of 880.00 Sqm. and height of 5.0 m up to the
truss bottom is planned near OSS, MCO section. Totally 15nos of repairable vehicle can
accommodate here for the further movements. This shed is planned with Galvalume sheet
roofing and ramp.
2.22 Repairable Vehicle Parking – 2 (15 Nos.)
Repairable Vehicle parking is planned with an area of 880.00Sqm. and height of 5 m up to the
truss bottom. This shed is planned near the vehicle stripping shed. Totally 15 Nos of repairable
vehicle can be accommodated in each parking sheds.
507 ABW 250

Part-A DPR
Process Buildings –Buildings to Be Refurbished For New Application
Existing Infrastructure
Existing infrastructure and facilities have become outdated being old vintage and have been rendered
deficient due to addition of load over the years, in terms of range (type) and quantity, the old Workshop
sheds are not suited to meet the present day requirements of overhaul of present equipment with high
technology and quality.
Most of the existing buildings are constructed way back in 1960’s and are old and occupied more real
estate area than needed. In the buildings, maintenance needs are heavy and are often ineffective such
as perennially leaking roofs that pose a hazard to sensitive and expensive equipment. Ventilation and
environmental control of the buildings are poor. Electrical wiring is dilapidated and unplanned with ad-hoc
electrical arrangements and improper earthing. Hence there is a need to modernize the layout of the
workshop as per new construction, refurbishment and demolition work to meet the functional
requirements of the workshop.
List of Refurbishment Building for New Applications–Process

 Painting Area
 Dust Proof Painting Booth
 OTRP
 Receipt & Issue
 Vehicle Washing Booth
 MAG-10
 Method Engineering Section
2.23 Painting Area & Dust Proof Painting Booth
The state of existing infrastructure is as follows.

 The painting facilities currently available are insufficient to handle the load of the facility.
There is no separate dust free assembly room for Engine assembly.
 Electrical wiring is dilapidated and unplanned with ad-hoc electrical arrangements and
improper earthing.
 Drainage channel of the building is not with suitable network to drain away the waste
generated.
Recommendations
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Part-A DPR
 Electrical Services / cables to be re worked with Proper circuit & connectivity.

 Drainage Network to be reworked and new channel for drainage flow to be provided.
2.24 OTRP (Workshop Service Group)

 The floor which is old and gets flooded during monsoon affecting the house keeping and
disposal facilities. Ventilation of the building is not sufficient for the repair works.
 The working life of the existing infrastructure is poor.
 Space in the A.C sheet roof shed is not adequate for storage and is old.
 Damaged Wall Plastering of 3m height from the original ground level.
 All windows were found to be damaged.
 Drainage channel of the toilet is not with suitable network to drain away the waste
generated.
 Worn out inner and outer painting to be rectified.
Recommendations
 Finishing exterior walls with textured and acrylic smooth exterior paints.
 Drainage Network to be reworked and new channel for drainage flow to be provided for
the toilets.
 Anodised aluminium window and ventilator shutters to be provided.
 Internal and External wall plastering as per specifications.
 Floor level of the existing building to be raised if required matching the proposed elevation
level.
 This structure is to be refurbished and renamed as OTRP Shed
2.25 Receipt & Issue and Vehicle Washing Booth

 Damaged Wall Plastering of 3m height from the original ground level.
 Worn out inner and outer painting to be rectified.
improper earthing.
Recommendations
 Finishing exterior walls with textured and acrylic smooth exterior paints.
507 ABW 252

Part-A DPR
 Painting of inner and outer walls as per specifications.

2.26 MAG 10

disposal facilities.
 Damaged Wall Plastering upto roof level.
generated.
 The first floor roofing sheds which are perennially leaking and as a hazard to the
expensive equipments.
improper earthing.
Recommendations
the toilets.
 Floor level of the existing building to be raised if required matching the proposed elevation
level.
 Provisions will be given for preventing the leakage in the roofs during rainy season by
repairing any damaged sheets.
 Damaged Roof sheets to be replaced with new sheets.
2.27 Method Engineering Section

disposal facilities.
generated.
507 ABW 253

Part-A DPR
Recommendations
the toilets.
 Floor level of the existing building to be raised of 0.3m
In addition to the above emphasis will be given as on the following Refurbishment of Existing
Buildings
 Flooring – Damaged Flooring to be modernized with the facilities like Non-Skid Ceramic
tiles, wall dadoingetc
 Toilet lines found in poor and depleted conditions to be modernized
 Officer Rooms to be refurbished with split AC provisions
 False Ceiling to be provided for the rooms with AC Provisions
 Sunshades, roof tiles found damaged to be rectified
 Rain water Pipes to be refurbished with new pipes
 Septictank, Manholes, Plinth Protection to be refurbished
 Damaged Doors & hinges to be replaced
 All Locks to be checked and refurbished in working condition
 Dilapidated Electrical wiring to be replaced
The extent of damage of the existing building can be exactly accessed only during the
commencement of Rectification works since the building is presently in use and also the
implementation schedule may take at least 3 to 4 years from the date of assessment of existing
condition of the buildings.
507 ABW 254

Part-A DPR
Buildings under Construction
2.28 Workshop Service Group Tools Stores
WSG is a RCC framed structure (G+1), planned with ground & first floor having an area of
1041.25 Sq.m. 2 Ton EOT Crane and PMSC had been provided for this building.
Workshop Service group is under construction building, having the following facilities.
Ground floor
 Field Repair Section
 Foreman Electrical
 Foreman Mechanical
 Workshop Service Group repair bay
 Sample testing room
 FRS Office
 Changing room cum rest room
 Expendable Maintenance store
 Plant & Machinery spare store
 Plant Maintenance section office
 Salvage store room
 Power tool store
 Special Machine tool store
 Machine tool store
 Tool collection area
 Fast moving store cum issue counter
 Hand tool store room
 Furniture/electrical store room
 Compliant cell
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 OIC Tools store
 Clerk office
 Electrical repair & Electrical rewinding
First floor
 Technical library
 Demo room
 Local purchase section
 Library (Docu)
 Computer repair centre
 Plant & Machinery room
 WSG Office
 Maintenance room
 OIC Office
 Rubber & Belt Gasket room
 OIC Office
 Control store room
 Changing cum rest room
 Class room
Since it is under construction,allied infrastructure such as fire fighting Ac provision IT infrastructures

etc.are included as part of the modernisation programme.
2.29 MCO Building
Proposed MCO Building is under construction, having an area of 607.5 Sq.m. It is a RCC framed
structure (G+1), 2 Ton EOT Crane had been provided for this building.
Ground floor is mainly catered to accommodates the following facilities,
 Workshop area
 Electrolyte Distillation room
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 Battery charging room

 Supervisor room
 Elect store room
 Elect Testing room
 Clutch testing room
 Cabin repair store room
 Axle Repair Room
 Gear Box repair & Store room
 Toilets
First floor facilities
 Bulk Store
 OIC Office
 Store Staff Office
 WI Office
 Document room
 Rest cum change room
 Toilet block
Since it is under construction,allied infrastructure such as fire fighting Ac provision IT infrastructures

etc.are included as part of the modernisation programme.
Note:
1. Individual Floor Plan, Section and Elevation for all the proposed buildings are enclosed in Part - A /
Volume – 1 / Annexure – IIA
2. Further, Individual Floor Plan for Refurbishment buildings & Under construction buildings are
enclosed in Part - A / Volume – 1 / Annexure – IIA
3. Building Specifications for all proposed buildings has been enclosed at the end of the volume.
4. Cost estimate had been enclosed in Part - A / Volume – 1 / Annexure – IIIA& III B
5. Scope of civil works are mentioned in Part - A / Volume – 2 / Annexure – I
6. Technical Specification for civil work is given in the Part - A / Volume – 2 / Annexure – II
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Allied Requirements
Power Requirements
Part-A DPR
3.1 Power Requirements
3.1.1 General Requirements

The electrical work consist of design, detailed engineering, supply, erection, testing &
commissioning, operation & Maintenance of the complete electrical facilities including supply of
all consumables, tools & tackles, equipment/gadgets required for proper installation, operation
& maintenance of Electrical system. Preparation of equipment specifications, data sheets,
drawings and standards are also considered.
3.1.2 Existing
The 507 ABW Power House has 3.3/0.400 kv 500 kva transformer, main power house with 500
kva (ss-2) 400 kva (chord road), 500 kva (EME Workshop), 250 kva (Domestic) transformers,
2x200kva DG set with step up facility transformer 0.415/3.3kv, and maximum demand of 400
kva (average).
3.1.3 Proposed:
The existing sanctioned maximum demand of 400 KVA increases to 1700 KVA during
modernization of ABW. To cater the max demand of 1700 KVA. One no of 11/0.430 kv Power
house, three numbers of compact substations are proposed. The MV panel with single bus bar
system is designed with two panels and a bus coupler in Power House to facilitate auto power
change during power failure.
The existing system of stepping down from 3.3/0.400kv is changed to 11/0.433kv and two
separate 11kv feeders are brought from CSEC as a feeding point to the proposed Power
House arrangement, to have better voltage regulation, interchangeability of equipments and to
meet high energy demand. This up gradation is to be carried out through MES for the proposed
requirements.
The electrical work comprises supply, installation, testing and commissioning of all internal
electrical work such as lighting wiring, fixing luminaries, laying of PVC conduits for machinery
power input, installing SSBs, DBs, APFCr panels, laying and termination of cable to the
machineries. This work includes supply of all materials as per specifications and drawing,
supplying, laying, fitting, fixing, testing, installation, commissioning the same & obtaining the
necessary safety certificate from Electrical & other agencies.
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The demand calculated is 1700 kVA after the erection of new machineries. The works are
executed as per specification & as per relevant IS codes.
The incoming supply is received and controlled by 11kv, 5 panel indoor type construction. Two
for receiving incoming supply and two for outgoing and one for bus coupler segment. The
incoming supply is received from the state Electricity board thru MES take over point. The
outgoing from metering panel is received by 5panel RMU indoor type and from that panel it
goes to Power House. From Power House, the 3c 300 sq.mm 11kv XLPE H.T cable laid to
CSS - 1. From Power House -1 H.T five panels, the ring main system cable goes to CSS-2
three panel and then to CSS-3. From CSS-3, H.T cable completes its path by ending the
termination with metering panel.
Power house-1 consists of 2nos 1000 kva ONLOAD Transformers coupled by MV panel bus
coupler with 2 nos 1000 kva DG set catering 80-85% of the load connected to this Power
House.Two numbers of step down ONLOAD transformer of 11 kv/415, 1000 kva(minimum), 17
steps of changing installed here. This Power house supplies power to Engineer Equipment
Assembly Group, Field Articulated Vehicle Assembly Group, GRG, Ancillary shed, OSS, MCO&
KRAZ stores, Caustic soda washing, Painting booth, WSG, boiler section, HVAC, ETP,
Compressor room, Method Engineering, Fire station, Lighting and small powers to the above
said buildings.
Compact Sub-Station-1 comprises of HT 3 panel SF6 insulated breaker with 750 KVA
hermetically sealed transformer and LT outgoings as per the requirements with 750kva, 415v 3
Phase acoustic model DG set having AMF facility.
Compact Sub-Station-2&3 comprises of HT 3 panel SF6 insulated breaker with 500 KVA
hermetically sealed transformer and LT outgoings as per the requirements with 500 kva, 415v 3
Phase acoustic model DG set having AMF facility.
This CSS-1 supplies power to Compressor room -2, HVAC feeder, Body Repair Group, ETH,
OTRP, Engine Repair Group , Engineer Equipment Assembly Group, lighting for the said
buildings, lighting and small power for Painting area, Scrap Yard, Guard post, Receipt and
Issue, PM office and Street Light feeder pillar.
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Compact Sub Station CSS-2 supplies power to technical Head quarters, KOTE, MAG10, pump
house, car parking-1, Bicycle & two wheeler parking-1,2, Repairable Vehicle parking-1 & 2 and
allied light & small power sockets.
Compact Sub Station CSS-3 supplies power to workshop service group, Method Engineering,
pump house, car parking 2 & security complex.
For details refer - General Drawings - External Electrical layout- Drg No: KAN-DD-ELE-GEN-
PTW-100051-0C , Main Single Line Diagram - 1 - Drg No: KAN-DD-ELE-GEN-PTW-100052-
0C and Main Single Line Diagram - 2 - Drg No: KAN-DD-ELE-GEN-PTW-100053-0C
The design criteria are based on the following factors:

1. Safety of personnel and equipment during operation & maintenance
2. Convenience of operation
3. Ease of Maintenance
4. Minimum fire risk
5. Max. interchangeability of the equipment
6. Standard rating to the large extent.
7. The design is such that maintenance of live equipment can be carried out safely without
much down time
3.1.4 Cable trenches and laying

The cable trenches are designed to give comfortable space while working. The cables are laid
in a rack system to maintain the gap between cables and easy maintenance.
Whenever a power cable crosses a communication cable, the cable is securely supported and
power cable go under the communication cable, maintaining a 300mm clearance.
The L.T cables are laid at a depth of 750mm (measuring on top the cable) covering with bricks,
on either side, with a sand cushion bed of 100mm top & bottom of the cable to protect the UG
cables from heavy vehicle movements. There is a separate trench for HT and LT cables.
A cable trench of width 900mm and depth of 1500mm given for laying of cables and earth flats.
The Panels and DB are standing type and mounted on the cable trenches. The incoming and
outgoing cables to the Machines are laid thru cable tray or thru concealed 75mm, 8kg/cm2 PVC
pipe. The PVC conduits are laid before finishing all flooring works. First preference to be given
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for laying the UG cable thru PVC pipe. Suitable length and size of Ladder fabricated in 50x6mm
M.s ‘L’ angle provided at every man hole of the trench to get down into the trench.
For details refer Part - A - volume 1 - Annexure - II B - Process Building - Switch board location
and cable trench details.
3.1.5 Lighting
The lighting level/intensity for office working area is taken as 300 lux. Passage is covered with
1x28 watts TL fittings. In false ceiling sections, 2 x 36 watts TL fittings are given. 2x LDB of 63
amps, 8way, 3phase 7 segment distribution board provided for lighting circuits. For workshop
area, to have a better working, 250 watts High bay Luminaries closed version with anodized
aluminium narrow beam and wide beam reflector comprised of Housing (HPK), Reflector (HPK
reflector) & Glass Cover (ZPK).luminaries including 250W HPI (Philips Cat. No. HPK225 I x
HPI-250W-BU NB GL or equivalent) is selected for a working level of 500 lux. In workshop area
bay light wiring is done through steel conduit.
Common wire-ways used for relatively light current-carrying conductors such as lighting and
socket-outlet circuits of 1.5sq.mm capacity. In every circuit, the no. of fittings is limited by 800
watts or 10 points. When wiring is installed in removable partitions, conductors are not
exposed and the metal supports are earthed. A separate bare earth continuity conductor is
drawn-in together with the current carrying conductors and is earthed to the metal parts of the
switches and/or the socket outlets. The luminaries fixed directly to the ceiling. PVC conduit
2mm thick, heavy duty, white colour used in concealed areas such as walls, floors, and ceilings
wiring conduit, switch boxes, fan hook points. DBs are concealed in RCC and brick works. 1x11
watt fittings in each toilet are provided for mirror light. Twin control switches are used for
Staircase lighting.
3.1.6 Power socket outlets

Heavy current-carrying conductors such as feeders to distribution boards and large power
points, more than 1.5 sq.mm are installed in separate conduits or wire-ways. 3 pin or 6 pin
sockets are used for small power outlets and the third pin is used for earth.
3.1.7 Ceiling fan and Exhaust fan

Ceiling fans of 1200 mm sweep special design energy saving ceiling fans along with
concealed fan hook box similar to Havell's ES-50/ Crompton or equivalent with low power
consumption, aluminium motor with double ball bearings, aluminium blades, down rod, canopy
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but without regulator given for all working places, lunch rooms & change rooms. Step type
continuously rotatable electronic type regulator is provided for speed controlling.
Each toilet 300 mm dia, 1400 rpm, double ball bearing, metal leaf, reversible, exhaust fan with
louvers provided.
3.1.8 Industrial Exhaust Fan

Industrial type wall mounted air circulating fan, sweep 610mm / 24 inch, 230volts, 50Hz, 550w,
900rpm, 10450 m3/ hr air delivery industrial exhaust fan including necessary clamps, nuts &
bolts plug fans, connection wires as required are provided.
3.1.9 Industrial Air Circulating Fan

Between 5mtr distances , two number of Industrial type Wall Mounted air circulating Fan -
sweep 600mm, 230 volts,50Hz, 250w, 1440 rpm, 400m3/min air delivery, Heavy duty wall
mounting Air circulators including necessary clamps, nuts and bolts with washers, plug tops,
connection wire are fixed at an height of 2.5 mtrs (min) level.
3.1.10 MV panel and Switchboard

Panels are fabricated out of 14 gauge CRCA sheet steel in cubical compartmentalized, free
standing floor / wall mounted, dust and vermin proof, with reinforcement of suitable size angle
iron, channel, T-Iron or flats as required cable gland plates are provided on top as well as
bottom to facilitate top/bottom entry of the cable to avoid bending or hanging of the cables.
The panels are treated with anti-corrosive process before powder coating. The panels are
suitable for 415v, 3 phase, 4 wire, 50 Hz supply, complete with earth bus and lifting hooks as
required, in case of large panels. All hardware like nuts and both used are galvanized and zinc
passivated to protect the material from corrosion and to give aesthetic look. The panels are
fabricated with suitable size aluminium bus bar for main and inter connecting switch gear and
earthing as per requirement of CEIG and IE regulations.
Draw out type ACB is selected for current ratings 800A & 630A to give trouble free years of
operations both electrical & mechanical in extreme tropical conditions to meet the stringent
requirement of protection and discrimination is low voltage networks, with electrically operated
mechanism.
ACB with over current protection device, Computer compatible and communication capable are
selected for getting control over load and protection of equipments under fault conditions.
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Sliding shutters are provided to prevent unauthorized access to “TRIP” & “Close” push button.
Multi tap CT’s provided to set various ranges of protection.
3.1.11 HT and LT Cables

The HT Cables are XLPE insulated, armoured cable aluminium configuring to IS7098 part-
2/1985 11KV(E) grade XLPE, 3 Core, Power cables selected are of high conductivity, stranded
and compacted, H.D aluminium circular shaped conductor with XLPE (Cross linked
Polyethylene) dry gas cured installation provided with shielding of extracted semi conducting
materials over conductor and XLPE insulation.
Outer sheath designed to afford high degree of mechanical protection and also heat, oil,
chemical and weather resistant, common acid, alkaline and sealing solution not have the
adverse effect on material of PVC sheath. Cables selected are suitable for laying in covered
trenches and/or buried underground in outdoor.
3.1.12 LT Power Cables

All Power cables are aluminum 4 core cables. Up to 20 hp/17.5 kW 4 core copper cables will
be used for machineries from PDB to machine control panel and black color core shall be
connected to earth. The minimum size of 10 sq.mm and above is selected for aluminium UG
cable. The cables are rated for 1100 volts for LV system.
The cross sectional area of neutral conductor of multi-core cables constitute about 50% of
phase conductor for cables having cross-sectional area of 35 sq.mm and above.
Cable Identifications
Cores shall be provided with the following color scheme of PVC insulation:
1 core … Red /Black/yellows/blue
2 core … Red and Black
3 core … Red, yellow, and blue
3 ½ / 4 core... Red, yellow, blue and black
3.1.13 Cable Selection

The power cable sizes selected on the basis of current loading, ambient temperature condition,
method of installation and permissible voltage drop in each circuit. The minimum cross section
of the cable has been determined on the basis of available short circuit current and tripping
characteristic of the circuit protective devices etc…
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3.1.14 Voltage Drop in Cables

The total allowable voltage drop in the power circuits from the load centers to any motor or
other consumers not exceeds 3%. The distribution of this voltage drop in different parts of the
system depends on the layout of the installation. Generally the voltage drops in the main
feeders from the load centers to the panels or PDB’s not exceeds 2% and in the sub feeders
from the panels or PDB to individual equipments or other consumers shall not exceed 3%.
3.1.15 MCCB
MCCB’s selected are IS 13947 part -2, IEC (6094) and IEC 60947-3 & IEC 60947 –part – 2,
suitable for universal mounting i.e. the load/line shall be interchangeable with shrouded
incoming contacts and minimum operating voltage of 415V. The thermal setting are adjustable
from 64 % to 100% of its normal current, the magnetic setting adjustable from 3.5 to 10 In
(normal current), trip reset is available Manual / Automatic. The Isolator switches for electronic
circuits to open the MCCB automatically and have fully insulated safety shutters.
The Overload Zone adjustable from 0.4 to 1 in with line (For 630 amps & above MCCB) and
Short circuit Zone adjustable from 1.5 to 10 In with time. The ratting of the switch gear is
selected as double the full load current of the connected load. Above 400 amps, micro
processor based MCCB are selected for more versatile load control and to limit fault level. All
outgoing switch gears are thermo magnetically operated continuously variable s/c, o/c with
front drive kit and spreaders.
3.1.16 MCB DB
MCB DBs are prewired and fabricated as per IS: 8623 and suitable for flush mounting &
surface mounting, with 100 A copper bus bar (For Horizontal type DB), neutral bar, earth bar &
cable ties for cable management and in case of Vertical DB the bus bar shall be of 200 A
rating with IP – 43 degree of protection. All the MCB distribution boards are fabricated out of 18
SWG thick sheets steel duly rust inhibited through a process of degreasing, pickling,
phosphating & powder coating to an approved colour over primer & shall be of the totally
enclosed dust proof type suitable for wall mounting. All components mounted on DIN rails &
covered totally with a steel sheet cover rendering it finger-safe. Access to the internal
connections can be made only through removing the cover sheet. All DB’s are internally
prewired using copper insulated high temperature PVC wires. Bus bars & neutral bar are fully
insulated with standard colour code. Bus bar withstanding capacity is 10kA. DBs have the
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facility of reversing door without modification, pan assembly for ease of installation &
convertible locking. The powers to the Switch board are provided through concealed PVC pipe.
For details of lighting, Power socket outlets, ceiling fan and exhaust fan, MCB DB refer Drawing
volume: Part A - Volume 1 - Annexure II - B process building - Internal Lighting & Power point
layout, Main single line diagram for Lighting and Power of each building.
3.1.17 Earthing
Two runs of 50 x 5 mm GI earth flat for machineries, SSBs & 25x4mm GI flat for PSDBs and
welding sets are laid. The said GI flats are connected with 2 no’s of pipe with earth around the
workshop shed with looping between the two adjacent earth pipes as shown in the drawing. 25
mm x4 mm GI flat earths are used for engine test beds, DB to connect to the main earth. Two
individual 6 SWG GI earth wires are used to connect the machineries to main earth flat.
Refer drawing: Part A - volume I - Annexure -II B - Process Building - earth flat layout of each
building.
3.1.18 Power Factor Improvement:

Automatic APFCr panel with harmonic filter is installed to maintain the power factor to unity.
Each Sub Switch board is connected with APFCr panel of capacity minimum 100 KVAr to 250
KVAr depends on the connected load. Minimum 8 steps relay is used. The ultimate power
factor to be maintained at unity power factor. Department wise the APFCr panel of adequate
capacity, min 1/3 connected load or as required to maintain unity power factor.
For details, refer Part A- Volume I - Annexure - II B - Switch board location and cable trench
layout and Main single line diagram of each for the above said building
3.1.19 DC rectifier Units

All assembly lines, repair sheds are provided with 34 kva, 24/48v DC, rectifier unit for testing of
DC run equipments and to crank/start the engines. For every five meter one 24/48v DC tap-off
boxes is provided. The DC bus to be 1000 amps bus bar. In Field Articulated Vehicle Assembly
Group, In Field Articulated Vehicle Sub Assembly Group shed, Ancillary Vehicle, two numbers
of rectifier unit installed. Each Rectifier Unit with 10 number of tape off boxes provided for
testing of machines.
For details, refer Part A- Volume I - Annexure - II B - Switch board location and cable trench
layout and Main single line diagram of each of the said buildings
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3.1.20 Safety Equipments:

In front of every SSB, MV Panel, MLSSB, PSSB, APFCr panel, minimum 10 mm thick, 1 meter
width rubber mat to be laid covering the entire length of the panel. At least 2 nos of 5 Kgs DCP
type fire extinguisher to be provided for each SSB, MLSSB and PSSB. Two numbers of
Electrical shock treatment chart in Hindi, Local language and English to be fixed each building.
Minimum one number of 30kgs foam type tally mounted fire extinguisher, 4 nos sand bucket
filled 2/3 to be kept for each DG sets.
New Buildings to be Constructed - Process

Electrical Load Details
Load in Load Total load in
S.No. Description
Kw factor Kw
1 Engineer Equipment Assembly group 148.9 0.4 60
2 Field Articulated vehicle assembly group 345 0.4 138
3 Field Articulated vehicle Sub assembly group 124 0.4 49
4 Engine repair group 246 0.4 98
5 General Engineering group 440 0.4 176
6 Ancillary shed 473 0.4 189
7 Workshop expense store / Battery charging section 20 0.4 8
8 Body repair group 252 0.4 101
9 Engine Test house 1353 0.4 541
10 Caustic soda washing 25 0.4 10
11 Vehicle Stripping shed 5 0.4 2
Engineer Equipment Stripping / Sub assembly
12 100 0.4 40
group
13 Technical Head Quarters 97.07 0.4 37
14 Lighting load for all Process building 270.20 0.46 118
15 Lighting load for all Non Process building 125 0.35 44
16 Street Light 19 0.5 10
17 High mast 23 0.5 12
18 ETP 35 0.4 14
19 STP 40 0.5 20
20 Pump House 40 0.2 8
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21 Fire Station, Stand by 250 0 0

22 Material Handling Equipment 669 0.048 33
Total Load in KW 5016 1706

Assume power factor 0.99 continuous
Total demand in KVA 1723
Say (KVA) 1700
Electrical Lighting & Small Power Load Details

Small
Lighting Total Load
S.No Name of Building Power
Load in KW
Load
A) Process Buildings
1 Engineer Equipment Assembly Group 9.31 36.0 45.3
2 Field Articulated Vehicle Assembly Group 54.41 36.1 90.5

Field Articulated Vehicle Sub Assembly
3 28.77 9.8 38.5
Group
4 Engine Repair Group 27.29 33.7 60.9
5 General Engineering Group 22.97 29.1 52.0
6 Ancillary Shed 13.1 18.0 31.1
Workshop Expense Store/Battery
7 3.68 7.6 11.3
Charging Section
8 Body Repair Group 20.51 15.4 35.9
9 Engine Test House 17.44 24.9 42.3
10 Caustic Soda Washing 1.5 0.0 1.5
11 OSS, MCO & KRAZ Stores 9.77 3.2 13.0
12 Vehicle Stripping Shed 6.56 2.1 8.7

Engineer Equipment Stripping/Sub
13 5.37 19.7 19.7
Assembly Shed
14 Outer Traffic Store 1.7 2 3.7
15 UG Sump-1 & 2 0.27 0.2 0.5
16 Compressor Room-1&2 0.67 0.1 0.8

17 Scrap Yard 1.23 0 1.2
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18 Over Hauled Vehicle Parking - (11Nos.) 0.58 0 0.6

19 Chassis Dynamo Meter 1.1 2.6 3.7
20 Repairable Vehicle Parking-1 (15Nos.) 0.75 0 0.8
21 Repairable Vehicle Parking-2 (15Nos.) 0.75 0.0 0.8
Sub Total ( 1 Ph ) 228 240 468
Total ( 3 Ph ) = 468/1.732 = 270.20 kw
Material Handling Equipment

Capacity Total in
Name of Building Qty KW
in (Ton) KW
2 5 14.0 28.0
1 Engineer Equipment Assembly Group 2 10 17.0 34.0
2 20 27.0 54.0
1 5 14.0 14.0
Engineer Equipment Stripping/Sub Assembly
2 1 10 17.0 17.0
Group
1 20 27.0 27.0
2 20 27.0 54.0
3 Field Articulated Vehicle Assembly Group
4 10 17.0 68.0
1 5 14.0 14.0
4 Field Articulated Vehicle Sub Assembly Group
1 10 17.0 17.0
5 Engine Repair Group 3 5 14.0 42.0
6 General Engineering Group 2 3 9.0 18.0
2 1 7.0 14.0
7 Ancillary Shed 1 2 7.0 7.0
1 5 14.0 14.0
1 10 17.0 17.0
8 Body Repair Group
1 20 27.0 27.0
9 Engine Test House 11 5 7.0 77.0
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2 10 14.0 28.0
10 Caustic Soda Wash
2 20 27.0 54.0
1 10 17.0 17.0
11 Vehicle Stripping Shed
1 20 27.0 27.0
SUB TOTAL 669
3.1.21 Air compressor

Two compressor rooms at both ends having 4 Nos x 368 cfm (55 kw) screw compressor @
7.5 kg / cm2 are installed one compressor room totally eight Nos, Two Compressors kept as
stand by. 4 inch m.s pipe ‘C’ class heavy duty (5.4mm thick min.) forms the main line.
Depending on the requirement of air, the compressors controlled by digitally. This is carried out
by load monitoring/sequencer computer system.
The screw compressor with sigma profile rotor, 55kw 368 cfm @7.5 Kg/cm2 or with equivalent
cfm/kw including oil, control panel, reverse rotation protection, single phase preventer NRV at
Outlet of compressor- size to suit the outlet pipe, tool kit, etc. as required to make it complete
including recommended mechanical, electrical and hydraulic spares for 2 years of trouble free
operation of compressor, etc. (Kaser, Atlas Copco, ELGI) are erected at the main compressor
room.
One number 610 ltr/sec – 4 micron Oil filter and one number 1500 cfm refrigerant type Air
driver for 3 compressors, one number of 2000 liters vertical Air Receiver tank forms one set.
Each compressor room has two sets. Air delivered from the screw compressor which is
connected to the surge pipe of dia 300 mm passes through the air drier first , oil filter and then
gets collected at the Air receiver tanks of 2000 lts capacity with an Air pressure Regulator (0-8)
kg/ cm2. The two outlet pipes are connected to an air flow controller. The outlet from the Screw
compressor is connected at angle of more than 500 in the direction of air flow as shown in the
direction. The ‘T’ connection are cross linked by a pipe of same dia at 500 to 600 as shown in
diagram to avoid pressure drop.
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The Main supply air pipe inter connecting the Process sheds is a 100 mm ‘C’ class MS pipe
with bypass gate valve arrangements. Inside the Processing shed, this 100 mm MS pipe ‘C’
class is in the form of a ring of Over Head pipe line and properly supported.
At the delivery points, 25 mm dia, MS pipe ‘C’ class are taken from the main line along with
flange S.S Ball valve and air pressure regulators. A small surge tank of 200 mm dia x 400 mm
length is provided with Outlet points of plug-in female type connectors for Pneumatic tools. The
air pipe line inside the shed forms the ring line with bypass arrangements so that maintenance
or work can be taken without affecting the work at any part of the workshop. The air pipe line to
be such that total pressure drop in the air line is not to be more than 0.3 psi at any point. Each
shed consists of 2 nos air receiver tank vertical as shown in the diagram with bypass
arrangements. For 2” flange - minimum six number holes, 3” to 4” flange – minimum eight
number of holes, 6” flange – 10 to 12 number of holes to be used. For jointing the flanges 3mm
gasket with metallic wires to be used. All pipe lines and joints, welding to be checked with soap
water solution for leakages in the presence of Engineer In charge or person authorized by him
and any leakage of air in the joints is not allowed.
GI duct of suitable size Tata make/or equivalent 14 swg thick for heat air ventilation from
compressor to outside the compressor room at height of minimum 12 feet to be fabricated and
fixed on screw compressor top to maintain the ambient temp. Exhaust fans and ceiling fan is to
be provided. The size of outlet side is 1.5 times the inlet size. Arrangements as shown in
diagram and to be tested for air leakage.
The minimum amount of storage is 6 gallon per cfm of capacity including storage in the pipe
lines and the no of Air receiver tank or capacity to be increased. This should be increased to 8 -
10 gallons per cfm of capacity for systems with sharp changes in demand places like air
cleaning by hoses and high consumption area. For details refer drg No: External compressor
layout – KAN-DD-ELE-GEN-PTW-100054-0C
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Part-A DPR
3.2 HVAC System
HVAC (Heating Ventilation and Air Conditioning) is the technology of indoor and automotive
environmental comfort. The main purposes of a Heating Ventilationand Air-Conditioning (HVAC) system
are to help maintain good indoor air quality through adequate ventilation with filtration and provide
thermal comfort.
The three central functions of Heating Ventilating and Air-conditioning are interrelated, especially with
the need to provide thermal comfort and acceptable indoor air quality within reasonable installation,
operation, and maintenance costs. HVAC systems can provide ventilation, reduce air infiltration, and
maintain pressure relationships between spaces.
3.2.1 Proposed HVAC System for 507 ABW

1. Split Units are provided, to maintain the required temperature to the office rooms / Staff
Room, Conference hall etc., and wherever required,
2. Centralized Air Conditioning system for Engine Repair Group
3. Air Shower & Air Curtains are provided to make dust free environment to the section, the
following buildings are planned for the same in the Process building,
 Engineer Equipment Group
3.2.1.1 Split unit System
 A split system is an air-conditioning or heat pump system that uses refrigerant as the heat
exchange fluid and has an evaporator, compressor, and condenser as separate
components. In most modern commercial applications, the compressor and condenser are
combined into a single piece of equipment called a condensing unit. Refrigerant piping,
custom-designed to meet the physical requirements of each individual application,
connects the system components. Split System air conditioners are more economical and
quieter to run than conventional units.
 An air-handling unit for a split system is typically located close to the air-conditioning
load.This enables air distribution using the minimum amount of ductwork and fan energy. It
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also permits buildings to be zoned on a floor-by-floor basis, eliminating the need for large
vertical duct chases and fire dampers. Split systems do not require large penetrations
through the building walls or roof
 Split systems may be applied to industrial, commercial, and residential comfort-cooling

applications. Quite often, split system equipment is also used for manufacturing and
process cooling applications. Popular applications include: office buildings, commercial or
public buildings, retail shopping, manufacturing facilities, churches and other places of
assembly, small health care facilities, and schools.
 Components of Split Systems
 Evaporator
 Compressor
 Condenser
 Refrigerant Piping
 System Design and Plant Selection
 The system design shall be done after detailed heat load calculations considering the
outside and inside design conditions, ventilation requirements and internal loads. The plant
selection shall be made on the basis of the calculated peak load, load diversity, partial load
requirements and standby capacity. The standby capacity in turn will depend upon the
number of hours of operation of the plant per day, relative importance of the installation
and functional requirements. Normally for 12 hrs operation of plant one number additional
unit of the same capacity as standby may be provided. For 24 hrs operation of plant, 100%
standby may be provided.
 The various components of the system shall be so selected as to match each other under
operating conditions of full load as well as anticipated partial loads.
 The overall dimensions of various equipment in the system shall be suitable for installation
in the available space. The permissible loading of the building structure, acceptable noise
level and aesthetics should also be considered
 Areas with different requirements of fresh air, degree of filtration and / or operating hours
shall need different and independent AHUs
 A sophisticated control system enables switching between the heating and cooling modes
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 In more sophisticated versions, the indoor units may operate in heating or cooling mode
independently of others
 This latter arrangement offers potential energy savings when heating and cooling are
required simultaneously in different zones
 This type of system requires no internal plant room space and offers great flexibility
through the many types of air handling units available
 When it is impractical to use a single split system for a building, or if zoning is necessary to
insure uniform comfort, multiple systems are commonly used. Zoning is achieved by
serving a group of rooms with similar heating and cooling load characteristics with a
separate unit. Because of the many unit sizes and combinations available, multi-unit
systems can be matched to the unique combinations of sensible and latent loads in each
zone.
The Summary of proposed HVAC system on split units for Process buildings are given in the
table below
Required Split Unit

HVAC Facilities No of Units
Capacity in TR Capacity in TR
Engineering Equipment Assembly Group

Officer room 1.5 1.5 1
Office room 1.5 1.5 1
2 3
Hydraulic Testing Lab 7
1 1
Discussion room 1.5 1.5 1
Discussion room 1.5 1.5 1
Field Articulated Vehicle Assembly Group
Sound Proof Room 10 2.5 4
Sound Proof Room 10 2.5 4
Field Articulated Vehicle Sub Assembly Group
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Required Split Unit

HVAC Facilities No of Units
Capacity in TR Capacity in TR
Engine Repair Group

Conference hall 1.5 1.5 1
General Engineering Group

Computer room 3 1.5 2
Conference hall 3 1.5 2
Ancillary Shed
Officer I/C 2.5 2.5 1
Engine Test House
Cabin - 8 Nos. 2 2 1
Workshop Expense Group / Battery charging section
R & I Officer room 1.5 1.5 1
Officer room 2 2 2
Body Repair Group
Officer room 2 2 1
OSS / MCO / KRAZ
MCO I/C Room 2.5 2.5 1
OSS I/C Room 2.5 2.5 1
Engineering Equipment stripping / sub assembly Group
3.2.1.2 Central Air Conditioning
Central air conditioning units are usually matched with a gas or oil furnace to provide heat
through the same set of ducts.
There are also central HVAC units called heat pumps that combine both the heating and
cooling functions. If you heat your home with electricity, a heat pump system is the most
efficient unit to use in moderate climates. It can provide up to three times more heating than the
equivalent amount of electrical energy it consumes. A heat pump can trim the amount of
electricity you use for heating as much as 30 percent to 40 percent. Even though air
conditioners and heat pumps require the use of some different components, they both operate
on the same basic principles.
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 Proposed Central Air Conditioning system for 507 ABW Kankinara

Engine Repair Group
Splits
Required Packaged Unit
S.No Location Units
Capacity In TR Capacity In TR
Types
Engine Repair Group
1. FIP & Injector Calibration Section 5 5.5 0
2. OSS Store 8 8.75 0
Storage Area For Repaired Engine
3. 10 11 0
Components No:1
Storage Area For Repaired Engine
4. 19 22 0
Components No:2
5. Assay No-1 5 5.5 0
6. Assay No-2 5 5.5 0
7. Assay No-3 5 5.5 0
8. Assay No-4 5 5.5 0
9. Assay No-5 5 5.5 0
10. Assay No-6 5 5.5 0
11. Repaired Engine Storage 11 11 0
12. Wide Passage (Part No-1) 11 11 0
13. Wide Passage (Part No-2) 5.5 5.5 0
14. Wide Passage (Part No-3) 11 11 0
3.2.1.3 Air Shower and Air Curtains

The biggest contaminant in a room is the dust particles attached to clothing, footwear and
materials. Air shower and air curtains help remove such dust particles by using an air jet to
blow at the said clothing and materials before entering the room.
The air shower is a high velocity, low pressure type system, providing a normal entrance to and
exit from a contamination controlled area. While the workmanship and materials are of a
professional quality, the air showers are ultimately engineered to incorporate an aesthetically
pleasing design to fit the general atmosphere of the room specifications.
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Each assembled Air Shower is a completely self-contained unit, equipped with air filtration
systems, blowers, motors, controls, a solid-state programmable microprocessor, interlocking
doors, lighting, and a pre-wired electrical panel.
Similarly, Air curtains are provided for small entries/exists generally covering the entire width of
the door.
Air Showers and Air curtains are proposed for the following groups,
S.No Description of Items Qty.
Process Building
Field Articulated Vehicle Assembly Group
1.0 Supply, installation, testing and commissioning of Air Shower arrangement for the
following custom sizes,
a) 5m X 5m X 5m 4
2.0 Supply, installation, testing and commissioning of Air curtains for doorway of size,
a) 1m wide 4
Engine Repair Group
3.0 Supply, installation, testing and commissioning of Air Shower arrangement for the
following custom sizes,
a) 5m X 5m X 5m 1
4.0 Supply, installation, testing and commissioning of Air curtains for doorway of size,
a) 4m wide 2
3.2.2 Code and Regulation Standards
The HVAC industry was historically regulated by the manufacturers of HVAC equipment, but
regulating and standards organizations are
 Heating, Air-conditioning & Refrigeration Distributors International (HARDI)
 American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE)
 The Indian Society of Heating, Refrigerating and Air Conditioning Engineers (ISHRAE)
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 Sheet Metal and Air Conditioning Contractors' National Association (SMACNA)
 Uniform Mechanical Code
 International Mechanical Code
 Air Movement and Control Association International, Inc. (AMCA)
 Carrier System Design Manual, Part 3, Chapter 3, Refrigerant Piping.
 Carrier reference manual: Refrigerant Piping for Split Systems. Form T200-64, Catalog
No. 791-064
 ASHRAE Refrigeration Handbook 1998, Chapter 2, System Practices for Halocarbon

Refrigerants.
 Carrier E20-II HVAC Program Series, Refrigerant Piping Design. Heating Equipment
 Conclusion
As per the standards & systems mentioned above, efficient Electrical & HVAC system has to
be installed and maintained.
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Part-A DPR
507 ABW 280

Water Supply System
Part-A DPR
3.3 Water Supply System

3.3.1 Water Requirement
As ascertained the total requirement of water/ day is about 6.00 lakhs Liters, the break up detail
is furnished below. This quantity includes the requirement of firefighting, miscellaneous
buildings and residential accommodation etc. At present, facility is available for 1.00 lakhs and
hence the balance quantity of 5.00 lakhs Liters is to be made available to meet the demand of
project on completion. In order to conserve potable water, it is proposed to use the clear
treated water from STP and ETP for Horticulture, Arboriculture and Landscaping etc
 Process Building - 0.53 lakhs litres.
 Domestic usage - 1.85 lakhs litres.
 Fire Fighting - 2.00 lakhs litres.
 Engine Test House - 1.00 lakhs litres.
 Future & Wastage - 0.62 lakhs litres.
Total Requirement - 6.00 lakhs litres
Break up Details of Water Requirement for 507 Army Base Workshop at Kankinara
S.No Description Litres/ Day
Domestic Usage including drinking purposes, Canteen, HVAC,
1. 1,55,000
Housekeeping, etc.
Technical Process requirements like Water Wash Booth, Engine
2. 83,000
Washing, Caustic Wash Booth, Electro Plating, CNC Machine, etc.
Sub Total 2,38,000
Future Expansion 20% 47,600
Sub Total 2,85,600
Add 5% for other use and wastage 14,300
3. Fire Fighting System - Static Tank 2,00,000

4. Engine Test House - Cooling Tower 1,00,000
Total Water Requirement for 507 ABW 6,00,000
Excluding Fire Fighting and Engine Test House daily water
3,00,000
Requirement
Existing Water Supply from MES 1,00,000
Required Water Demand after Modernization 2,00,000
 Treated water from ETP&STP will be recycled for Horticulture & Arboriculture Purposes.
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3.3.2 Existing Facilities

At present the total water requirement is being supplied by MES and the workshop is receiving
about 1 lakh liters from MES. To receive and distribute water, an overhead tank (OHT) of
capacity 1 Lakh gallon is available for distribution of water. From OHT water is being distributed
to the total campus to meet the water requirements. Considering the Condition of existing pipe
line, the age of old pipe line, it is suggested to lay a new pipe line so that it can serve for long
time. The quantity of water received and the storage facility available is adequate to meet the
present requirement only. For future requirement arrangement has to be made for additional
quantity of water and its storage.
3.3.3 Proposal
After modernizing the existing Army Base Workshop at Kankinara the total requirement of
water will be around 6.00 Lakhs Liters. The shortage between the total requirement (including
Fire Fighting & Engine Test House) and the supply received from MES is 5.00 Lakhs Liters.
This has to be met from Bore Wells only. After including the water requirement for Firefighting
and future requirement, two bore wells are needed near Static water tank which are proposed.
Considering the water table at Kankinara 507 ABW, It is assumed that 6 Nos of Bore wells may
meet the short fall of water supply which will be about 5.00 Lakhs Litres. The number of Bore
Wells mentioned above is tentative. This may vary based on the Yield and diameter of the Bore
wells. The diameter of the Bore well will be 250mm. Water pumped from the Bore well will be
passed through a Filter cum Softening Plant to suit the required standard of the Base
Workshop.
The existing UG Sump & Overhead tank is to be retained / refurbished for using it in the future
to meet the fire fighting requirements.
3.3.4 Overhead Tank cum UG Sump

The new storage sumps provided will be an underground sump (UGS). The Sump provided
near Vehicle washing Booth is of 3.0 Lakh Litres Capacity with an overhead tank of 1.50 Lakh
Litres capacity, over it and the other sump provided near Engine Test house is of 1.50 lakh
litres capacity with and overhead tank of 1.00 lakh litres capacity, over it. The structure is of
RCC type which will be leak proof and a seamless structure. The typical Sump details aregiven
in the Drawing No: KAN-DD-ARC-TSIN-009-105601 and KAN-DD-ARC-TSIN-013-111401 in
Part - A / Volume - 1 / Annexure - II (A).
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The existing UG Sump of 2.50 Lakh litres capacity with separate Over head water tank of 1.50
lakh litres capacity had been utilized for storage of water for Fire Fighting requirements.
3.3.5 Distribution system

For effective distribution of water the workshop area has been bifurcated into two zones namely
Zone I and Zone II. A distribution Ring main will be laid in both zones covering all the buildings
to ensure adequate pressure supply to buildings. The water received from the MES and from
all the bore wells (6 nos) will be collected in 3 tanks whose capacity will be 3.0, 2.5 & 1.5 lakh
litres. Though this tank is a collection tank, the same can be utilized as settling tank also there
by the floating dirt will be stopped from the supply. Zone - I consists of 2 No. of Underground
Sump of capacity 1.50 & 3.00 Lakhs Litres. In this Zone a separate Overhead Tank of capacity
1.00 & 1.50 Lakhs Litresis proposed in which 1.00 lakh litres OHT has been planned
exclusively for Engine Test House.
Zone - II is provided with 1 No of Overhead Tank and Underground Sump of capacity 1.50
&2.50 Lakhs Litres, which is shown in the drawing No. KAN-DD-WSS-GEN-PTW-100106. In
this Zone, the water from the UG sump will be pumped to OHT which will be located nearer to
UGS and from OHT water supply will be made to all service buildings to meet the domestic
requirements. The service buildings will have the provision of terrace tanks. The terrace tanks
will be used to store the supply from the OHT. This storage will further be drawn for various
consumption points of the buildings. The supply from OHT to terrace tank will be by gravity.
This system will be more helpful for distribution, since the system does not involve any
pumping. Maintaining workshop buildings under one zone exclusively will help to have intense
care on shop lines.
Since the factory compound is divided into two zones, as explained above two sets of OHT,
UGT pumps and motors have been constructed for distribution. Each pump house will be
provided with two numbers of electrically driven pumps for boosting water from UGS to OHT.
Out of these two pumps one will be acting as a stand by pump. As the distribution cannot be
made collectively for domestic and flushing purpose, it is proposed to have separate line from
terrace tank to various supply points of domestic and flushing separately.
3.3.6 Industrial Supply

The distribution system for supply of water to workshops is similar to the system explained for
service and miscellaneous buildings. The distribution system consists of independent GL sump
OHT, filter beds, etc. Provision of exclusive distribution line proposed for workshops will help to
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pay intensive maintenance of the system which will ensure continuous supply to shops without
any interruption.
3.3.7 Water Treatment

The water from the UG sump before reaching the OHTs, the supply will be passed through a
sand / carbon / filter for filter up the suspended solids. The filtered water will be further
chlorinated to the extent of requirement, there after the chlorinated water reaches the OHTs for
distribution.
3.3.8 Drinking Water

Drinking water for each zone will be supplied directly from the respective Terrace Tank through
multistage water purifier (Mini RO plant) fixed at drinking water fountain points. We ascertained
that in each shop staff strength is maximum 200 Persons.
So drinking water required is only 200 x 3 = 600 lit / day
Providing 3 fountain in a shop
Capacity of RO required = 600/3 = 200 lit / day maximum
Considering the above, requirement at each location, it is recommended to provide a mini RO

of capacity 200 Liters / day, whichwillbe more suitable.
Moreover even if a RO goes out of order, other two RO plant inside the shop will work as
standby, Servicing point of view, mini RO’s are very easy to service them. The expenditure of
maintenance is comparatively very low.
Therefore providing a central system of RO plant is not recommended.
3.3.9 Recommendation for Refurbishment Buildings

Most of the toilets in various buildings are sufficiently old. The fixtures and fittings used in the
toilets need total replacement. The toilets available are required to be relocated to improve
ventilation and natural light. The flooring and dado tiles also need replacement. Therefore only
the main wall of the toilet blocks in each building alone will be retained. The internal
arrangement of toilets urinals and wash basins will be rearranged to convenience and for
aesthetic appearance as per requirement.
The old pipe lines / drainage lines available are not in good condition and they are also to be
replaced. We recommend CPVC pipe for replacement in view of its merit, such as reasonable
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cost, long life etc. As regards fittings, CP fittings are recommended which will last for long
duration against rust.
3.3.10 Pump Requirement

 Two pumps– one working and one as stand by(22lps @ 35m head each) in Zone I sump of
3.00 lakh liters capacity to pump the water to the 1.50 lakh liters Over Head Water Tank in Two
hours time.
 Five pumps (11.6 lps @ 20m head each)Two numbers in Engine Test House sump of capacity
1.50 lakh liters to pump the water to the 1.00 lakh liters Over Head Water Tank in Two hours
time. A separate full-fledged cooling tower system also required for Engine Test House to
recycling the water.(Three numbers for recycling system)
 Two pumps– one working and one as stand by (22lps @ 35m head each) in Zone II sump of
2.50 lakh liters capacity to pump the water to the 1.50 lakh liters Over Head Water Tank in two
hours time.
 Six pump sets (280 lpm @ 105m head each) for bore wells.
 Four pump sets (11.6 lps @ 15m head each) forpumping water from Raw water collection
sump to Filter plant.
 Two pump sets (8 lps @ 15m head) for pumping water from Raw water collection sump to
Engine Test House – Blower.
The above pumps are to be provided in the UG sumps associated with pump houses and
OHTs.
In general, all the internal Water Supply arrangements for each of the Process buildings has
been executed under the Part-A of the project along with the Construction of all Overhead
Tanks (OHTs) and Underground Sumps (UGSs) including the pump house and supply,
installation of all the equipments like pumps/motors, etc.
The Distribution network for water supply (inclusive of all appurtenances) completely for the
Process Buildings will be executed in Part-A along with the setting up of Softening Plant and
other necessary equipment including the sand/carbon filters, pumps, etc. and terrace
tanks/pumps.
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507 ABW 286

Effluent Treatment Plant
Part-A DPR
3.4 Effluent Treatment Plant
The treatment of effluents discharged after the various manufacturing processes in the workshops will
be carried out using Effluent Treatment Plant.Based on quantity of waste water, existing system, land
requirements, Effluent treatment system has been designed.
3.4.1 Installation of ETP

One number of ETP has been proposed for 507 ABW and the waste water generated from each
zone will be connected to this ETP.
The estimation of effluent is provided below,
S. No Description of fixtures Total Qty in Liters
Caustic wash Booth, Water wash Booth, Engine washing, Electro

1 78,000
plating, CNC Machine
Add 15% for future and wastage 11,700
Total Water Requirement (Approx.) 89,700
Say 90,000
85 % of Water supplied is taken as Effluent generated 76,500
Therefore Capacity of ETP Recommended 100 KLD
3.4.2 Treatment Processes

Wastewater treatment is divided into four major steps or categories
 Preliminary treatment may involve a number of unit processes to eliminate undesirable
characteristics of wastewater received from the collection system. Processes include use
of screens and grates to remove large particles, comminutors for grinding of coarse solids,
pre-aeration for odor control, and some removal of grease.
 Primary treatment, also called primary clarification, involves removal of readily settle able
solids prior to biological treatment. Settling basins or sedimentation chambers are the
main unit involved, but various auxiliary processes, such as flotation, flocculation, and fine
screening, may also be used.
 Secondary treatment involves the purification of wastewater primarily by decomposition of
suspended and dissolved organic matter by microbial action. Numerous biological unit
treatment processes are available, but most can be classified as land treatment,
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pond/lagoon, activated sludge, or biological filtration methods, such as disc rotating

biological filters.
 Auxiliary treatment encompasses a large number of mostly physical and chemical unit
processes that can be used before or after secondary biological treatment to meet specific
treatment objectives. The term secondary clarification or tertiary treatment may be applied
to unit processes that follow secondary treatment.
 From ETP waste-water is allowed to enter into aeration chamber, it is mixed with an active
biomass in rolling action which results in adequate mixing. Chambers are filleted on each
side along the bottom to enhance rolling motion of water which is provided with oxygen by
passing diffused air through waste-water. In addition to this, after the process of aeration
waste-water flows to clarifiers which has a hopper bottom configuration where solids settle
down during the settling period.
 These solids are returned by airlift pumps to the aeration chamber to maintain maximum
efficiency of the biological process. Finally, a skimmer airlift pump is used to return float-
able solids and scum to the aeration chamber for further processing. Now, the treated
water is made to flow from the clarifier to a disinfections chamber for treatment prior to
discharge in order to complete the treatment process.
3.4.3 Proposed System

The effluent generated from the workshops will be collected through a separate network from
all the workshop structures. The collected effluent will be taken to ETP after passing through
grit well, bar screen well and collection well. The treated effluent from ETP will be used for
Horticulture / Arboriculture and Landscaping purpose. Necessary infrastructure such as pump
house, sewage pumps etc. will also be provided in the system.
3.4.4 Connection System

The effluent and waste from each of the workshop areas has to be treated in order to dispose
safely and harmlessly. The ETP network is proposed to be interconnected to all the workshop
floor areas mainly for areas like electroplating section, Phosphating sections, chrome plating
section, CNC machines, etc. The effluent from these areas needs to be compulsorily treated
before disposal.
The vent system is of water tight and gas tight designed to prevent escape of foul gas and
odour from various fixtures. Provision of vertical vent is made for hygiene, safety
considerations, and to avoid entry of foul smell entering into occupied areas.
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Vent system has been designed to facilitate escape of gases and odour from all parts of
effluent and waste system to the atmosphere at a point above the building and to allow
admittance of air to all part of the system, so that siphon age, aspiration or back pressure
conditions do not cause loss of seal at traps.
The out let of each building is connected to main pipeline. The main pipeline will run close to
every building enable to collect the effluent to ETP. The collected effluent will reach ETP for
final treatment. The network will be a gravity line; the non-interrupted service will be available
throughout the year.
It is proposed to provide PVC (SWR) pipe for external manhole to manhole connection for ETP
network. The Effluent system network line has been preferably taken outside the building. Also
the bypass connection has been by gravity instead of using pumps to lift effluent from
equalization tank.
It is recommend using PVC (SWR) pipes for carrying effluent, considering the long life of
service, less friction against the flow, less joints due to long length of pipes etc.
 It is very easy to maintain and achieve the proposed slope due to its length.
 Due to light weight the pipes can be handled easily.
 During maintenance period any replacement is possible easily as this pipe can be cut in
short time with less effort.
 The sizes of the pipes provided are minimal as the system is bifurcated into the STP
network and ETP network.
It is recommended to use 150mmΦ pipe initially and increase it to 250mm Φ at the tail end.
Also, it is recommended to lay the pipe with slope of 1:150 to 1:250 according to the contour
and 1:250 at the tail end. I.e. near ETP entrance. This is adequate to maintain self-cleaning
velocity to keep the pipe clean.
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Part-A DPR
507 ABW 290

Storm Water Management System
Part-A DPR
3.5 Storm Water Management System
3.5.1 Storm Water Drains
The existing drainage system is inadequate and most of the locations, the drains are not
designed for the capacity of storm water. During rainy season, inundation takes place in most
of the area. The outlet of disposal point is not adequate in the area of the discharge. Few roads
alone have the provision of storm water drain. In most of the area only surface flow takes place
during rainy season.
Hence, the drainage system needs to be redesigned to take into account the peak runoff,
topography and nature of terrain etc. it is proposed to provide RCC rectangular drain and
drains covered at the entry points of buildings. The internal drains and main drains are
designed as a rectangular section.
3.5.2 Calculation of Runoff
The maximum rain for the past 50 years considered for calculation of runoff. However the max
rain fall is taken as 100mm for the calculation, to achieve the rational drain size.
The total area of the project is about 25.90 acres. The slop of the size is very gentle. However
the slope for the calculation is taken from the contour map. As the site is mostly covered with
buildings and roads, the impervious coefficient is taken as 90%.
/
Q = Runoff in cubic meter
A = Area in hectors
R = Maximum Rainfall intensity (100mm)
S = Slope of the ground
C = Impermeability Factor
3.5.3 Design of Drain Size
The size of drain depends on the velocity which has the bearing on the slope of ground. In our
case, natural slope of the ground is 1 in 250 which works to 1.5m/sec. This velocity is adequate
to keep the drain silt free.
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I=AxV
 CPHEEO – Manual on water supply and treatment
 CPHEEO – Manual on sewerage and sewage treatment
 SP 35 – Manual on water supply and treatment
 Indian Standards
 Water board regulations
As the size is arrived based on the total area of the project and the maximum rain, this can be
followed as main drain of the system. Similarly sizes of the feeder drain size will be arrived
based on the catchment area.
3.5.4 Drain Structure
It is proposed to construct RCC drain of designed section with slotted cover slab enable to
collect rainwater from adjoined areas too.
The collection of rain water from the road surface will be let into drain through outlets with
grating. The outlets/spouts will be provided at 6.0m intervals for the case of single side camber
and 12.0m on both sides for both side camber roads. The total collection of rain water through
drain will be stored in a retention pond which will be used to meet the need of horticulture and
landscaping. If any surplus flow from the pond the same will be harvested as explained below.
3.5.5 Slope of drain
A suitable slope of 1 in 250 is adopted in the drain network which is needed to achieve the self-
cleaning velocity. While fixing the slope of the drain the natural slope of the ground is also
taken into consideration. Adequate care is taken to achieve silt free erosion free drain during
service
3.5.6 Road Crossing
Where ever the drain crosses the road suitable NP2 class RCC pipe is proposed to carry rain
water. The vent of the pipe will be equal to the cross sectional area of drain needed at the
crossing. Necessary protection will also be provided at the inlet and outlet of crossing to avoid
road erosion. Necessary silt trap also will be provided to keep the RCC pipe free from silting.
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3.5.7 Collection Tank
A drain water collection tank is also proposed. The capacity of tank will be decided to meet the
max possible utility of rainwater. This arrangement is proposed to enhance the rain water
harvesting system explained below.
Note:
1. Cost Estimate for Internal Water Supply & Sanitary Arrangements(Process Buildings) are
enclosed in Part - A / Volume – 1 / Annexure – IIIA
2. Scope of work is enclosed in Part - A / Volume – 2 / Annexure – I
3. Specification for Firefighting Facility is enclosed in Part - A / Volume – 2 / Annexure - VIII and
Water Supply & ETP are in Part - A / Volume – 2 / Annexure - IX
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Part-A DPR
507 ABW 294

Fire Fighting System
Part-A DPR
3.6 Fire Fighting System

3.6.1 Existing Fire Fighting System
At present, for Internal Fire Suppression System the buildings are provided with Fire
Extinguishers. For external Suppression System the Under Ground Sumps are located at
various places and in case of fire, the Fire Engine comes to Rescue to the affected area and
collect the water from the nearby sump to extinguish the fire.
3.6.2 Proposed Fire Fighting System

An automatic fire Fighting control system is proposed for 507 Army Base Workshop.
The classification of building is done according to the use and character of the occupancy for
providing Firefighting facilities. The classification is as follows.
Group A Residential
Group B Educational
Group C Institutional
Group D Assembly
Group E Business
Group F Mercantile
Group G Industrial
Group H Storage
Group J Hazardous
The proposed Fire Extinguishing System comprises of the following:-

1. Fire Extinguishers.
2. Wet Riser / Dry Riser with hose reels.
3. Automatic Sprinkler System.
4. Manually Operated Electric Fire Alarm Systems
5. Smoke Detector
6. Internal / External Hydrant System with Under Ground Sump and a Pump House.
Out of the above installations, few of them are normally provided based on the fire hazard
category.
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3.6.3 Fire Hazard Classification of Buildings at 507 ABW, Kankinara

Fire
Hose Dry Wet Down Yard SD
S.No. Building Name Group of the Building Extingu AS MCP TT TP
Reel Riser Riser Comer Hydrant /FD
isher
New Buildings to be Constructed - Process
Engineer Equipment Assembly

1. G-1-(iii)Low Hazard P P - P - P - - P - -
Group
2. Field Articulated Vehicle Assembly G-1-(iii)Low Hazard P P - P - P - - P - -
Field Articulated Vehicle Sub

3. G-1-(iii)Low Hazard P P - P - P - - P - -
Assembly Group
4. Engine Repair Group G-2(iv)- Moderate Hazard P P - P - P - P P - -
5. General Engineering Group G-2(iv)- Moderate Hazard P P - P - P - P P - -
6. Ancillary Shed G-2(iv)- Moderate Hazard P P - P - P - P P - -
Workshop Expense Store / Battery

J – 1-(ii) Hazardous
7. Charging Station (With Gas P P - P - P - P P - -
(High)
Flooding System)
8. Body Repair Group G-1-(iii)- Low Hazard P P - P - P - - P - -
Engine Test House (With Gas J – 1-(ii) Hazardous

9. P P - P - P - P P - -
Flooding System) (High)
10. Caustic Soda Wash G-1-(i)- Low Hazard P - - - - - - - - - -
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Part-A DPR
Fire
Hose Dry Wet Down Yard SD
S.No. Building Name Group of the Building Extingu AS MCP TT TP
Reel Riser Riser Comer Hydrant /FD
isher
11. OSS, MCO & KRAZ G-1-(iii)-Low Hazard P P - P - P - - P - -
12. Vehicle Stripping Shed G-1-(iii)-Low Hazard P P - P - P - - - - -
Engineer Equipment Stripping /

13. G-2-(iv)-moderate P P - P - P - P P - -
Sub Assembly Group
14. Outer Traffic Stores E-1 Low Hazard P - - - - - - - - - -
15. Compressor Room 1 & 2 G-2-(i)Moderate Hazard P - - - - - - - P - -
16. Chassis Dynamometer G-1 -a-(i) Low Hazard P - - - - - - - - - -
Buildings Under Construction
17. Workshop Service Group G-1-(iii)-Low Hazard P P - P - P - - P - -
MCO Building / Overhauled Vehicle

18. G-1-(iii)-Low Hazard P P - P - P - - P - -
Parking
Note - 1: * DC - Down Comer

* P– Provided * MCP - Manually Operated Electric Fire Alarm Systems
* FE - Fire Extinguisher * SD - Smoke Detector
* HR - Hose Reel * TT - Terrace Tank
* DR - Dry Riser * TP -Terrace Tank with Pump
* WR - Wet Riser * AS - Automatic Sprinkler System
All standards & classifications shall comply with NBC 2005. * YH - Yard Hydrant
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Note - 2:
1. An Underground Static Water Storage Tank and Underground Pumps are common for all buildings in the workshop.
2. External layouts & Individual Floor Plan, Section and Elevation (Civil works) for all the proposed buildings are enclosed in Part - A / Volume – 1 / Annexure
– IIA
3. External & Internal Fire Fighting Drawings are enclosed in Part - A / Volume – 1 / Annexure – II B
4. Abstract Cost estimate has been enclosed in Part - A / Volume – 1 / Annexure – III A
5. Detailed Cost estimate has been enclosed in Part - A / Volume – 1 / Annexure – III B
6. Scope of works are given in Part - A / Volume – 2 / Annexure – I
7. Specifications for Fire Fighting Systems & Minimum Requirement of Gas Flooding System has been enclosed at Part - A / Volume – 2 / Annexure – VIII
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Part-A DPR
 Wet Riser
The Wet Riser is tapped from the common external Firefighting ring main. The ring main is in turn
connected to an Underground Static Water Tank. Wet riser is always kept filled in condition of water
at 3.5 kg/cm2. Whenever fire occurs inside the building the hydrant attached to the wet riser is used
to extinguish it. Each hydrant of this kind covers an area of about 1000m2 of building floor area. The
Wet risers has to be situated not farther than 30m from any point in the area covered by hydrant as
per the recommendation of IS 3844 - 1989. The Wet riser runs through fire shaft from external
Firefighting ring main to top floor of the building with one hydrant head or more in each floor.
To facilitate the extinguishing of fire from a distance, separate hose pipes of 15m length (2 nos.)
are provided with a facility to connect them together with coupling.
To maintain the required pressure, 25mm Base branch Pipe with nozzle is also fixed in the hose
pipe, in addition first aid hose real arrangement is also provided in the same pipe ducts to fight
small fires.
Additionally, fire buckets are also provided at various locations throughout the workshop.
 Down Comer
The down comer pipe connects the terrace pump and wet riser. The terrace pump draws water
from the terrace tank which is filled with water for Firefighting purpose exclusively. If wet riser is
unable to receive water from external ring main the terrace pump will start automatically and supply
water from the terrace tank to wet riser, there by water supply to internal hydrant will be ensured.
Ref IS 3844 – 1989
 Automatic Sprinklers: -
Automatic sprinklers are provided in a building which is more than 15m in total building height and
handling most hazardous works inside. The functions of sprinklers are fully automatic. During fire if
the temperature of the room increases more than 58°C the sprinkler will break automatically due to
temperature. The opened sprinklers thereafter will spray water on the fire. This automation is in
addition to the function of internal hydrant which is operated manually during fire.
To supply water to sprinklers inside the building, sprinklers are connected to sprinkler riser. These
risers are in turn connected to sprinkler supply ring main which is connected to a pump in the Under
Ground Static Water Tank.
Each sprinkler takes care of 4 Sq.m of fire area. Based on this norm, numbers of sprinklers
required are decided.
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Sprinkler spray is only a first aid attempt to extinguish the fire. Simultaneously the smoke defectors
relay its sense of fire incident to fire alarm control panel. On receipt of the relay from smoke
detector the alarm hoots. On hearing the hooter soundfire brigade has to run to the spot for
extinguishing the fire.
 Portable fire Extinguishers
Portable fire extinguisher is an active fire protection device used to extinguish during emergency
situations. Typically a fire extinguisher consists of a hand held cylindrical pressure vessel
containing an agent which can be discharged to extinguish a fire.
 Water Co2 fire extinguisher
 Mechanical from fire extinguisher
 Dry chemical power fire extinguishers
 Co2 flooding system fire extinguishers.
The above mentioned extinguishers are suitable for any one or more class of fires only, but do not
cover the class from A to F. But dry chemical powder extinguisher is suitable for all class of fire
from A to F. Hence it is recommended to provide only Dry chemical power extinguisher, so that
every class of fire at any place could be extinguished easily.
 Gas Flooding System

 Engine Test House
 Workshop Expenses Store/Battery Charging Station
The Gas Flooding System includes Supply, Installation, Testing and commissioning of Automatic
Clean Agent Flooding System complete for Electrical panels with fire trace tube, Cylinder, Valves,
Integration with Main Fire Alarm Control Panel for Status monitoring etc. the Work to be executed
by authorized & certified Fire Trace installer shall cover :
1. Providing Direct panel Gas Flooding System with linear Fire trace tube inside the panels.
2. Arrangement of clean Gas Agent for flooding inside the panels.
3. Audio - Visual annunciation devices for indicating incidence of fire.
4. Any other item required to the successful commissioning of the system.
The electrical panel fire suppression system will be complete with Direct Clean Gas storage
cylinders for required capacities, Extinguisher agent as specified, Linear fire trace tubing, filling and
end - of - line adaptors, pressure switches, Control equipment and all necessary accessories and
push in fitting to form a complete and working installation to protect the Electrical panel in case of
fire.
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Part-A DPR
The panel to be protected will be determined as per the approval of the Engineer - in - charge. The
system will have an interface with Main Fire Alarm and Control Panel. In case of Fire in the
concerned Panel, Indication of Fire discharge status comes in Main Fire Alarm and Control Panel.
Minimum requirement of Gas flooding System mentioned in the Drawing. This system is specialized
for Engine Test House Fire Fighting only.
 Control System
The system has been designed for operation automatically so that as and when water is drawn
from the system through any hydrant, the pumps will operate automatically and feed water in to the
system. However once a fire pump start working, it will be stopped only manually (except jockey
pump) or on account of any fault or non-availability of power supply to electrical pumps or low water
level in UG / Terrace tank. Facility shall also be provided for manual operation. A selector switch for
auto/manual selection shall be provided in each pump.
The control system has been designed to provide the following sequence of operation.
a) The Pressurization Pump to maintain pressure in the system and shall operate only on account
of slow pressure loss. In case of sudden pressure loss the Pressurization Pump shall not
operate. The pump shall start when the water pressure in the system falls to a pre-set value
(about 0.35 kg/cm2below normal system pressure) and shut down when the system pressure
reaches the set value. Both limits shall be adjustable.
b) Main Electrical Fire Pump shall operate on account of sudden pressure loss. So long as Main
Electric Fire Pump is working, other Fire Pumps will not operate. The pump has to start when
the water pressure falls to a pre-set value in the system (about 1 kg./cm2 )
c) The Diesel Fire Pump has to start on sudden pressure loss, only in case supply to Main Electric
Fire Pump is not available or within a pre-set time the Main Electric Fire Pump fails to start or
fails during operation. No other pump will be working when Diesel Engine Fire Pump is in
operation. Audio-Visual Alarm shall be available to indicate failure of Main Electric Fire Pump.
d) A three attempts starting facility will be provided for diesel pump.
e) If within a pre-set time, the standby pump also fails to start or fails to develop pressure, the
standby pump shall also be shut down and locked out. An audio visual alarm indication shall be
given at the control panel.
f) The Terrace Pumps will start on sudden loss of pressure only when both the Fire Pumps have
either failed to start or exhausted water. In addition start / stop push buttons shall be provided
at ground floor near internal hydrant for starting the pump manually. Where fire control room
has been provided, remote operation of terrace pump may be done from fire control room in
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Part-A DPR
place of internal hydrant. The control panel for terrace pumps shall control room in place of
internal hydrant. The control panel for terrace pumps shall be provided near the pumps in a
suitable enclosure to avid unauthorized operation.
g) Only one pump will be working at a time. In manual mode more than one pump can be started.
h) Water level in UG and terrace tanks shall be monitored and in case of low water level, pumps
connected with the tank shall not operate (even on manual mode) or stop operation as the case
may be. An audio-visual alarm shall be given at the control panel.
 Under Ground Static Water Tank

Water required for sprinkler system and hydrant system is supplied from static water tank. Based
on the recommendation of National Building Code, 2 lakh liters of water will be stored. Water for
supplying the external hydrants and sprinklers is pumped from this tank.Two suitable electrical
pumps (4560 lpm at 70m head) the parameters of the pump furnished is fixed considering delivery
pressure and standard quantity of water required for firefighting.
Out of two electrical pumps, one electrical pump is for hydrant and other one is for sprinkler. For
standby service one diesel pump of same capacity of main pump shall also be installed. In addition
a jockey pumps (180 lpm @ 70m head) to supplement the main pumps to develop additional
pressure shall also be installed. The jokey pump and Diesel pump will function as stand by pump
for sprinkler as well as for hydrants. These pumps will be accomodated in the pump house as
recommended by IS 3844-1989. Water required for Under Ground Static Water Tank will be
supplied from MES Source / Bore well.
 Yard Hydrant
The yard hydrants have been connected to ring mains directly. This will be the 63mm single
headed hydrant. Then hydrants are to be installed at maximum of 45m intervals and at salient
points wherever found necessary. Hose pipe of 63mm dia and 15m long with male and female
coupling at both ends will also be provided to hydrants.
 Fire Brigade inlet

A fire service inlet at ground level with NRV will be provided to the rising main of each zone for
charging the wet raiser by fire pump as per IS 3844-1989 recommendation.
 Pump House
For housing the fire pumps and jokey pump a separate pump house has to be provided. The size of
pump house shall be not less than 6mx8m, since two electrical pumps are to be installed.
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Part-A DPR
 Hydrant and Sprinkler Ring Mains

In this project, it is proposed to use GI pipe for rising mains / down corner as per IS 3844-1989 para
5.7 and IS3844-1989 vide para 7.5 GI pipes shall conform to IS 1239 Part -1979. It is also
recommended to route the ring main to cover the entire area of the project as well as every building
as recommended by NBC code i.e minimum 2m and maximum 15m from the face of the building,
so that the service facility of the hydrant will be ensured for all the buildings.
According to the classification the firefighting facilities / equipment recommended by NBC are
shown in the firefighting drawings. The recommendations made by NBC are furnished below. In
addition detailed drawings are also provided where in firefighting requirements are shown clearly.
The internal firefighting arrangements for all process buildings are to be catered to, in this part of
execution of the project.
The external facilities like yard Hydrants, underground sump, Hydrant & Sprinkler ring mains, etc.
shall be carried out in Part – B of execution of the project.
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Part-A DPR
507 ABW 304

House Keeping
Part-A DPR
3.7 House Keeping
3.7.1 General
Housekeeping is the act of cleaning the rooms, furnishings and outside area of a home /
workplace. In a campus, housekeeping is the act maintaining the entire campus which
includes rooms, furnitures, equipments, roads, etc clean. Housecleaning includes activities
such as disposing of rubbish, cleaning dirty surfaces, dusting and vacuuming.
Effective housekeeping can eliminate some workplace hazards and help get a job done safely
and properly. Poor housekeeping can frequently contribute to accidents by hiding hazards
that cause injuries. If the sight of paper, debris, clutter and spills is accepted as normal, then
other more serious health and safety hazards may be taken for granted.
Housekeeping is not just cleanliness. It includes keeping work areas neat and orderly;
maintaining halls and floors free of slip and trip hazards; and removing of waste materials
(e.g., paper, cardboard) and other fire hazards from work areas. It also requires paying
attention to important details such as the layout of the whole workplace, aisle marking, the
adequacy of storage facilities, and maintenance. Good housekeeping is also a basic part of
accident and fire prevention.
Effective housekeeping is an ongoing operation: it is not a hit-and-miss cleanup done

occasionally. Periodic "panic" cleanups are costly and ineffective in reducing accidents.
3.7.2 Existing Scrap Dumping Unit
The present system will be incapable of handling scrap disposal and cleansing of the
workshop as the Master layout/Process is altered and the existing facilities are insufficient.
3.7.3 Proposed Scrap Dumping Unit
Scrap yard unit is proposed separately for collecting different types of scraps from various
units. This scrap yard unit is planned near the Engine Test House. Also, in each of the
working groups one separate room / space is proposed for scrap collection. The daily scrap
shall be stored in the separate place identified for scrap disposal in each group. Further, the
scrap shall be shifted to the Scrap yard.
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Part-A DPR
3.7.4 Proposed House Keeping Equipments for 507 ABW
Housekeeping is not just cleanliness. It includes keeping work areas neat and orderly;
maintaining halls and floors free of slip and trip hazards; and removing of waste materials
(e.g., paper, cardboard) and other fire hazards from work areas.
The proposed housekeeping equipments for Process Buildings are,
 Suction Sweeping machine or Equivalent
 Battery operated ride on scrubber cum drier machine or Equivalent
 Automatic scrubber cum drier machine
 Mini scrubber cum drier machine
 Flipper + Manually Operated sweeping machine
 Wet & dry Vacuum cleaner or Equivalent
 TTS Telescopic pole (9 meters) with cob- web brush
 Cold Water High pressure jet cleaner or Equivalent
 EZE Clean Mops 50 cm
The summary of Recommended housekeeping equipments for Process Building
Proposed Housekeeping equipment is used to clean the floors / spaces within the buildings,
Toilets and outside of the building, the following housekeeping equipment is recommended for
common to workshop buildings.
3.7.4.1 Suction sweeping machine
 Suction sweeping machine is mainly used to clean road areas . sufficient quantity of
Suction sweeping machine has been proposed to clean entire premises
3.7.4.2 Battery operated ride on scrubber cum drier
 Battery operated ride on scrubber cum drier machine is mainly used to clean Major Shop
floor area which is recommended for main groups like Engineering Equipment Assembly
Group, Field Articulated Vehicle Assembly Group, General Engineering Group, Body
Repair Group & OSS / MCO / KRAZ etc.,
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3.7.4.3 Automatic scrubber cum drier
 Automatic scrubber cum drier machine is mainly used to clean the oily / greasy surfaces.
So that sufficient number of Automatic scrubber cum drier machines are recommended for
Engine repair group, body repair group and assembly groups etc.,
3.7.4.4 Mini scrubber cum drier machine
 Mini scrubber cum drier machine is used to clean Shop floor area, it is recommended for
all the groups
3.7.4.5 Flipper + Manually Operated sweeping machine
 Flipper + Manually Operated sweeping machine is used to clean Sweeping narrow areas
in all buildings, which has been Proposed to Clean entire premises and it is a portable
equipment used to handle in any floor.
3.7.4.6 Wet & dry Vacuum cleaner
 Wet & dry Vacuum cleaner is used for general cleaning which is suitable for all types of
building. Sufficient number of machines is proposed for entire premises.
3.7.4.7 TTS Telescopic pole
 TTS Telescopic pole (9 meters) with cob - web brush is used to clean roofs / Ceilings,
which has been proposed for all the buildings
3.7.4.8 Cold Water High pressure jet cleaner
 Cold Water High pressure jet cleaner is used to clean toilet area, proposed to all buildings
& mops for general cleaning.
3.7.5 Specifications for proposed housekeeping equipments
3.7.5.1 Suction Sweeping machine

Key features of the machine are
 Diesel Engine operated Ride on Suction Sweeping machine

 Area to be cleaned 22630 Sq.m
 Proposed to Clean Complete Road areas & Shop floor area
 The Specifications are given below
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Part-A DPR
Sweeping Width mm 1219
With one side / two side brushes mm 1575 / 1930
Sweeping performance (Theoretical) m2/h 7168/25340
Dirt hopper volume liters 620
Emptying height up to mm 1624
Filter area m2 10.22
Power / output kW 27.9
Speed km/h 6.09
Weight, ready for operation kg 1587
Length x Width x Height mm 2667x1524x1407
3.7.5.2 Battery operated ride on scrubber cum drier machine
 Battery operated ride on scrubber cum drier machine
 Area to be cleaned 20,718 Sq.m (60%Area considered

for cleaning)
 Proposed to Clean Process Buildings - Major Shop floor area
Working Width mm 800
Suction width mm 1100
Theoretical are performance m2/hr 5200
Working speed km/hr 6.5
Travel Speed km/hr 7
Running time hours 3(minimum)
Power Supply Volt 24V 240Ah ( 320Ah Optional)
Air Volume, Vacuum cu.m/hr 118
Vacuum pressure mm of H2O 1730
Drive motor power watts 750
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Part-A DPR
Brush motor power watts 2x550
Vacuum motor power watts 550
Fresh tank liters 120
Collection tank liters 120
No. of brushes nos. 2
Brush diameter mm 405
Brush speed rpm 180
Brush pressure Kg 50
Length with squeegee mm 1750
Height mm 1410
Width with / without squeegee mm 1100/885
Turning circle in aisle mm 1800
Weight (with batteries) Kg <400-575
Noise level dB 69
3.7.5.3 Mini scrubber cum drier machine

 Mini scrubber cum drier machine
 Proposed to Clean process building - Major area cleaning
3.7.5.4 Flipper + Manually Operated sweeping machine
 Flipper + Manually Operated sweeping machine

 Proposed to Clean Sweeping narrow areas in Technical area
Working Width with Side Brush mm 650
Working Width without Side Brush mm 460
Machine Width with Side Brush Mm 780
Height with Handle Mm 1010
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Part-A DPR
Weight (ready for operation) Kg 26
Capacity of Hopper Lit 40
Maximum Theoretical - Area Performance* m2/hr 2600
Maximum Practical - Area Performance** m2/hr 1640

3.7.5.5 TTS Telescopic pole (9 meters) with cob- web brush
 TTS Telescopic pole (9 meters) with cob- web brush
 Proposed to Clean roofs / Ceilings Cleaning for Technical area
3.7.5.6 Cold water High pressure jet cleaner
 FTP 1910 Cold water High pressure jet cleaner
 Area to be cleaned - For entire premises
 Proposed to Clean Toilets
Operating pressure Bar 30-130 30-190
Volume I/h 300-600 450-900
Intel water temperatures oC 50 50
Phase/Voltage/Frequency f-V-Hz 1/230/50 3/400/50
Power W 3200 5400
Motor speed RPM 1400 1400
Detergent tank I 7.5 7.5
Electric cable length M 4.5 4.5
Dimensions – LxWxH Cm 73x43x88 73x43x88
Weight Kg 46 47
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Part-A DPR
3.7.5.7 Wet and dry vacuum cleaner

 Soteco abse 303 wet and dry vacuum cleaner
or equivalent
 Area to be cleaned – For entire premises
 Vacuum cleaner for general vacuuming to whole premises
3.7.5.8 Heavy duty Vacuum cleaner
 Delfin DG70 heavy duty Vacuum cleaner
 Heavy duty vacuum cleaner for machines chip collection
Note:
1. Abstract Cost estimate has been enclosed in Part - A / Volume – 1 / Annexure – III A
2. Detailed Cost estimate has been enclosed in Part - A / Volume – 1 / Annexure – III B
3. Scope of works are given in Part - A / Volume – 2 / Annexure – I
4. Specifications for Housekeeping equipment has been enclosed at Part - A / Volume – 2 /
Annexure – VIII
5. Any other item required, shall also be designed and Supplied by the LSTK Contractor based on
the discussion with the client without any extra cost.
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Part-A DPR
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Assembly Line Integration
Part-A DPR
3.8 Road Infrastructure
3.8.1 General
Road development for the movement of vehicles, MHEs and personnel’s are proposed based
on road design. The entire road system is designed such that there is clear demarcation
between the pedestrian path and the vehicular road by use of levels and materials
3.8.2 Existing Condition of Road Network

The present road network is deficient with the following factors.
 Non standard carriageway width
 Improper drainage provision
 Poor pavement composition
 Settlements with pot holes
 Lack of road furniture

The present road system is provided with bituminous concrete pavement for the admin area
and stone block for the workshop area.
3.8.3 Road Design

The roads in the project area are developed based on existing sub grade soil characteristics,
CBR and traffic volume (MSA). Pavement composition will be arrived based on IRC 81, IRC
37.
3.8.4 Design of Pavement

Design of pavement composition is based on the load factors, CBR values, and other
parameters.
Pavement Composition:
The pavement composition is based on the sub soil parameters and traffic volume. This Site
have been planned with various pavement composition such as
 Bitumen Road
 Paver Blocks
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Part-A DPR
3.8.5 Drainage System

Drainage systems are designed as per IRC – SP – 42 “Guidelines on Road Drainage”. The drainage is
designed to suit the road area under coverage, gradient etc. Concrete/ lined drains are proposed for a
drainage system.
3.8.6 Proposed Cross Section

Bitumen Road is proposed inside of the workshop with varying road widths such as 3.5 m, 7 m,
7.5 m, 8 m & 10 m. Moreover 15m wide Road is proposed in Main Gate Entrance to meet their
requirements for easy access to the Workshop and 17 m road is planned for loading and
unloading purposes near Body Repair Group.
The following Road Cross Section has been proposed for the 507 Army Based Workshop
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Part-A DPR
 With reference to the above section, Bituminous Concrete payment would be done as
specified above in consecutive layers respectively.
 On both sides of the road, Path way has been planned below which Storm Water Drains also
planned depending upon the volume of rain water that would be collected in monsoons.
 For smaller road width, camber would be provided towards storm water drain to drain away
the collected water and both side camber would be provided along both ends of the road for
wider widths of road more than 8m.
3.8.7 Proposed Pedestrian Walkway

Pedestrian walkway is proposed in both the sides of the road section over the drains as shown
in the figure above. The pedestrian pathway shall be made of Paver Blocks with the required
pattern having width is about 1 m.
3.8.8 Road Delineators

Road Delineators are generally intended to delineate roadway, abstraction and object on the
roadway. Delineators for the project sites are designed depending upon the site conditions.
3.8.9 Road Markings and Road Furniture

Road Markings and Road Furniture’s play’s an essential role in guiding the vehicles to move in
right path which includes the following facilities:
 Road marking, traffic guidance, regulation and control

o Marking on Intersections
o Markings at Hazardous Locations
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Part-A DPR
o Marking for Parking

o Pedestrian Crossings
 Traffic safety and relief measures
 Lighting
 Landscaping and arboriculture
 Traffic control system
 Road signs
o Cautionary / Warning Signs
o Road delineators and road markings
o Informative Signs (Signages)
3.8.10 Proposed Road Network

In the present layout, the road network system is covered with following types.
 Carriageway for a varying width of 7 m, 7.5 m, 8 m & 10 m.
 15m wide Road is proposed in Entrance to meet their requirements for easy access to
the Workshop
 Carriageway having a width of 17 m for Loading / Unloading purposes
 Paver blocks are designed for the pathway having the width of 1m
The drawings showing the Road network and the cross section are enclosed in Part – A /
Volume – 1 / Annexure - IIA - Building Drawings
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Budgetary Cost Estimate
Part-A DPR
4.0 Budgetary Cost Estimate
General
The total area of the project is approximately about 25.90 Acres. Total built up area for is about
53541.28 Sq.m
The cost estimate for the above project has been worked out based on the Bill of Quantities worked
out for major items of work on the basis of Military Engineering Services (MES). The cost index
adopted for Military Engineering Services (MES) and Delhi Schedule of Rates (DSR) is 25%.
For the items not covered in MES rates, DSR rates have been adopted. For Non Schedule of rate
items (MR) Market rates has been adopted.
Items of work
The items of works are grouped under 6 major headings as detailed below:
S.No Description of work Items of work

1. Site clearance  Clearing & grubbing
 Dismantling of existing RCC / Brick Masonry structures
2. Earth work  Earth work excavation for ordinary soil
 Site filling with borrow material from approved source
 Site filling with useful material obtained from excavation.
 Excavation and disposal of unsuitable materials
3. Foundation  Open foundation
 Pile foundation
4. PCC Work  1:4:8 Concrete mix
 1:5:10 Concrete mix
5. RCC Work  M-20 Grade of concrete
 M-25 Grade of concrete
 M-30 Grade of concrete
4. Brick Work  Brick work in fly ash bricks, straight or curved on plan exc 6m
mean radius, built in modular bricks in Cement mortar 1:6
 Brick work in fly ash bricks, straight or curved on plan any
radius in half brick thick walls built in modular bricks in
Cement mortar 1:4
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Part-A DPR
S.No Description of work Items of work

5. Floor finishes  Granite flooring
 Kota stone flooring
 Vitrified tiles flooring
 Laminated Wooden flooring
 Screed flooring
 Non-Skid ceramic tiles flooring
 Chequered precast concrete tiles flooring
 Interlocking paver blocks
 Granite Wall cladding in front of compound wall
6. External Works  External works includes Construction of Bituminous roads,
Paved roads, Stone pitching pavements, Drains, Compound
wall and Test Track
 Landscaping and Firefighting works
 Part A – Process Buildings (Technical Infrastructure)
Part A cost includes the particulars about the Process Buildings / Technical Infrastructure that
has been designed largely for the Base Workshops improvements and other necessary
Production / Overhaul oriented requirements as follows.,
1. PMSEs
2. Test Equipment
3. Material Testing Equipment
4. Civil works - Process Buildings required to house PMSEs
5. CNC M/Cs
6. Power Management System for PMSE & Power Back up
7. Distribution Network Control System (Automation – Manufacturing Execution system)
8. IT Support for various process and Data capture
9. Internal Water supply, Sanitary, Electrical works and Fire fighting
10. Inventory Storage and Management
11. Heat Ventilation & Air Conditioning (HVAC)
12. Modern Housekeeping
13. Assembly Line Integration Facility
507 ABW 318

Part-A DPR
4.1 Cost Estimate – Process Building Break up
Total Amount in
S. No Cost Elements Percentage
Crs
PART - A - Process
I List of New Buildings to be Constructed
a) Building Infrastructure 116.88 38.27 %
New Machineries to be established ( Plant & Machinery,

b) 58.45 19.14 %
CNC, Material handling, Electronics)
c) New Testing Equipment to be established 58.34 19.10 %
d) Inventory Storage and Management 13.93 4.56 %
Manufacturing Execution system & Support facilities (IT

e) 7.31 2.39 %
Infrastructure for automation of processed)
f) Assembly Line Integration Facility 8.39 2.75 %
Total 263.29 86.21 %
Price Escalation @5% 13.16 4.31 %
Project Management Consultancy during Execution Stage

7.90 2.59 %
@ 3%
Post Implementation operation & Maintenance Support @

13.16 4.31 %
5%
Contingencies @ 3% 7.90 2.59 %
PART -A TOTAL COST 305.42 100 %
507 ABW 319

Part-A DPR
4.2 Cost Break up for Process Buildings
TOTAL AMOUNT IN
S.NO COST ELEMENTS
CRS
A) BUILDING INFRASTRUCTURE
1 Engineer Equipment Assembly Group 8.83
2 Field Articulated Vehicle Assembly Group 18.56
3 Field articulated vehicle Sub Assembly Group 10.68
4 Engine Repair Group 8.45
5 General Engineering Group 7.15
6 Ancillary Shed 4.64
7 Workshop Expenses Stores/Battery Charging Shop 1.82
8 Body Repair Group 5.69
9 Engine Test House 7.36
10 Caustic Soda Washing 0.77
11 OSS, MCO & KRAZ Stores 10.78
12 Vehicle Stripping Shed 2.83
13 Engineer Equipment Stripping and Sub Assembly Group 5.67
14 Outer Traffic store 0.34
15 Effluent Treatment Plant Works & Collection net work 0.89
16 Scrap yard 0.47
17 Compressor room & Pneumatic lines 1.43
18 Overhauled Vehicle Parking -1 (11 nos) 0.55
19 Chassis Dynamometer 0.39
20 Repairable Vehicle Parking-1 (15 Nos) 0.64
21 Repairable Vehicle Parking-2 (15 Nos) 0.64
22 Old buildings to be refurbished for new application 3.64
23 Old buildings to be demolished 3.71
507 ABW 320

Part-A DPR
TOTAL AMOUNT IN
S.NO COST ELEMENTS
CRS
24 Power Back up ,Electrical Safety Equipments & Rectifier Unit 4.12
25 UG Sump, Over Head Tank & Distribution Net Work System 5.14
Shifting of Machines including necessary foundations re-fixing of

26 1.69
machines etc…,complete.
Total- A 116.88
B) NEW MACHINERIES TO BE ESTABLISHED
PLANT & MACHINERY
1 Field Articulated Vehicle Group 5.40
2 Engineer Equipment Group 4.62
4 Ancillary Group 2.18
6 Body Repair Section 3.90
7 Workshop Service Group 0.31
8 OTRP 0.53
9 Traffic Stores 0.06
10 Method Engineering Group 0.44
11 Electronics Repair Section 0.51
Common Facilities
1 Water Wash Booth (2 Nos) 1.50
2 Caustic Booth (2 Nos) 1.50
Sub-Total 31.07
CNC Machines
2 Method Engineering 5.06
Sub-Total 7.55
507 ABW 321

Part-A DPR
TOTAL AMOUNT IN
S.NO COST ELEMENTS
CRS
Material Handling
1 FAV Stripping Shed 1.07
2 FAV Sub Assembly Group 0.52
3 FAV Assembly Group 6.87
4 EEG Sub Assembly Group 0.91
5 EEG Assembly Group 2.73
7 Engine Test House 0.82
8 Body Repair Section 0.88
9 Ancillary shed 0.34
11 Caustic Soda Wash 0.51
12 Common Material Handling Equipment to Workshop 2.88
Sub-Total 19.83
Total-B 58.45
C) NEW TESTING EQUIPMENT TO BE ESTABLISHED
1 Field Articulated Vehicle Group 9.15
2 Engineer Equipment Group 1.14
5 Ancillary Group 0.09
6 Method Engineering 0.57
7 Electronics Repair Section 0.19
8 Common Testing Equipment To Workshop 0.75
Total- C 58.34
507 ABW 322

Part-A DPR
TOTAL AMOUNT IN
S.NO COST ELEMENTS
CRS
D) INVENTORY AND STORAGE MANAGEMENT
1 Pallet AS/RS 6.44
2 Mini-Load AS/RS 5.99
3 Conventional System 1.50
Total- D 13.93
E) MANUFACTURING EXECUTION SYSTEM & SUPPORT FACILITIES (IT INFRASTRUCTURE

FOR AUTOMATION OF PROCESSED)
A) Manufacturing Execution System 4.00
B) Support Facilities for MES
Network Cable & Switching (Cat6 UTP Cable & Fiber Cable,
Fiber Media Convertor ,Patch Panel,4U (19.7") wall mount
i) 0.17
Cabinet ,Gigabit Switch,RJ-45 Cat6 UPT LCS, (Jacket) white, Cat
6, UTP Mounting Card – 3.5 Ft user end (1Mtr & 2 Mtr)
ii) Workstation server & RSS Feed Server, Server and Tablet 1.64
Hard wares (Printers (Laser jet / Inkjet etc.,),Docking Station 4-

Port,Standalone Fingerprint Time and attendance cum Access
iii) 0.90
control, UPS ,Display Board HD LED 40” & KIOSK, Router,
Hardware Firewall, Fax & Bar Code Reader)
iv) Software (CATIA V5R19, Master CAM etc.,) 0.49
v) Provision of IT Facilities for the following buildings
RTIN - 04 Receipt & Issue 0.05
RTIN - 06 MAG 10 0.05
Sub Total (B) 3.31
Total- E 7.31
507 ABW 323

Part-A DPR
TOTAL AMOUNT IN
S.NO COST ELEMENTS
CRS
F) ASSEMBLY LINE INTEGRATION FACILITY
1 Site Grading Work 3.38
2 Roads 4.54
3 Paver Block Pavement 0.47
Total - F 8.39
Note:
1. Abstract Cost Estimate for Process Buildings has been enclosed in Part – A / volume – 1 /
Annexure – III A
2. Detailed Cost Estimate for Process Buildings has been enclosed in Part – A / volume – 1 /
Annexure – III B
3. Cost estimate for Plant Machinery special Equipment (PMSEs), Testing equipment, Material
Handling Equipment & Inventory Storage System has been enclosed in Part – A / volume – 1 /
Annexure – IV
507 ABW 324

Recommendations
Part-A DPR
5.1 Trade Re – Structure
 The present authorization of industrial and non industrial manpower of 507 Army Base
Workshop are as follows
Category Ault Held Deficiency
(a) Industrial 429 429 NIL
(b) Non Industrial 122 122 NIL
Total 551 551 NIL
 There are 22 Trades in Industrial category and 23 Trades in Non Industrial Category.
 The Present Trade Structure is as under
Industrial
 Vehicle Mechanic (MV)
 Engineering Equipment Mechanic
 Tin & Copper Smith
 Electrician
 Electrician Power
 Machinist
 Ref Mechanic
 Armr
 Moulder
 Ptr & Dec
 Rubber & Plastic Moulder
 Tool Maker
 Upholster
 Welder
 Pattern Maker
 Carpenter and Joiner
 Electroplating Deposit Mechanic
 Heat Treatment Mechanic
 Inst Mechanic
507 ABW 325

Part-A DPR
 Labourer
 Fitter
 Telecom Mech
Non Industrial
 Office Supdt
 Office Assistant
 Clerk
 Stenographer
 Pharmacist
 Draughtsman
 Daftary
 Gardener
 Leading Hand Non –Technical
 Laboratory Asst
 Motor Drivers
 Messenger
 Orderly (Hospital)
 Storekeepers and Asst. Storekeepers
 Supervisor Technical
 Supervisor Non-Technical
 Sweepers
 Telephone Operators
 Supervisor Fire Staff
 Leading Hand Fire
 Fire Engine Driver
 Fireman
 Canteen Staff
 Due to modern CNC Machines and state of the Art Material Testing Laboratory, Material
handling equipment and Housekeeping equipment, it is recommended that the following trades
be re-categorized as under
507 ABW 326

Part-A DPR
a. Machinist
 CNC Operator
 CNC Programmer
 CAD / CAM Operator
b. Labourer
 Crane Operator
 Trolley operator
 Material Handler
c. Sweeper
 House Keeper
d. Draughtsman
e. Telecom Mech
 Computer Mechanic Hardware
 Computer Mechanic Software
 With suitable restructuring, we recommend 25 trades in Industrial category and 21 trades in

non-industrial category. The recommended trade structure is as under.
Industrial
 Vehicle Mechanic (MV)
 Engineering Equipment Mechanic
 Tin & Copper Smith
 Electrician
 Electrician Power
 CNC Operator
 CNC Programmer
 Ref Mechanic
 Armr
 Moulder
507 ABW 327

Part-A DPR
 Ptr & Dec

 R & P Moulder
 Tool Maker
 Upholster
 Welder
 Pattern Maker
 Carpenter and Joiner
 Electroplating Deposit Mechanic
 Heat Treatment Mechanic
 Inst Mechanic
 Crane Operator
 Trolley operator
 Material Handler
 Fitter
 Computer Mechanic Hardware
 Computer Mechanic Software
Non Industrial
 Office Supdt
 Office Assistant
 Clerk
 Stenographer
 Pharmacist
 Gardener
 Laboratory Asst
 Motor Drivers
 Messengers
 Orderly (Hospital)
 Storekeepers and Asst. Storekeepers
 Supervisor Technical
 Supervisor Non-Technical
 House Keeper
507 ABW 328

Part-A DPR
 Telephone Operators
 Supervisor Fire Staff
 Leading Hand Fire
 Fire Engine Driver
 Fireman
 Canteen Staff
 The carrier path for a typical technician is recommended as under.

1) Trainee (Fresh ITI) + training for six months to a year ->Junior Technician
2) Junior Technician + six to seven years → Technician
3) Technician + Six to seven years→ Expert Technician
4) Expert Technician+ Six to seven year→ Master Technician
5) Master Technician +3 Years→ Supervisor
6) Supervisor + 5years→Workshop Officer
 Training: It is recommended that training through OEM be organized to upgrade the skills of the
following tradesmen.
a. CNC Operator
b. CNC Programmer
c. CAD / CAM Operator
d. Crane Operator
e. Trolley Operator
f. Material Handler
g. House Keeper
h. CAD / CAM Operator
i. Computer Mechanic Hardware
j. Computer Software Developer
 Conclusion
Due to modernization even though the capacity of the workshop has almost doubled, we do not
recommend any further changes in the authorization of civilian manpower. However, we
recommend that the skills of the present tradesmen be upgraded through organized training with
the OEM.
507 ABW 329

Part-A DPR
507 ABW 330

Part-A DPR
5.2 Benefits of Modernization

Aim of Modernization
Modernization of 507 Army Base Workshop aims at
a) Improved plant layout by grouping related to repair & overhauling operations
b) New Buildings, Infrastructure and Allied services
c) Latest plant, Machinery and specialized equipment
d) To improve production capacity and quality of overhaul of Vehicles
e) Reduced complexity in operations through Manufacturing Execution System.
f) Modern reverse engineering facilities for indigenisation in manufacturing of spares
Benefits of Modernization
1) The proposed Modernization plan of 507 Army Base workshop can bring about the following
benefits
a) Increase in Capacity
 Field articulated Vehicle (FAV) overhauling is increased from current capacity
to 156 vehicles.
 FAV engine overhauling is increased from current capacity to 204 engines
b) Indigenization
A state of art Reverse Engineering laboratory with automation of design and modern testing
facilities has been provided. This will enable the workshop to manufacture spares not
available through normal sources of supply. A high state of indigenization of spares can be
achieved and reduction in the number of bottlenecks due to non-availability of spares. This
will in turn ensure smooth production flow of overhaul of vehicles and engines.
c) Improvement in layout
A detailed survey of the complete Base workshop was carried out and thereby old buildings
to be demolished, buildings to be refurbished and new buildings to be constructed for
modernization process has been clearly identified. The Master plan was redesigned by
grouping of buildings with reference to the technical process of the base workshop. Multi-
storied buildings were considered to maximize space utilization with dust, temperature and
humidity control. The complete layout of the workshop was formulated to minimize movement
of Men, Material and Equipment. Separate parking sheds have been provided for parking of
repairable and overhauled vehicles. Also pollution control, landscaping, water bodies and
open space have been provided.

Part-A DPR
d) Automation
A customized ERP solution has been provided which is flexible and robust and incorporates
the needs of all the departments with a single view of the system. The ERP solution has been
designed so that it can be easily integrated with Project Emerald. The ERP solution will
enable effective tracking of work orders, On-line spares management and process control.
Further, effective production, planning and maintenance can be scheduled with real– time
Management Information System.
e) Latest Machinery
A state of the art Machine shop has been provided with latest CNC Machines. This will
enhance the capacity and capability of the workshop to manufacture high quality spares.
Increased machine utilization and machine availability can be achieved. Further substantial
reduction in number of spares failed and rework percentage can be achieved.
f) Centre of excellence
 Automatic Gear Box Testing
 Hydraulics
 Rubber & Plastic Moulding
 Manufacturing of spares.
 Reverse Engineering and indigenization
g) Reduction in Maintenance Cost

Modern manufacturing techniques, 5S principles and On-line maintenance scheduling will
enable increase in Mean Time between failures (MTBF), reduction in Mean time to repair
(MTTR) of plant and machinery and increase overall efficiency of the workshop.
h) Elimination of waste
The re-engineered process and latest manufacturing techniques will eliminate substantial
production of waste. Substantial savings can be achieved by reduction in tooling cost, rework
percentage, fuel, oil, power consumption and maintenance cost.
i) Safety and security

The safety and security of the workshop has been enhanced by providing state of the art
security systems in terms of baggage scanners, Automatic boom barriers, Surveillance
cameras and biometric attendance systems. Also the fire fighting systems has been designed
as per NBC 2005 norms. Automatic Alarm systems, yard hydrants, sprinkler systems and Fire
extinguisher have been provided

Part-A DPR
1. Tangible Benefits
a. Increase in capacity to overhaul of FAV to 156 vehicles / year
b. Increase in capacity to overhaul of Engineer Equipment to 56 vehicles / year
c. Increase in engine overhauling capacity to 204 engines
d. Establishment of centre of excellence for Automatic Gear box testing, Hydraulics, Rubber
and Plastic moulding, Manufacture of spares and Reverse Engineering
e. State of art engine test house
f. Segregation of dirty area for stripping and cleaning process and clean area for assembly
process
g. Establishment of Manufacturing Execution system along with its support facilities
(Networking system)
h. Buildings designed to conform to green building concepts to save energy
i. Installation of the latest security system
j. State of art buildings with modern allied facilities for fire fighting, housekeeping etc.
k. Establishment of Modern CAD/CAM centre
l. Increase in overhaul productivity
m. Increase in Quality of product and reduction in no of failures
n. Increase in Machine utilization with higher efficiency
o. Increase in Mean Time between Failures (MTBF)
p. Reduction in Mean Time to Repair(MTR)
q. Increase in Overall Equipment Efficiency (OEE)
r. Reduction in
 Rework Percentage
 Rework hours
 Rejection rate
 Waste generation
 Power consumption
 Fuel & Oil consumption
 Maintenance cost
 Tooling cost
 Procurement / Ordering cost
 Cost of inventory
 Sparer retrieval time

Part-A DPR
 Absenteeism
 Accidents
2. Intangible Benefits
 Capacity and capability enhancement of the workshop
 Efficient utilisation of men, machine and material
 Safe Material management
 Improved working Environment
 Improved quality of the component in wide range
 Improved Quality of Overhauling process

Part-A DPR
5.3 Key Performance Indicator (KPL)
 Precision quality of the products.

 Organized layouts.
 Easy identification of problems in the electronic circuits/components.
 Less repair time for the electronic machines.
 Less time consumption for production and transportation.
 Micro Machining and Assembly.
 Less skilled labour.
 Online Spares management.
 Easy material handling systems.
 Modern State of art Equipments.
 Ergonomic layouts.
 Versatile and easy to use machines.
 No significant downtime.
 Less maintenance for machines.
 Creative design possibilities.
 Dedicated tools to get the best performance.
 One machine many process concepts.
 Wide range of components production.
507 ABW 335

Part-A DPR
507 ABW 336

Building Specifications
Part-A DPR
6.0 Building Specifications

6.1 Engineer Equipment Assembly Group
CIVIL WORKS
Description Specification
 Pile Foundation: However the type of foundation shall be
Type of Foundation
finalized by the vendor after detailed soil investigation
Basement Height  0.6m from Finished Road Level (FRL) and level as per
drawing, filled with Murom/Bajiri.
ANTI-Termite Treatment  Treat backfill and basement of foundation with Chlorpyrifos
emulsifiable emulsion at the rate recommended by the
manufacturer.
 Treating the top surface of filled earth at the rate of 5 liters of
Chlorpyrifos emulsifiable emulsion per square meter of
surface including external perimeter of the building.
 Treating the soil under plinth protection at the rate of 5 liters
of Chlorpyrifos emulsifiable emulsion per square meter of
surface area.
 Treating the soil along with external perimeter of building at
the rate of 2.25 liters of Chlorpyrifos emulsifiable emulsion
per meter of the perimeter wall.
Damp Proof Course  In cement mortar 1:2, 20 mm Thick.
Grade of concrete M25 grade concrete
 Footing, Columns, Beams, Mezzanine slab
M30 grade concrete
 Flooring
Plinth protection  Plinth Protection 1.20m Width all around the Building using
M20 concrete 150mm thick top finished with necessary slope
to drain the rain water.
Type of Flooring Main Shop area
 Minimum 150mm thick Screed Flooring: Production Area,
Tools Room, Machine shop, Spares store, Consumable
store, Tools room, Scrap store, Hydraulic Testing Section,
OBM Facility dust free room, Gear box section
The requirement given above is minimum requirement.
Further requirement of epoxy coating is to be finalized based
on the machinery requirement
507 ABW 337

Part-A DPR
 22mm thick Precast Cement concrete tile flooring: Ramp

Toilet areas
 Non-skid joint free ceramic flooring tiles– 300x300x8mm thick
 Wall Dadoing with Granite Tile 450x350x8mm.
 PVC Corner Beading
 20 mm Thick Granite Platform for fixing Washbasins.
 Urinal Partition of Size 750 x 500X 18 mm Thick.
 Service area: Flooring with Kota Stone Finish.
 Mezzanine Floor with Vinyl Tile Finish.
Type of Super Structure Outer walls
The approximate height of each type of cladding is given
below.
Fly ash brick work in C.M 1:5,230mm thick about 5 m height.
Metal sheet louvers about 3.0m height beyond Colour Metal
Siding
Colour Metal Siding up to bottom of gutter level beyond Metal
sheet louvers.
Depending upon the openings, sunshade projection, approach
ramp, down take pipe etc… the height may vary. Refer concept
drawings plan, elevation and sections given in drawing volume.
Inner Wall Partitions
All inner walls shall be fly ash brick up to the required height
Type of Joineries Sliding Door

 Manually Operated Sliding door, Size as per drawing.
Doors
 Steel Single/Double Leaf Puff Door, sizes as per drawing.
Toilet door
 FRP Door frame with 30 mm thick FRP shutter.
Window
 Aluminium window with suitable grills to prevent monkey /
birds entry.
Ventilator
 N type Ventilator with 6 mm thick glass, sizes as per drawing.
 Turbo ventilator: Industrial Hi-Grade 600mm dia Aluminium
vane gravity type turbo vent as per drawing
Roof height (clear)  10.50 m (From FFL to Truss Bottom Level).
507 ABW 338

Part-A DPR
Mezzanine Level  5.90 m from FFL

Roofing system  Conventional steel truss and Cold roll Purlin sections
supported over RCC columns & covered with double skin
roofing.
Type of Roofing Double Skin Roofing:
 Roofing with Galvalume sheet 0.60 mm thick and 50mm thick
Glass wool insulation density 24 kg/m3 with G.I. Sub purlin
of 50 x 50 x1.6 mm above liner panel of 0.5mm thick
Galvalume colour coated sheet.
 Sky light: Polycarbonate Translucent Sheet 2mm thick.
 Ridge ventilator: Ridge Ventilators are gravity type,
fabricated from galvanized steel sheets, minimum throat
width is 300 mm, length being 3m with manually operated
mechanical control dampers, at 6m interval
0.5mm thick corrugated roof cover sheet above false
ceiling.
Roof Gutter  Galvanized metal sheet Eaves Gutter of Size 184x191mm
made out of 1.2mm thick.
Down Spout pipe  Rectangular shaped, Colour Coated 0.5mm thick metal sheet
down spout pipe of Size 130x150mm.
False Ceiling Mezzanine floor area.
 Anodized aluminium snap grid frame work of Size of grid
605 x 605mm, Seamless calcium silicate ceiling made out of
1800 x 1200 mm size board, reinforced with cellulose fibre,
fixed to the ceiling section with 25 mm long self drilling and
tapping screws
Finishing Ceiling
 Plastering with CM 1:4 minimum 10 mm thick.
Internal
External
 Plastering with CM 1:4 minimum 20 mm thick applied as
three coats plastering (10mm+5mm+5mm thick) each.
Painting Inner Side walls
 PU paint Minimum 2.4m height: Solvent free polyurethane
coating 150 micron film thickness comprising of a primer and
flexible top coat.
 For rest of the height: Two Coats of Oil Emulsion white or
507 ABW 339

Part-A DPR
tinted, over one coat of water thinnable cement primer of

approved brand.
Outer side walls
 Two Coats of Acrylic Smooth exterior weather shield paint
over one coat of water proofing cement paint.
Ceiling
 Two Coats of Oil Emulsion, white or tinted, over one coat of
water thinnable cement primer of approved brand.
Structural Steel Fe 410-W(Grade-E- 250) A quality
 Roof trusses (framed) trussed, purlins, crane gantries, rails
and fastenings and heavy bracket framing, and Staircase.
Fe 490-W(Grade-E- 350)
 Structural steelwork in columns, beams, trusses, purlins,
platforms, ladders, monorails, staircases, supports.
Purlins  Cold Formed Light Gauge galvanized 'C' Purlins (Hot
galvanised iron as per IS 811, Material property as per IS
1079-1973, Design as per IS 801-1975).
Structural Steel Painting  75 micron thickness Epoxy paints over 75 micron thickness
primers including scraping and cleaning.
Hand Rail and Steel  Two coats of Synthetic Enamel paint over ready mixed red
Ventilator oxide zinc chromate primer.
Staircase Inner
 Steel Staircase.
Grade of steel All Reinforced cement concrete works
 Fe 500 D
Expansion Joint  Strip seal expansion joints are provided
Electrical Trenches  RCC Trench as per the size required, finished with CM 1:3
Mix
 Three Layer of Integral cement based treatment for water
proofing.
Machine Foundation  Machine foundation has to be designed as per the
machinery requirement. Minimum M25 grade concrete with
necessary grouting materials as per the specification of the
supplier. Grade shall be finalized by the vendor based on the
individual machinery
507 ABW 340

Part-A DPR
INTERNAL WATER SUPPLY WORKS
CPVC Pipes (Internal) Grade Schedule 80 in Conformity to IS 15778.

Urinal flush valve, Flush valve, The Product Shall be from approved Vendors.
Bip cock, Angle valve, Mirror,
Health faucet
Two way Bibcock In Conformity to IS 8937.
Pillar Tap, Gate valve Shall be conformity to IS 1735/SR 35
Internal distribution pipe lines shall be connected to external main distribution line with
necessary valves.
INTERNAL PLUMBING WORK
Granite Wash Basin-Sink, The Supply shall be as per the product from the approved
Porcelain Wash Basin, Waste vendor or its equivalent
Coupling, Bottle trap, Trash,
Cleanout plug, Peg set,
European Water closet, Indian
Water Closet, Paper Holder,
Urinal, Floor Trap, Urinal Trap,
Cockroach Trap, Hand Drier
PVC (SWR) (Internal) As per IS 14735
The outgoing line from various sanitary fixtures has to be connected with external sewer system
through inspection chamber and gully traps.
FIRE FIGHTING WORKS
This building falls under G1 (III) LOW hazard category as per NBC 2005.The fire suppression
requirement as per NBC and IS are furnished below with code numbers. This work has to be
executed strictly as per NBC and as per the need of local fire authorities, besides adherence to IS
codes wherever furnished.
Fire Extinguisher: Water type As per IS 15683

fire extinguisher, Dry powder
fire extinguisher
Hose Reel In Conformity to IS 636 /1988
Wet Riser Shall meet the requirement of 6.4.8.1 page 54 of NBC
Automatic Sprinkler system Shall confirm to IS 15105.
507 ABW 341

Part-A DPR
Should meet the requirement of 5.1.7 page 46 of NBC.

Smoke Detector Shall confirm to IS 11360.
Underground static water Grade of Concrete RCC M-30 and meet the requirement of 5.1.6
storage tank, UG Sump page no 46 of NBC.
First aid hose As per IS 884/1985.
Double head coupling for As per IS 901/1988.
hydrant
Fire bells As per IS 928/1984.
Heat sensitive fire detector As per IS 2175/1988.
Fire bucket As per IS 2546/1974.
Duct fire detector IS 2175.
Internal hydrant Shall meet the requirement of 6.4.8.2 page 55 of NBC.
Ring main for External & ‘C’ Class heavy duty MS Pipe conforming to IS 3589.
internal hydrants and Ring main
for sprinklers
507 ABW 342

Part-A DPR
6.2 Field Articulated Vehicle Assembly
CIVIL WORKS
Type of Foundation
manufacturer.
 Treating the top surface of filled earth at the rate of 5 liters of
Chlorpyrifos emulsifiable emulsion per square metre of
 Treating the soil under plinth protection at the rate of 5 liters
of Chlorpyrifos emulsifiable emulsion per square meter of
surface area.
the rate of 2.25 litre of Chlorpyrifos emulsifiable emulsion per
metre of the perimeter wall.
 Footing, Columns, Beams, Mezzanine slab
M30 grade concrete
 Flooring
 Minimum 150mm thick Screed Flooring: Production area
/Machinery Area, passage area and walkway area, Sound
Proof Room, Scrap Room.
 Vitrified Tiles of Size 600x600x10mm thick: Locker room,
Lunch room, Air shower, QC Team, Supervisor room, Officer
507 ABW 343

Part-A DPR
room
 Kota stone flooring 25mm thick : Foreman room,
Rooms 1-8
Toilet areas
 Non-skid joint free ceramic flooring tiles– 300x300x8mm
thick.
 Wall Dadooing with Granite Tile 450x350x8mm.
 Urinal Partition of Size 750 x 500X 18 mm Thick.
below.
Siding
sheet louvers.
drawings plan, elevation, and sections given in drawing volume.
 All inner walls shall be fly ash brick up to the required height.
Doors
Toilet door
Window
birds entry.
Ventilator
 N type Ventilator with 6 mm thick glass, sizes as per drawing
507 ABW 344

Part-A DPR

roofing.
For Mezzanine cover sheet - Single Skin Roofing
 0.5mm thick corrugated roof cover sheet above false ceiling.
False Ceiling Sound Proof room, Lunchroom, Scrap stores, Lockers room,
Q.A. Team room, Q.C. Team room, Officer room, Foreman
rooms, Supervisor rooms, Rooms 1 to Rooms 8.
tapping screws
Finishing Ceiling
Internal
External
507 ABW 345

Part-A DPR

 PU Paint minimum 2.4m Height: Solvent free polyurethane
flexible top coat.
 For rest of the Height: Two Coats of Oil Emulsion white or
approved brand.
Outer side walls
Ceiling
1079-1973, Design as per IS 801-1975)
Water Proofing  Laying of brick bats of size 25mm with cement mortar 1:5
admixed with water proofing compound as per IS 2645 with
required slope and thickness and top covered with
hydraulically pressed burnt clay tile of size
200x200x19/20mm machine made pointing with cement
mortar 1:3 with water proofing compound.
Structural Steel Painting  75 micron thickness Epoxy paint over 75 micron thickness
primer including scraping and cleaning
ventilator oxide zinc chromate primer
Staircase Inner
Grade of steel All Reinforced cement concrete works
 Fe 500 D
507 ABW 346

Part-A DPR

Mix
proofing.
Machine foundation  Machine foundation has to be designed as per the machinery
requirement. Minimum M25 grade concrete with necessary
grouting materials as per the specification of the supplier.
Grade shall be finalized by the vendor based on the

Health faucet
necessary valves.
507 ABW 347

Part-A DPR
FIRE FIGHTING WORKS


fire extinguisher
Underground static water Grade of Concrete RCC M-30 and
storage tank, UG Sump Meet the requirement of 5.1.6 page no 46 of NBC.
hydrant

for sprinklers
507 ABW 348

Part-A DPR
6.3 Field Articulated Vehicle Sub Assembly Group
CIVIL WORKS
Type of Foundation
manufacturer.
 Treating the top surface of filled earth at the rate of 5 litres of
 Treating the soil under plinth protection at the rate of 5 litres
of Chlorpyrifos emulsifiable emulsion per square metre of
surface area.
 Columns, Beams,
M30 grade concrete
 Flooring
 Minimum 150mm thick Screed Flooring :Shot Blasting,
Paint booth, Clutch Assembly section, Gear box section,
Transfer Gear Box Section, Winch Gear box section, Axle
section, Welding section, Hot & Cold Ancillary section,
Caustic washing booth, Steering gear box, Testing section,
Tool room, Scrap stores, Expandable store, Machine shop,
Passage.
507 ABW 349

Part-A DPR

 Vitrified tiles of size 600x600x10mm thick: Locker or
Change room, Office Room, Supervisor room, Discussion
room, QA Team room.
 Kota stone flooring of 25mm thick: Foreman room, Future
expansion
below.
Metal sheet louvers about 3 m height beyond Colour Metal Siding
Sheet Louvers
 All inner walls shall be fly ash brick up to the required height.
Doors
Toilet door
Window
birds entry.
Ventilator
507 ABW 350

Part-A DPR
supported over RCC columns & covered with Double skin
roofing.
 Roofing with Galvalume sheet 0.60 mm thick Galvalume
colour coated sheet.
False Ceiling Future Expansion, Electrical Section, Brake valve & Hoses
section, Officer room, Foreman room, Supervisor room,
Discussion room, Q.A. Team room
Anodized aluminium snap grid frame work of Size of grid 605 x
605mm, Seamless calcium silicate ceiling made out of 1800 x
1200 mm size board, reinforced with cellulose fibre, fixed to the
ceiling section with 25 mm long self drilling and tapping screws
Finishing Ceiling
Internal
External
 PU Paint minimum 2.4 m Height: Solvent free polyurethane
flexible top coat.
approved brand.
Outer side walls
507 ABW 351

Part-A DPR

Ceiling
1079-1973, Design as per IS 801-1975).
Steel ventilator  Two coats of Synthetic Enamel paint over ready mixed red
oxide zinc chromate primer
Grade of steel All Reinforced Concrete works
 Fe 500 D
Mix
proofing.

Health faucet
507 ABW 352

Part-A DPR
necessary valves.
FIRE FIGHTING WORKS
executed strictly as per NBC and as per the need of local fire authorities, besides adherence to
IS codes wherever furnished.

fire extinguisher
hydrant
507 ABW 353

Part-A DPR

for sprinklers
507 ABW 354

Part-A DPR
6.4 Engine Repair Group
CIVIL WORKS
Type of Foundation
manufacturer.
surface area.
 Minimum 150mm thick Screed Flooring :Water wash,
Caustic soda wash, Orion solution bath, Kerosene &
Vibrator, Scrap store, Oil pump & Water pump OH Section,
Cylinder head OH Section, Painting shop, Accessories Drop
OH Section, Fume Extraction system, Engine block OH
Section Repairable Engine Storage, Stripping Area, Welding
section, Passage, Tool room, Starter & Alternator OH
Section, Oil sump OH Section, FIP & Injector Calibration
section ,OSS Store, Storage area for repaired engine
components, Air shower, AHU Unit, Assay 1-6,Repaired
Engine storage
507 ABW 355

Part-A DPR
 Vitrified tiles of size 600x600x10mm thick: QA Team

room, Supervisor room, Change room, QC Team room,
Officer room, supervisor room, Foreman room
Toilet areas
thick.
 Urinal Partition of Size 750 x 500X 18 mm thick polished
granite.
 Mezzanine Floor: Vinyl Tile Finish.
below.

sheet louvers.
Doors
Toilet door
Window
birds entry.
Ventilator
507 ABW 356

Part-A DPR

supported over RCC columns & covered with Double skin
roofing.
For Mezzanine cover sheet - Single Skin Roofing
False Ceiling FIP & Injection calibration, OSS & Store, Storage area for
repaired Engine Components, Passage, QA Team room,
Supervisor rooms, conference hall, lunch room, change
room, Repaired engine storage,Assy+1,2,3,4,5&6,QC Team
room. Officer room, Foreman room
Finishing Ceiling
Internal
External
507 ABW 357

Part-A DPR

flexible top coat.
approved brand.
Outer side walls
Ceiling
Structural steelwork in columns, beams, trusses, purlins,
1079-1973, Design as per IS 801-1975).
Staircase Inner
Grade of steel All Reinforced concrete works
 Fe 500 D
 Columns, Beams, Mezzanine slab
M30 grade concrete
 Flooring
507 ABW 358

Part-A DPR
Electrical Trenches  RCC Trench as per the Requirement.

 RCC Wall 200 mm thick, Base slab 200 mm thick, Finished
with CM 1:3 Mix
proofing.
 Heavy Duty G.I Manhole Cover @ 20m Interval and as per
the requirement.

Health faucet
necessary valves.
507 ABW 359

Part-A DPR
FIRE FIGHTING WORKS

This building falls under G2 (iv) Moderate hazard category as per NBC 2005.The fire suppression

fire extinguisher
hydrant
for sprinklers
507 ABW 360

Part-A DPR
6.5 General Engineering Group
CIVIL WORKS
Type of Foundation
manufacturer.
surface area.
M30 grade concrete
 Flooring
 Minimum 150mm thick Screed Flooring :Lathe Section,
Boring Section, Moulding Section, Special Machine Section,
Space for storage of manufacturing spares, Passage, Lathe
Section, Press section, Cutting Section, Raw Material Store,
Retained machines, Milling Section, Drilling section, Grinding
Section, Welding Section, Wood Section.
507 ABW 361

Part-A DPR

 Vitrified Tiles 600x600x10mm size: Locker /Change room,
Foreman, Supervisor, Conference hall, Computer room,
Officer room (AC)
 22mm thick Precast Cement Concrete Tiles: Ramp
Toilet areas
thick.
granite.
Service Area
 Flooring with Kota Stone Finish.
below.
Fly ash brick work in C.M 1:5,230mm thick about 5.0m height.
Sheet Siding
Colour metal sheet siding up to bottom of gutter level beyond
Metal sheet louvers.
All inner walls shall be Fly ash brick up to the required height.
Doors
Toilet door
Window
507 ABW 362

Part-A DPR
birds entry.
Ventilator
roofing.
fabricated from galvanized steel sheets; minimum throat
mechanical control dampers, at 6m interval.
False Ceiling  Anodized aluminium snap grid frame work of Size of grid
tapping screws.
Finishing Ceiling
 Plastering with CM 1:3 10 mm Thick
Internal
 Plastering with CM 1:4 minimum 12 mm Thick
External
 Plastering with CM 1:4 minimum 20 mm Thick applied with
507 ABW 363

Part-A DPR
three coat plastering (10mm+5mm+5mm thick).

flexible top coat.
approved brand.
Outer side walls
Ceiling
1079-1973, Design as per IS 801-1975).
Staircase Inner
 Fe 500 D
with CM 1:3 Mix
507 ABW 364

Part-A DPR

proofing.
the requirement.

Health faucet
necessary valves.
507 ABW 365

Part-A DPR
FIRE FIGHTING WORKS


fire extinguisher
hydrant
for sprinklers
507 ABW 366

Part-A DPR
6.6 Ancillary Shed
CIVIL WORKS
Type of Foundation
finalized by the vendor after detailed soil investigation.
manufacturer.
surface area.
M30 grade concrete
 Flooring
 Minimum 150mm thick Screed Flooring :Electroplating
shop, Smithy shop/Heat Treatment Section,Retained
Machines, Centre of excellence, Carpentry, Testing Section,
Machine shop, Store rooms.
507 ABW 367

Part-A DPR

 Vitrified Tiles of size 600x600x10mm size: Supervisor
room, Office I/C, Lunch room
Toilet areas
thick.
Urinal Partition of Size 750 x 500X 18 mm thick Polished granite
Service Area
 Flooring with Kota Stone Finish
below.
Fly ash brick work in C.M 1:5,230mm thick up to bottom of gutter
level.
Doors
Toilet door
Window
birds entry.
Ventilator
507 ABW 368

Part-A DPR

roofing.
False Ceiling Store & office cabin, Store & lunch room, Testing section
Finishing Ceiling
Internal
External
flexible top coat.
approved brand.
507 ABW 369

Part-A DPR
Outer side walls

Ceiling
1079-1973, Design as per IS 801-1975).
Staircase Inner
Grade of steel All Reinforced Concrete works
 Fe 500 D
with CM 1:3 Mix
proofing.
the requirement.
507 ABW 370

Part-A DPR

Health faucet
necessary valves.
FIRE FIGHTING WORKS


fire extinguisher
507 ABW 371

Part-A DPR

hydrant
for sprinklers
507 ABW 372

Part-A DPR
6.7 Workshop Expenses Stores / Battery Charging Section
CIVIL WORKS
Type of Foundation
manufacturer.
surface area.
M30 grade concrete
 Flooring
 Minimum 150mm thick Screed Flooring :Work shop
expense store
 Vitrified Tiles of size 600x600x10mm size: Office room,
R & I Officer, Supervisor
 Kota stone Flooring 25mm Thick: Battery charging shop,
507 ABW 373

Part-A DPR
Consumable store, Spare store

Toilet areas
thick.
Urinal Partition of Size 750 x 500X 18 mm thick Polished granite
Service Area
below.
level.
Doors
Toilet door
Window
birds entry.
Ventilator
Lift  Hydraulic Lift of ISI make with Capacity for minimum 6
Persons of not less than 450 kg has to be provided.
507 ABW 374

Part-A DPR

roofing.
False Ceiling Store & office cabin, testing section
Finishing Ceiling
Internal
External
 Plastering with CM 1:4 minimum 20 mm Thick applied
with three coat plastering (10mm+5mm+5mm thick).
flexible top coat.
approved brand.
507 ABW 375

Part-A DPR
Outer side walls

Ceiling
1079-1973, Design as per IS 801-1975).
Staircase Inner
Grade of steel All Reinforced Concrete Works
 Fe 500 D
with CM 1:3 Mix
proofing.
the requirement.
507 ABW 376

Part-A DPR

Health faucet
necessary valves.
FIRE FIGHTING WORKS

This building falls under J1 (ii) hazardous (High) category as per NBC 2005.The fire suppression

fire extinguisher
507 ABW 377

Part-A DPR

hydrant
for sprinklers
507 ABW 378

Part-A DPR
6.8 Body Repair Group
CIVIL WORKS
Type of Foundation
manufacturer.
surface area.
 Columns, Beams
M30 grade concrete
 Flooring
 Minimum 150mm thick Screed Flooring :Raw material
store, Scrap store, Welding shop, Machine shop, Painting
booth, Testing section, Passage, Shot Blasting section,
Sheet metal shop, Carpentry section, Upholstery, Electrical
section, Consumable store, OSS Store, Tool room.
507 ABW 379

Part-A DPR
 Vitrified tiles of size 600x600x10mm thick: Locker /

Change room, Dining hall, Supervisor room, officer room
 Kota stone flooring of 25mm thick: Fore man room
 Ramp - Chequered precast concrete tiles 22mm thick.
Toilet areas
thick.
granite.
Service Area
below.
Siding
sheet louvers.
All inner walls shall be Fly ash brick up to the required height
Doors
Toilet door
Window
birds entry.
Ventilator
507 ABW 380

Part-A DPR

roofing.
False Ceiling Officer room, Supervisor room, Foreman room and Dining.
tapping screws
Finishing Ceiling
Internal
External
507 ABW 381

Part-A DPR

flexible top coat.
approved brand.
Outer side walls
Ceiling
1079-1973, Design as per IS 801-1975).
 Fe 500 D
Expansion Joint  Strip seal expansion joints are provided.

507 ABW 382

Part-A DPR

Health faucet
necessary valves.
FIRE FIGHTING WORKS


fire extinguisher
507 ABW 383

Part-A DPR

hydrant
for sprinklers
507 ABW 384

Part-A DPR
6.9 Engine Test House
CIVIL WORKS
Type of Foundation  Open Foundation: However the type of foundation shall be
Grade of concrete  M20 & M25 Grade for other RCC Works.
Grade of steel  Fe 500 D.
Basement Height  0.60m from Finished Road Level and as per drawing.
Basement filling  Filled with Murom/Bajiri.
Type of Flooring  Ramp and passage - Chequered precast concrete tiles 22mm.
 Tools stores, Fuel Oil stores - Machine cut Kota stone slab
flooring 25mm thick.
 Washbasin– Granite Flooring – 25mm thick.
 Granite stones on nosing of stairs with minimum three
horizontal grooves
 QA Staff, foreman room, supervisor room, R & I - Vitrified
Ceramic Tiles Size -600x600x10mm thickness.
 Engine Test beds: Hardener flooring such as Ironic flooring of
minimum 50mm thick.
 Toilet Flooring- Non-skid ceramic flooring tiles – 300x300x8mm
thick.
 Toilet Wall Dadooing up to 2.1m height –Glazed Ceramic tiles
Size-350x250x7 & 450x350x7mm.
 PVC corner beading
Plinth protection:  Plinth Protection 1.20m Width all around the Building using M20
concrete 150mm thick top finished with necessary slope to
drain the rain water.
Type of Super Structure  Fly ash Bick work in CM 1:5 mix - 230mm thick
Type of Joineries  Doors:
 Sound Proof Steel Single/Double Leaf Puff Door, sizes as
per drawing
 Pressed steel frames of Factory made and ISI approved –
165x60mm & Flush shutters of BWR quality of ISI standards –
40mmthick with both faces are covered with decorative face
veneer with lipping.
507 ABW 385

Part-A DPR
Window
 Aluminium window with suitable grills to prevent monkey / birds
entry.
 Ventilator
 N type Ventilator with 6 mm thick glass, sizes as per drawing
 Toilet door: Flush shutters, solid core construction, with block
board core and plywood face panels, commercial type on both
sides.30mm thick & both faces are covered with decorative
face veneer with lipping / frame to match ® 30mm thick &
Pressed steel frames 125 x 60mm size.
Sound Proofing  The test cabins / test house / test cells / cubicals shall be sound
proof / Acoustic System comprising of:-(Maximum Permissible
noise should be 70dcb)
 Sound Proof wall and ceilings.
 Sound lock cabin of 3.0m x 5.0m x 4.7m ht.
 Sound proof door of 4 x 5.9m.
 Operator door of 1m x 2.2m
 The inside wall of the rooms shall be covered with sound proof
panels to with stand the sound produced by the Engine. It shall
be double skin made of minimum 20mm thick panels with rock
wool as in fill / insulation materials.
 The overall thickness of the panel including infill and internal
sheet material shall be around 100mm thick.
 The panels shall be stable and solid with minimum movement
or vibration in any direction.
 The sound proof panels should resist action of usual cleaning
agents (detergents and disinfectants) used in pharmaceutical
industry
 The door of the test cabins/ test cells /cubicals will be 4m (L) x
6m (H) for smooth feeding of the engine assys on the test
beds of testing. The thickness of doors will be sound proofing
material should be 25mm and double steel / iron doors (2.2m
each)
 Covered drainage with close grills shall be provided inside the
test beds.
Roof height (clear)  7.00m (GFL to FFL).
507 ABW 386

Part-A DPR
 3.6m (FFL to Terrace Floor Level)
Water Proofing on terrace Laying of brick bats of size 25mm with cement mortar 1:5
Hydraulically pressed burnt clay tile of size 200x200x19/20mm
machine made pointing with cement mortar 1:3 with water proofing
compound.
Type of Roofing  RCC Roof Slab
Finishing  Ceiling & Internal wall plastering in CM 1:4 mix – 10/minimum
12mm thick.
 External wall plastering in CM 1:4 mix – minimum 20mm thick.
Ceiling  Officer room, Foreman room, Supervisor room, R & I:
Anodized aluminium snap grid frame work for false ceiling all
as specified Size of grid 605 x 605mm. Seamless calcium
silicate ceiling made out of 1800 x 1200 mm size board.
Painting  Inside: Two Coats of Oil Emulsion white or tinted, over one
coat of water thinnable cement primer of approved brand.
 Ceiling: Distempering walls with distemper dry, white or tinted
and over base coat of water proofing cement paint.
 Outside: Two coats of Acrylic Smooth exterior paint over base
coat of water proofing cement paint.
 Steel and Iron surfaces : Synthetic Enamel paint
Miscellaneous  Entrance & Staircase: Stainless steel handrail

Health faucet
necessary valves.
507 ABW 387

Part-A DPR
FIRE FIGHTING WORKS

This building falls under J1 (ii) hazardous (High) category as per NBC 2005.The fire suppression

fire extinguisher
hydrant
507 ABW 388

Part-A DPR

for sprinklers
507 ABW 389

Part-A DPR
6.10 Caustic Soda Washing
CIVIL WORKS
Type of Foundation
manufacturer.
surface area.
 Minimum 150mm thick Screed Flooring in Washing area,
Production area /Machinery Area, passage area and
walkway area.
Toilet areas
thick.
507 ABW 390

Part-A DPR

granite.
Service Area
below.
Siding
sheet louvers.
 All inner walls shall be Fly ash brick up to the required height.
Doors
Toilet door
Window
birds entry.
Ventilator
supported over RCC columns & covered with single skin
roofing.
Type of Roofing Single Skin Roofing:
507 ABW 391

Part-A DPR

For Office and Foreman rooms cover sheet - Single Skin
Roofing

Finishing Ceiling
Internal
External
flexible top coat.
approved brand.
Outer side walls
Ceiling
507 ABW 392

Part-A DPR

1079-1973, Design as per IS 801-1975).
ventilator oxide zinc chromate primer.
 Fe 500 D
 Columns, Beams
M30 grade concrete
 Flooring

Health faucet
necessary valves.
507 ABW 393

Part-A DPR
FIRE FIGHTING WORKS
This building falls under G1 (I) LOW hazard category as per NBC 2005.The fire suppression

fire extinguisher
hydrant
for sprinklers
507 ABW 394

Part-A DPR
6.11 OSS Stores, MCO Stores & KRAZ Stores
CIVIL WORKS
Type of Foundation
manufacturer.
surface area.
 Columns, Beams
M30 grade concrete
 Flooring
 Minimum 150mm thick Screed Flooring :Conventional
system
 Vitrified tiles of size 600x600x10mm thick: Lunch room,
OSS I/C Room (AC), MCO I/C Room (AC), MCO Office Staff
room, Lunch room.
507 ABW 395

Part-A DPR
 22mm thick chequered precast concrete tiles: Ramp

Toilet areas
thick.
granite.
Service Area
below.
level.
Doors
Toilet door
Window
birds entry.
Ventilator
Roof height (clear)  14.30 m (From GFL to Truss Bottom Level).
Lift  Hydraulic Lift of ISI make with Capacity for minimum 6
507 ABW 396

Part-A DPR
Persons of not less than 450 kg has to be provided.

roofing.
Roofing

Finishing Ceiling
Internal
External
flexible top coat.
approved brand.
Outer side walls
507 ABW 397

Part-A DPR

Ceiling
1079-1973, Design as per IS 801-1975).
 Fe 500 D

Health faucet
necessary valves.
507 ABW 398

Part-A DPR

FIRE FIGHTING WORKS

fire extinguisher
hydrant
for sprinklers
507 ABW 399

Part-A DPR
6.12 Vehicle Stripping Shed
CIVIL WORKS

Type of Foundation
manufacturer.
surface area.
 Columns, Beams
M30 grade concrete
 Flooring
below.
Siding
sheet louvers.
507 ABW 400

Part-A DPR

Type of Joineries Toilet door
Window
birds entry.
Ventilator
roofing.
For Stripping Area cover sheet - Single Skin Roofing
False Ceiling  Supervisor Room : Anodized aluminium snap grid frame
work of Size of grid 605 x 605mm, Seamless calcium
silicate ceiling made out of 1800 x 1200 mm size board,
reinforced with cellulose fibre, fixed to the ceiling section with
25 mm long self drilling and tapping screws
507 ABW 401

Part-A DPR
Finishing Ceiling
Internal
External
flexible top coat.
approved brand.
Outer side walls
Ceiling
1079-1973, Design as per IS 801-1975).
 Fe 500 D
Expansion Joint  Strip seal expansion joints are provided.
507 ABW 402

Part-A DPR

Health faucet
necessary valves.
FIRE FIGHTING WORKS

fire extinguisher
507 ABW 403

Part-A DPR

hydrant
for sprinklers
507 ABW 404

Part-A DPR
6.13 Engineer Equipment Stripping and Sub Assembly Group
CIVIL WORKS
Type of Foundation
drawing, filled with Murom/Bajiri
manufacturer.
surface area.
 Columns, Beams
M30 grade concrete
 Flooring
below.
Siding
sheet louvers.
507 ABW 405

Part-A DPR

Doors
Toilet door
Window
birds entry.
Ventilator
Mezzanine Level  5.90m From FFL
roofing.
Roofing

507 ABW 406

Part-A DPR
False Ceiling  Mezzanine Floor : Anodized aluminium snap grid frame

work of Size of grid 605 x 605mm, Seamless calcium
silicate ceiling made out of 1800 x 1200 mm size board,
reinforced with cellulose fibre, fixed to the ceiling section with
25 mm long self drilling and tapping screws
Finishing Ceiling
Internal
External
flexible top coat.
approved brand.
Outer side walls
Ceiling
1079-1973, Design as per IS 801-1975).
507 ABW 407

Part-A DPR

 Fe 500 D
Expansion Joint  Strip Seal Expansion Joints are provided
with CM 1:3 Mix
proofing.
the requirement.
Miscellaneous  Staircase: Stainless steel handrail

Urinal flush valve, Flush valve, Bip The Product Shall be from approved Vendors.
cock, Angle valve, Mirror, Health
faucet
necessary valves.
507 ABW 408

Part-A DPR

FIRE FIGHTING WORKS

This building falls under G-2 (iv) Moderate hazard category as per NBC 2005.The fire suppression
Fire Extinguisher: Water type fire As per IS 15683

extinguisher, Dry powder fire
extinguisher
Underground static water storage Grade of Concrete RCC M-30 and meet the requirement of 5.1.6
tank, UG Sump page no 46 of NBC.
Double head coupling for hydrant As per IS 901/1988.

Ring main for External & internal ‘C’ Class heavy duty MS Pipe conforming to IS 3589.
hydrants and Ring main for
sprinklers
507 ABW 409

Part-A DPR
6.14 Outer Traffic Stores
Basement filling  Filled with Murom/Bajiri filling

Type of Flooring  Store room- Machine cut Kota stone slab flooring 25mm
thick.
 Ground Floor : LPO Room,
: Vitrified Ceramic Tiles Size -600x600x10mm thickness.
 Toilet Flooring - Non-skid ceramic flooring tiles –
300x300x8mm thick.
 Toilet Wall Dadooing up to 2.1m height –Glazed Ceramic
tiles Size-350x250x7 & 450x350x7mm.
PVC corner beading  PVC corner beading
Plinth Protection  Plinth Protection 1.20m Width all around the Building using
Type of Super Structure  Fly ash Bick work in CM 1:5 mix - 230mm thick
Type of Joineries  Doors: Pressed steel frames of Factory made and ISI
approved – 165x60mm & Flush shutters of BWR quality of
ISI standards – 40mmthick with both faces are covered with
decorative face veneer with lipping.
 Windows: Aluminium window with suitable grills to prevent
monkey / birds entry.
 Ventilators : N type Ventilator with 6 mm thick glass, sizes
as per drawing
 Toilet door: Flush shutters, solid core construction, with
block board core and plywood face panels, commercial type
on both sides.30mm thick & both faces are covered with
decorative face veneer with lipping / frame to match ® 30mm
thick & Pressed steel frames 125 x 60mm size.
Roof height (clear)  3.60m (FFL to Top of Roof slab).
507 ABW 410

Part-A DPR
Finishing  Ceiling & Internal wall plastering in CM 1:4mix minimum
10/12mm thick.
 External wall plastering in CM 1:4 mix minimum 20mm
thick.(1st coat 10mm, 2nd coat 5mm, 3rd Coat 5mm)
Ceiling  Ground Floor : LPO Room
; Anodized aluminium snap grid frame work for false
ceiling all as specified Size of grid 605 x 605mm.
Seamless calcium silicate ceiling made out of 1800 x
1200 mm size board
Painting  Ceiling: Distempering walls with distemper dry, white or
tinted and over base coat of water proofing cement paint.
 Inside: Two Coats of Oil Emulsion white or tinted, over one
coat of water thinnable cement primer of approved brand.
 Outside: Two Coats of Acrylic Smooth exterior paint over
base coat of water proofing cement paint.
 Steel and Iron surfaces : Synthetic Enamel paint
Miscellaneous  Entrance & Staircase: Stainless steel handrail

Health faucet
necessary valves.
507 ABW 411

Part-A DPR
Granite Wash Basin-Sink, Porcelain Wash The Supply shall be as per the product from the
Basin, Waste Coupling, Bottle trap, Trash, approved vendor or its equivalent
Cleanout plug, Peg set, European Water
closet, Indian Water Closet, Paper Holder,
Urinal, Floor Trap, Urinal Trap, Cockroach
Trap, Hand Drier
through inspection chamber and gully trap.
FIRE FIGHTING WORKS
This building falls under E1 LOW hazard category as per NBC 2005.The fire suppression

extinguisher
Manually Operated Fire Alarm System As per approved vendors.
Underground static water storage tank, Grade of Concrete RCC M-30 and meet the
UG Sump requirement of 5.1.6 page no 46 of NBC.
Ring main for External & internal
‘C’ Class heavy duty MS Pipe conforming to IS 3589.
hydrants and Ring main for sprinklers
507 ABW 412

Part-A DPR
6.15 Scrap yard
Description Specifications
 Open Foundation: However the type of foundation shall be
Type of Foundation
M30 grade concrete
 Flooring
level
All inner walls shall be Fly ash brick up to the required height
Roof height (clear)  5.00 m (From FGL to Truss Bottom Level).
supported over RCC columns & covered with Single skin
roofing.
0.5mm thick corrugated roof cover sheet above false ceiling.
Finishing Ceiling
Plastering with CM 1:4 minimum 10 mm thick.
Internal
Plastering with CM 1:4 minimum 12 mm thick.
External
507 ABW 413

Part-A DPR

 PU paint Minimum 2.4m height: Solvent free polyurethane
flexible top coat.
approved brand.
Outer side walls
Ceiling
1079-1973, Design as per IS 801-1975).
Grade of steel All Reinforced Concrete Works
 Fe 500 D
Mix
proofing.
507 ABW 414

Part-A DPR

507 ABW 415

Part-A DPR
6.16 Compressor Room (1&2)
Type of Foundation Open Foundation :However the type of foundation shall be

Grade of concrete M20 & M25 Grade for other RCC Works.
Grade of steel Fe 500 D.
Basement Height 0.60m from formation Ground Level.
Basement filling Filled with Murom /Bajiri.
Type of Flooring Compressor room- Reinforced Cement Concrete Flooring

150mm thick.
Ramp: Chequered Precast concrete tiles -22mm thick
Type of Super Structure Fly ash Brick work in CM 1:5 mix - 230mm thick
Type of Joineries Doors: Pressed steel frames of Factory made and ISI approved
– 165x60mm & Flush shutters of BWR quality of ISI standards –
40mmthick with both faces are covered with decorative face
veneer with lipping.
Window
Aluminium window with suitable grills to prevent monkey / birds
entry.
Ventilator
N type Ventilator with 6 mm thick glass, sizes as per drawing.
Toilet door: Flush shutters, solid core construction, with block
board core and plywood face panels, commercial type on both
sides.30mm thick & both faces are covered with decorative face
veneer with lipping / frame to match ® 30mm thick & Pressed
steel frames 125 x 60mm size.
Roof height (clear) 5.6m (FFL to Top of Roof slab).
Type of Roofing RCC Roof Slab
507 ABW 416

Part-A DPR
Water Proofing on terrace Laying of brick bats of size 25mm with cement mortar 1:5
Hydraulically pressed burnt clay tile of size 200x200x19/20mm

machine made pointing with cement mortar 1:3 with water
proofing compound.
Finishing Ceiling & Internal wall plastering in CM 1:3 mix – 10/minimum

12mm thick.
External wall plastering in CM 1:4 mix – Minimum 20mm thick.
Painting Inside: Two Coats of Oil Emulsion white or tinted, over one coat
of water thinnable cement primer of approved brand.
Ceiling: Distempering walls with distemper dry, white or tinted
and over base coat of water proofing cement paint.
Outside: Acrylic Smooth exterior paint over base coat of water
proofing cement paint.
Steel and Iron surfaces : Synthetic Enamel paint
Urinal flush valve, Flush valve, The Product Shall from approved Vendors.
Health faucet
necessary valves.
Granite Wash Basin-Sink, The Supply shall be as per the product from the approved vendor
Porcelain Wash Basin, Waste or its equivalent
507 ABW 417

Part-A DPR

The outgoing line from various sanitary fixtures has to be connected with external sewer system through
inspection chamber and gully traps.
FIRE FIGHTING WORKS
This building falls under G 2-(i)-Moderate hazard category as per NBC 2005.The fire suppression
requirement as per NBC and IS are furnished below with code numbers. This work has to be executed
strictly as per NBC and as per the need of local fire authorities, besides adhering to IS codes wherever
furnished.

fire extinguisher


hydrant
for sprinklers
507 ABW 418

Part-A DPR
6.17 Overhauled Vehicle Paring 1
Kerb wall
Type of Foundation
 M25 grade concrete.
ANTI-Termite Treatment  Treat backfill and basement of foundation with
Chloropyriophos emulsifiable emulsion at the rate
recommended by the manufacturer.
Chloropyriophos emulsifiable emulsion per square metre of
of Chloropyriophos emulsifiable emulsion per square metre
of surface area.
the rate of 2.25 litre of Chloropyriophos emulsifiable
emulsion per metre of the perimeter wall.
Type of Flooring Main Parking area
Screed Flooring
 I st layer - Sub grade 300 mm thick
 II nd layer -Granular Sub Base 150 mm thick.
 III rd layer - Steel mesh 8 dia 200 c/c both ways.
 IV th layer - RCC M30 Grade Concrete and Leveled with
Power trowel.
Type of Super Structure  Tubular section as per drawing
Roof height (clear)  5.0 m (From FFL to Truss Bottom Level)
Roofing system  Tubular Section covered with Single Skin Roofing.
 0.6mm thick Galvalume colour coated sheet.
Structural Steel I. S.1161-1979 grade St.-240 quality

 Steel work in tubular trusses including special shaped
washer etc
507 ABW 419

Part-A DPR
galvanized iron as per IS 811, Material property as per IS

1079-1973, Design as per IS 801-1975).
Structural Steel Painting  Structural Steel
 Epoxy paint over one coat of primer.
 Fe 500 D
 Kerb wall
M30 grade concrete
 Flooring
FIRE FIGHTING WORKS


extinguisher
Manually Operated Fire Alarm As per approved vendors.
System
Underground static water storage Grade of Concrete RCC M-30 and meet the requirement of
tank, UG Sump 5.1.6 page no 46 of NBC.
507 ABW 420

Part-A DPR
Ring main for External & internal ‘C’ Class heavy duty MS Pipe conforming to IS 3589.
hydrants and Ring main for
sprinklers
6.18 Chassis Dynamometer
Basement filling  Filled with Murom/Bajiri.
Type of Flooring  Office Room- Machine cut Kota stone slab flooring 25mm
thick.
 Ramp, Chassis Dynamometer Room - Chequered precast
concrete tiles 22mm thick.
Type of Super Structure  Fly ash Brick work in CM 1:5 mix - 230mm thick
Type of Joineries  Rolling Shutter: Steel Rolling Shutter
 Windows/ Ventilators: Aluminium window with suitable grills
to prevent monkey / birds entry.
Roof height (clear)  5.00m (FFL to Top of Roof slab).
Finishing  Ceiling & Internal wall plastering in CM 1:4 mix minimum
10/12mm thick.
 External wall plastering in CM 1:4 mix minimum 20mm thick.
507 ABW 421

Part-A DPR
Painting  Inside: Distempering walls with distemper dry, white or

tinted and over base coat of water proofing cement paint.
 Outside: Two or more coats Acrylic Smooth exterior weather
shield paint over one coat of water proofing cement paint.
Miscellaneous  Entrance & Staircase - Hand rails for wooden and half round
with support steel balusters.
FIRE FIGHTING WORKS

This building falls under G1-a-(i) LOW hazard category as per NBC 2005.The fire suppression
extinguisher, Dry powder fire extinguisher
Underground static water storage tank, UG Grade of Concrete RCC M-30 and meet the
Sump requirement of 5.1.6 page no 46 of NBC.
Ring main for External & internal hydrants ‘C’ Class heavy duty MS Pipe conforming to IS 3589.
and Ring main for sprinklers
507 ABW 422

Part-A DPR
6.19 Repairable Vehicle Parking 1&2
Kerb wall
Type of Foundation
 M25 grade concrete.
ANTI-Termite Treatment  Treat backfill and basement of foundation with
Chloropyriophos emulsifiable emulsion at the rate
recommended by the manufacturer.
Chloropyriophos emulsifiable emulsion per square metre of
of Chloropyriophos emulsifiable emulsion per square metre
of surface area.
the rate of 2.25 litre of Chloropyriophos emulsifiable
emulsion per metre of the perimeter wall.
Type of Flooring Main Parking area
Screed Flooring
 I st layer - Sub grade 300 mm thick
 II nd layer -Granular Sub Base 150 mm thick.
 III rd layer - Steel mesh 8 dia 200 c/c both ways.
 IV th layer - RCC M30 Grade Concrete and Leveled with
Power trowel.
Type of Super Structure  Tubular section as per drawing
Roof height (clear)  5.00 m (From FFL to Truss Bottom Level)
Roofing system  Tubular Section covered with Single Skin Roofing.
 0.6mm thick Galvalume colour coated sheet.
Structural Steel I. S.1161-1979 grade St.-240 quality

 Steel work in tubular trusses including special shaped
washer etc
galvanized iron as per IS 811, Material property as per IS
507 ABW 423

Part-A DPR
1079-1973, Design as per IS 801-1975).

Structural Steel Painting  Structural Steel
 Epoxy paint over one coat of primer.
 Fe 500 D
 Kerb wall
M30 grade concrete
 Flooring
Note - 1
Turbo Ventilator - Industrial Hi-Grade 600mm dia Aluminium vane gravity type turbo vent as per drawing
Note - 2
Toilet Arrangements
i. The recommended flooring materials, Water proof materials and quantities for all toilets are the
minimum requirements. However LSTK contractor shall employ, if any additional provisions
required based on the discussion with the client and Engineer in Charge without any extra cost.
ii. LSTK contractor shall be carried out, If any internal modification suggested by the client /
Engineer in Charge, without any extra cost
iii. Necessary shop drawings include the internal fixtures and arrangements of wall tiles etc., it shall
be submitted by contractor and get approved from Engineer in Charge / Client before execution.
Moreover, Toilets in Mezzanine floor shall be provided with proper arrangements of sunken and water
proofing materials by the LSTK contractor as per the client requirements
507 ABW 424

Implementation Strategy
Part - A DPR
507-ABW IMPLEMENTATION STRATEGY PART - A - NEW BUILDINGS TO BE CONSTRUCTED (PROCESS)
YEAR - I
12 Demolition RFBD in Shifting Built up Cost in
BUILDINGS 1 2 3 4 5 6 7 8 9 10 11 REMARKS
Months In Sq.M Sq.M in Sq.M area in Sq crores
UC-01 Workshop service group Occupation of the building 2107.00
UC-02.MCO Building/Over Hauled Vehicle Parking Occupation of the building 776.00
TIN 04 Engine repairgroup Construction & Occupation of new building 2493.00 2493.00 8.45
TIN -08 Body repair group Construction & Occupation of new building 2125.00 2125.00 5.69
TIN 09 Engine test house Construction & Occupation of new building 2882.00 2882.00 7.36
TIN 13 Engineer Equipment Stripping / sub assembly group Construction & Occupation of new building 2262.00 2262.00 5.67
TIN- 14 Outer traffic store Construction & Occupation of new building 103.20 103.20 0.34
TSIN -11OHT & TSIN -13 UG Sump-2& Over head tank ,TSIN 09-UG sump
Construction & Occupation of new building 506.81 506.81 5.75
1& OHT For ETH with Distribution net Work System
TSIN-10 -Scrap yard Construction & Occupation of new building 400.00 400.00 0.47
OBD 89 kraz group shifted in this shed temporarily

AIN -15 Over hauled vehicle parking(11 Nos) 540.00 540.00 0.55
with 20Tcrane.
AIN -16 Chassis Dynamometer Construction & Occupation of new building 224.00 224.00 0.39
Power Back up ,Electrical Safety Equipments & Rectifier Unit Installation 1.20
Compressor room - 1&2 & Pneumatic lines 1.43
SHIFTING OF MACHINERIES FROM OLD BUILDINGS

OBD 05 closed vehicle parking Shed no 9. Existing parking to be shifted to open area. 2520
OBD-89 Kraz group Shifted to AIN -15 Over hauled
(OBD-89) Kraz group 2314
vehicle parking
OBD-37 Guard office & OBD-39 Guard room. OBD-36 guard room & OBD-
shifted to open space 267
38 Cycle stand.
OBD 90 Cabin repair section Cabin repair section shifted to Old OTRP 642
OLD BUILDINGS TO BE DEMOLISHED
OBD 80 Water reservoir & OBD 81 Shed Demolition 34 0.003
OBD 05 closed vehicle parking Shed no 9. Demolition 2520 0.233
(OBD-89) Kraz group Demolition 2314 0.255
OBD 90 Cabin repair section Demolition 642 0.060

OBD -8 Toilet, OBD -9 Toilet ,OBD 10 Kraz blacksmith, OBD 82 Water
Demolition 492 0.047
tank,OBD 83 Building, OBD -06 Abonded
OBD 76 Water reservoir,OBD 77Caustic soda,OBD 78 shed,OBD-74,OBD
75.
OBD-37 Guard office & OBD-39 Guard room. OBD-36 guard room & OBD-
38 Cycle stand.
OBD 65-66,67,68,69 Toilet Demolition 35 0.002
OBD 48 cycle shed,OBD 85 guard room Demolition 600 0.056
AREA COST AREA COST
- Shifting 17098 0.507 - Refurbishment - -
- Demolition 7266 0.719 - Construction 11536.01 37.3
507 ABW Mukesh & Associates

Part - A DPR
YEAR - II
12 Demolition RFBD Shifting in Builtup area cost in
BUILDINGS 1 2 3 4 5 6 7 8 9 10 11 REMARKS
Months in Sq .M in Sq .M Sq .M in Sq .M crores
TIN 01 Engineer equipment assembly group Construction 4197.00 8.83
TIN 02 Field articulated vehicle assembly group Construction 6410.00 18.56
TIN 03 Field articulated vehicle sub assembly group Construction 3662.00 10.68
TIN 07 Workshop Expense store & battery charging station Construction & Occupation of new building 600.00 600.00 1.82
TIN 10Caustic soda washing Construction & Occupation of new building 200.00 200.00 0.77
TIN 12 Vehicle stripping Construction & Occupation of new building 750.00 750.00 2.83
AIN 18 Repairable vehicle parking -2 (15 nos) Construction & Occupation of new building 880.00 880.00 0.64

OBD 3 MCO group MCO group shifted to old OBD 19 MCO store 3832.00
OBD 13 Engine wash bay Engine wash shifted to new Engine repair group 228.00
Compressor facilities shifted to new compressor room, GM production

OBD 14 Central compressor,OBD 15 G.M production, OBD 16 shed,OBD 17EMS 295.00
shifted to old Admin building
OBD 32Electroplating/blacksmith&copper smith,OBD33Moulding & OBD 43 shed Temporarily Shifted to AIN 15 Over hauled vehicle parking 989.35
OBD 3 MCO group Demolition 3832.00 0.36
OBD 2 Engine repair group Demolition 3832.00 0.55
OBD 04 Body repair section Demolition 4522.00 0.42

OBD 88 Engine test house OBD 73 water reservoir,OBD 86 guard room,OBD 87
Demolition 622.00 0.02
Cycle shed
OBD 13 Engine wash bay Demolition 228.00 0.02
OBD 14 Central compressor,OBD 15 G.M production, OBD 16 shed,OBD 17EMS Demolition 295.00 0.03
OBD 11 building,OBD 12 Guard room Demolition 42.00 0.00
OBD 46 EST office Demolition 390.67 0.05
OBD 31 MT parking shed &OBD 28 shed Demolition 441.94 0.04
OBD 45 Security office Demolition 103.00 0.01

OBD 44 shed,OBD 47 shed,OBD 84 BEDI, OBD 59 BEDI,OBD 60, OBD 61,OBD
Demolition 236.39 0.02
62,OBD 63 BEDI
OBD 30 Commandant office Demolition 169.00 0.02
OBD 42Canteen Demolition 582.15 0.06
OBD 32Electroplating/blacksmith&copper smith,OBD33Moulding & OBD 43 shed Demolition 989.35 0.09
OBD 40 Labour room,OBD 41 shed Demolition 138.51 0.01
OBD 34-Guard room,OBD 35 Building,OBD 79 Toilet ,OBD 34 fire station Demolition 273.59 0.02
AREA COST AREA COST
- Shifting 6594.35 0.195 - Refurbishment - -
- Demolition 16697.60 1.72 - Construction 16699.00 45.53

Part - A DPR
YEAR - III
12 Builtup
Demolition RFBD in Shifting in Cost in
BUILDINGS 1 2 3 4 5 6 7 8 9 10 11 Month REMARKS area in Sq
in Sq .M Sq .M Sq .M crores
s .M
TIN 11 OSS, MCO& KRAZ stores Construction 3200.00 10.78
AIN 17 Repairable Vehicle parking shed-1 Construction&Occupation of the building 880.00 880.00 0.64
Assembly integration testing facility Construction 3.80
Inventory Storage and Management Installation 3.60
TIN 01 Engineer equipment assembly group Occupation of new building 4197.00
Old Kraz group & Field articulated vehicle assembly facility shifted to new
TIN 02 Field articulated vehicle assembly group 6410.00
building
TIN 03 Field articulated vehicle sub assembly group Construction & Occupation of new building 3662.00
Machine shop shifted to AIN 15 Over hauled vehicle parking temporarily

OBD 1 Machine shop 2815.00
and will be there until the year 2019 last quarter.
OBD 19 MCO Store MCO store shifted to Machine shop& then demolition 2584.96
OBD 20 Kraz store Kraz store shifted to Machine shop& then Demolition 3012.04
OBD 07 Battery Charging shop, OBD 21& 22 Shed Battery charging shifted to TIN 07 WES/ battery charging. 338.94
OBD 23 painting decorator,Carpenter upholster,pattern making. Shifted to TSIN 10 Salvage dump tempoarily &thenDemolition 360.22
OBD 27 Car parking Shifted to TSIN 04 fire station temporarily. 59.22

OBD 27 Car parking Demolition 59.22 0.01
OBD 29 Kote Demolition 155.23 0.05
OBD 19 MCO Store Demolition 2584.96 0.24
OBD 20 Kraz store Demolition 3012.04 0.28
OBD 07 Battery Charging shop, OBD 21& 22 Shed Demolition 338.94 0.03
OBD 23 painting decorator,Carpenter upholster,pattern making. Demolition 360.22 0.03
OBD 24 Ladies lunch room - OBD25 recreation room Demolition 416.78 0.04
OBD 57 Administration blocks& OBD 58& OBD 26 Demolition 1047.77 0.08
OBD 49,OBD 50,OBD 51,OBD 52,OBD 53,OBD 54,OBD 55,OBD56 shed Demolition 1171.72 0.11
AREA COST AREA COST
- Shifting 21245.38 0.63 - Refurbishment
- Demolition 9146.88 0.88 - Construction 4266 20.12

Part - A DPR
YEAR - IV
Demolition in RFBD in Shifting in Builtup area Cost in

BUILDINGS 1 2 3 4 5 6 7 8 9 10 11 12 Months REMARKS
Sq .M Sq .M Sq .M in Sq .M crores
TIN 05 General Engineering group Construction & Occupation of new building 2588.00 2588.00 7.15
All facilities shifted to new builing, Electroplating,Moulding,

TIN 06 Ancillary shed Blacksmith from AIN 15 O/H .veh.parking&Painting decorator 1760.00 1760.00 4.64
,carpenter upholster,pattern making from TSIN 10 Scrap yard
TIN 11 OSS, MCO& KRAZ stores MCO,KRAZ store materials shifted from OBD 1 Machine shop 3200.00 0.00
TSIN 05 ETP&collection network system Construction&Shifting 150.00 150.00 0.28
Assembly integration testing facility Construction 4.59
Inventory Storage and Management Construction 10.33
Manufaturing Execution system & Support facilities for

Construction 7.31
MES
Power Back up ,Electrical Safety Equipments &
Construction 0.22
Rectifier Unit
OLD BUILDINGS TO BE REFURBISHED FOR NEW APPLICATIONS
RTIN 01 Painting area Refurbishment 880.00 0.51 0.52
RTIN 02 Dust proof painting booth Refurbishment 221.00 221.00 0.27
RTIN 03 OTRP Refurbishment 1152.00 1152.00 0.72
RTIN 04 Receipt &Issue Refurbishment 675.00 675.00 0.45
RTIN 05 Vehicle washing booth Refurbishment 475.00 475.00 0.32
RTIN 06 MAG 10 Refurbishment 338.06 338.06 0.22
RTIN 07Method Engineering section Refurbishment 629.36 629.36 0.34
Water Supply , Electrical & Fire Fighting for

0.80
Refurbishment
OBD 18 MI Room Demolition 752.93 0.07
OBD 1 Machine shop Demolition 2815.00 0.31
AREA COST AREA COST
- Shifting 12000 0.356 - Refurbishment 4370.42 3.64
- Demolition 7266 0.38 - Construction 7630 34.52

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PART A

507 - FINAL DETAILED PROJECT REPORT

Part A Project Overview Page No

1.1 Preface ......................................................................................................... 1

1.2 Project Background ....................................................................................... 1

1.3 Principle ......................................................................................................... 2

1.4 Overview of 507 Army Base Workshop ........................................................ 2

1.5 Role of the Workshop .................................................................................... 3

1.6 Vision Statement ........................................................................................... 3

1.7 Project Objectives ......................................................................................... 4

1.8 Load Profile ................................................................................................... 4

1.9 Benchmark for Modernization ....................................................................... 5

1.10 Benefits of Modernization .............................................................................. 5

1.11 Execution Methodology ................................................................................. 6

1.11.1 Understanding the Process and Data Collection ................................. 6

1.11.2 Data Collection ..................................................................................... 7

1.12 Study Findings ............................................................................................... 8

1.13 Existing Infrastructure.................................................................................... 9

1.13.1 Administration Department .................................................................. 9

1.13.2 Production Department ....................................................................... 12

1.13.3 Works Department .............................................................................. 17

1.14 Proposed Facilities for Modernisation of Base Workshop ............................ 20

1.14.1 Layout of the Workshop ...................................................................... 20

1.15 Capacity Enhancement Due To Modernisation ............................................ 22

1.15.1 Field Articulated Vehicle output........................................................... 22

1.15.2 FAV Engines output ............................................................................ 22

1.15.3 Process Improvements........................................................................ 23

1.16 Allied Requirements ...................................................................................... 27

1.17 List of Buildings Under Construction ............................................................. 28

1.18 Old Buildings to be Refurbished for New Application ................................... 28

1.19 Old Buildings to be Demolished .................................................................... 30

1.20 Key Features of Building Layout ................................................................... 41

1.20.1 Green Concept .................................................................................... 42

1.20.2 Structure of DPR ................................................................................. 45

1.20.3 Detailed list of DPR volumes............................................................... 46

1.0 Study Findings and Recommendations ……………………………………… 49

1.0.1 Existing Infrastructure ………………………………………………… 49

1.0.2 Need for Modernization ………………………………………………… 49

1.0.3 Master Plan …………………..……………………………………… 49

1.1 Production Group 51

1.1.1 KRAZ REPAIR GROUP (FIELD ARTICULATED VEHICLE GROUP)……… 52

1.1.1.1 Function of the group ………………………………………………… 52

1.1.1.2 Current process ………………………………………………………… 52

1.1.1.3 Current Workflow……………………………………………………… 53

1.1.1.5 Issues & Gap analysis ………………………………………………… 54

1.1.1.6 Improvement opportunities ………………………………………… 54

1.1.1.7 Future expansion needs …………………………………………… 54

1.1.1.8 Recommended process ……………………………………………… 55

1.1.1.9 Loading & Unloading ………………………………………………… 55

1.1.1.10 Water Washing Process …………………………………………… 59

1.1.1.11 Stripping Process …………………………………………………… 60

1.1.1.12 Degreasing and paint removal process …………………………… 61

1.1.1.13 Shot Blasting ………………………………………………………… 62

1.1.1.14 Sub-assembly repair & overhauling process ……………………… 63

1.1.1.15 Assembly Process ………………………………………………… 64

1.1.1.16 In – line Assembly …………………………………………………… 64

1.1.1.17 Effective ergonomics ………………………………………………… 67

1.1.1.18 Post-over Hauling Process …………………..……………………… 70

1.1.1.19 Pert Analysis of Kraz (FAV)…………………………………………… 70

1.1.1.20 Flow path analysis of FAV overhauling process …………………… 71

1.1.1.21 Loading & Unloading Process………………………………………… 72

1.1.1.22 Machinery Requirement ……………………………………………… 73

1.1.2 ENGINEERING EQUIPMENT GROUP