Presentation on theme: "Maintenance Management Fleet Health is secret of our Strength"— Presentation transcript:
1 Maintenance Management Fleet Health is secret of our Strength Best Practices inMaintenance ManagementFleet Health is secret of our Strength
2 Fleet Maintenance in APSRTC 1st TIERAt depots, preventive maintenance schedules, attention of running repairs, unit changes & fitness work and Coach work & Upkeep2nd TIERAt workshops - major overhaul of units & busesAt Tyre Retreading shops - retreading and repair of tyres
3 Objectives of Fleet Maintenance Preventive maintenance to vehicles for roadworthy fleet with good appearance, upkeep & comfortPunctualityZero AccidentZero Breakdown & Zero CancellationMinimum operational cost to earn profitsSustainability & growth of organizationLowest emission levels
4 INDICATORS OF EFFECTIVE FLEET MAINTENANCE PARAMETERTargetUptoJan’121HSD KMPL (Total)5.175.305.13HSD KMPL(Excl.Spl type)5.265.402Breakdown Rate0.100.070.083% Mech. Cancelation0.230.110.194Total Tyre Life1.681.841.705% New Tyre Scrap2.371.303.176New Tyre Mileage62897--672827RT Factor2.702.588Lub KMPL1117118911749Spring Consumption78505510Fleet Utilization99.4599.6095.40
5 APSRTC has established very precise Preventive Maintenance Policies which are flexible in design and rigid in implementation.The Maintenance Policies are primarily designed based on the manufacturers’ recommendations, product duty cycles and application environment.The vehicles undergo preventive maintenance schedules at Depots with the material support from Zonal Stores, aggregates support from Zonal Workshops and Tyres from Tyre Retreading shops
6 Basic Requirements for Effective Fleet Maintenance ManpowerTools, Plants& MachinerySpare PartsFuel & LubUnitaggregatesInfrastructure –Yard, Sheds,Maintenance Pits,IlluminationComputers &Softwareto Provide a Safe,Clean, Comfortable,Environment friendly,Reliable andCost effective Busfor Operation
7 STANDARD DEPOT LAY OUT Security Vehicle dispatch Gentset Cycle stand Oil BunkDC(oils)Washing PlantToiletsSmithyElectricalPainter & TrimmerTyresDC(T&P)Dining hallStoresMF/AMF roomMaintenance PitsSch-III/IV floor
8 Delegation of various responsibilities in a Depot Garage FunctionCustodian/ InchargeSecurity of Premises, Property & assetsSecurity SI/Head Guard &Security Guards in three shiftsIndenting, Receipts, Issues & Accountal of HSD Oil & LubricantsDepot Clerk &Asst.Depot Clerk (Oils)Tools, Plants & EquipmentDepot Clerk/Asst.Depot Clerk (T&P)Tyres indenting, Receipt, issues & AccountalAsst. Depot Clerk (Tyres)Stores & InventoryStores Supervisor &Asst.Depot Clerk (Stores)Shift MaintenanceSuperintendent(Mech)/Dy.Supdt (M)/Leading HandGeneral ShiftSuperintendent (M)/ Dy.Supdt(M)Maintenance of records, documentation & correspondenceAsst.Depot Clerk (Gen)
21 OVERHAULING ACTIVITIES AT WORKSHOPS There are 7 workshops situated at Uppal, Karimnagar, Vijayawada, Vizianagaram, Kadapa, Nellore and TirupathiThe main functions of Workshops are :i) Complete Overhauling of Buses.ii) Sundry repairs of Buses.iii) Reconditioning of aggregates likeEngine, Gear box, Front Axle,Rear Axle, FIP etc, and supply todepots on counter exchange basis.
26 Preventive Maintenance Schedules adopted at Depots NoMaintenanceSchedulePeriodicity of MaintenanceDistrict OperationCity Operations1Sch-IDaily2Sch-IIWeekly3Sch-III12,000 Kms for Ord15,000 kms for New& special type9,000 Kms for all12,000 kms for New4Sch-IV36,000 Kms for Ord45,000 kms for New27,000 Kms for all36,000 kms for New5F.C.AttentionInitially after 2 yrsof commissioning& annually thereafter
27 Oil, Filter & Coolant changes Description of LubricantLEYLANDTATAEngine Oil Long Life CH436,000 for Dist24,000 for City36,000(18,000 for Cummins)Engine oil other than CH415,000/ 16,00018,000Gear Box oil Ordinary32,000Gear Box oil Extra Long life40,00072,000Differential oil OrdinaryDifferential oil Extra long life48,000P.Steering oil & Filter80,000Clutch Kits & Clutch FluidCoolant75,0003.00 lakhs(or) 2YrsContd..
28 Filter Changes Description of Filter LEYALND TATA Fuel Filter Felt 20,00027,000Fuel Filter Paper30,000 &20,000 for BS-II36,000 &18,000 for BS-IISpinon Fuel filters25,000 BS-II18,000 TCFuel Strainers (Baby filters)50,000clean at 9,000Dry Air Filter element Primary72,000Dry Air Filter element Secondary2,16,000
29 In addition to the above certain periodical works like Refurbishing of Special type vehicles, Chemical washing of Seats are also incorporated in the Preventive maintenance programmes
30 Programming of Preventive Maintenance Schedules at Depots The advance planning of vehicles for various preventive maintenance activities is obtained through computer software called “Vehicle Maintenance System” (VEMAS).The due dates, done dates and coverage of Kms etc for all types of maintenance activities are generated by VEMAS
33 Sch-I MaintenanceSchedule-I or Daily Maintenance is carried out in two shifts.All the vehicles after completion of the scheduled operation undergo Sch-I Maintenance.Sweeping, Cleaning & Washing of buses, Arresting leakages of water, fuel, oils, replenishing the levels, tightening of all bolts and nuts, Checking of road springs & their mountings, Rectification of defects pointed out by Drivers, Inspection of Tyres and minor coach works are taken up in Sch-I.The works allotted & works attended in Sch-I are recorded by the Shift Incharge Supervisor duly obtaining the Signatures of the concerned.
34 Vehicle Back History Register DateComplaints on thecondition of vehicleFailuresRemarksof theSupervisorwho supervisedthe repairs/maintenanceSignatureof AE/ DMAs perlogsheetTyre Mech.ObservationVBH register is a very important register in maintenance management. It gives complete picture of the health of the vehicles. The repetitive nature of complaints depicts the quality of scheduled maintenance at the depot. The vehicle defects shall be thoroughly reviewed by the Sch-III/IV maintenance incharge before docking the vehicle and ensure that root cause for the defect is totally eliminated during Sch-III/IV maintenance.
35 Sch-II MaintenanceEvery vehicle undergoes Sch-II Maintenance once in a week (Excluding those undergone Sch-III/IV) for about 2-3 hoursIn addition to all the activities of Sch-I, the following works are taken up in Sch-IIComplete washing through MWPLubricating all grease pointsCleaning of BreathersAir Cleaner maintenanceBattery MaintenanceTyres rotationSteering & Brake test
36 Sch-III & IV Maintenance Sch-III/IV Maintenance is carried out based on the prescribed mileage. The vehicle is docked for 8 hrs in General shift.One senior most Supervisor is deployed at each depot to look after Sch-III/IV maintenance.Two Mechanics & Two assistants for Sch-III and Three Mechanics & 3 Assistants for Sch-IV are deployed per vehicle in addition to the Artisans.All major repair & maintenance works are carried out in Sch-III/IV maintenance.The vehicles are inspected before docking & after completion to ensure qualityThe workdone along with signature of the concerned are recorded in a register
37 Important aspects while docking the vehicles for Sch-III/IV Take up the vehicle for maintenance at the right time. Avoid delay/backlog.Inform the fixed Drivers about docking of vehicles for Sch-III/IV.Ensure thorough washing/MWP before docking.Synchronize other maintenance activities like FC, Unit changes, Filter/Oil/Coolant changes, Body attention, Painting etc with Sch-III/IV to save manpower & vehicle days
38 Important Coach works covered during Sch-III/IV Tightening of all Body U’bolts, cabin foundation bolts.Repairs to damaged body panels, exterior & interior roof panels, parcel racks, Luggage carrier, ladder & unloaderRepairs to Stepwell, stanchions, Passenger Assist rails, Driver partition, flooring, Dashboard, Engine hood, Entrance door & Driver’s doorDicky doors, locks and gas springs in Special type vehiclesContd..
39 Important Coach works covered during Sch-III/IV Repairs to broken pillars & cross bearersAttention to Destination frames & boardsReplacement/ repairs to broken seat frames, torn seat cushions & upholsteryAttention to Seats inclining mechanism, Hand rests, foot rests, pouches, bottle holders etc in special type vehiclesAttention to Driver Seat and adjusting mechanismContd..
40 Attention to Antisag bar & out riggers Replacement of damaged window frames, broken shutter glasses, windscreen glasses.Replacement of terene felt, fitment of shutter knobsAttention to battery boxArresting water leakagesExterior/ Interior paint touch up
41 Manpower Planning for Preventive Maintenance at Depots
42 Manpower planning is an essential prerequisite in Depot Maintenance Head Office communicates sanctions for each category of manpower by working out the requirement based on the average schedules operated by an unit during the period from July to December.The requirement of Supervisors and Artisans is worked out based on the slabs in schedules.The arrived norm based on the slabs is generally adopted for staff requirement at depotsFilling of vacancies either through direct recruitment or through promotion is strictly based on sanctions only
43 The success of Depot Maintenance management primarily depends on proper deployment of manpower and effective utilization of their servicesHighly skilled and experienced men shall be deployed in major maintenance programmes like Sch-III/IV, H.R.G and KMPL works.Senior most supervisor of the Depot next to Maintenance Incharge shall be assinged to look after of General Shift maintenance.
44 Depot Slabs for Supervisors & Artisans Categoryup to 4445 to 4950 to 5455 to 5960 to 6465 to 6970 to 7475 to 7980 to 8485 to 8990 to 9495 to 99100 to 109120 to 149150 & AbvAE(M)1SUPDT(M)2DY.SUP(M)LH34CB/PBTYRE MECH5ELEC AC/DCPAINTERWELD/T.STRIMMERB.SMITHH.MAN
45 Typical Man Power Deployment for maintenance in a Depot with 100 fleet CategoryNormMenMechanical Foreman0.0491Asst. Mechanical Foreman2ChargemanLeading Hands0.0374Total Supervisors0.0869Mechanics0.3535Helpers/ Shramiks0.5050Artisans0.2121Total1.15115
46 Deployment of Mechanics & Helpers for maintenance in a Depot with 100 fleet ActivityMechanics@ Norm 0.35Helper/ Shramik@ Norm 0.50Sch.I Maintenance1618Sch.II Maintenance4Sch.III/IV Maintenance910Heavy Repairs1KMPL Attention2Oil changesVehicle Dispatch3Tyres preparationDGT & StoresBattery maintenanceHSD oil top-upTotal3550
47 Deployment Artisans for maintenance in a Depot with 100 fleet CategoryNormMenCoach Bulider0.0394DC/AC Electrician0.0475Tyre Mechanic0.0343Welder/ Tinsmith0.0101Trimmer0.0242PainterBlacksmith0.022HammermanTotal0.2121
48 Manpower deployment for shift maintenance Deployment of manpower for Sch-I/II maintenance shall be done carefully keeping the number of vehicles to be maintained in each shift into considerationThe allocation of man power should match the buses to be maintained in that shift based on bus schedules. Allocation of manpower dis- proportionate to the number of buses will lead to underutilization of men and ineffective maintenanceCare shall be taken to ensure adequate manpower during night shifts as majority of the vehicles undergo Sch-I/II maintenance during this shift.
49 Outsourcing activities at Depots In order to overcome shortage of manpower, and difficulties in filling of vacancies, APSRTC is outsourcing certain maintenance activities like Cleaning, sweeping & washing of Buses, HSD oil Top-up, Semi-skilled men as Assistant to Mechanics etc at Depots for smooth maintenance of vehicles.
50 Outsourcing activities at Depots It is equally important for Supervisors to monitor the deployment of men by the outsourcing agencies and their quality of work.It is the responsibility of the Supervisors to ensure proper work allocation to the outsourced men.Supervisors shall also ensure the safety of the workers engaged through outsourcingThe records of attendance, details of work done etc, pertaining to outsourcing shall be maintained properly by the Supervisor concerned.
52 Provision of required tools, plants and equipment for smooth maintenance of vehicles is of highest importance in Depot Maintenance management.Depot Clerk is the custodian of all Mechanic tools, special tools, plants and machinery available in the Depot. The ‘T&P Return’ shall be maintained properly indicating the locality of each & every item of the Garage.
53 Important T&P required for smooth maintenance NoDescriptionExpected lifein Years1D.G.Set202Air Compressors153Car washers74Automatic Washing Plant5Arc Welding M/c6Gas Welding equipment8HP Greasing equipment10Bucket type Grease Gun9Jib CraneTrolley Jack11Bench Vice12Bench GrinderContd..
54 Important T&P required for smooth maintenance NoDescriptionExpected lifein Years13Drilling M/c1014Sewing M/c15Pop rivet guns516Paint Spray gun17Battery Charger18Cell Tester319Hydrometer20Injector Tester21Wall gauges22Electronic gauges23Hand grinding M/c724Mechanic’s work benchContd..
55 Important T&P required for smooth maintenance S.NoDescriptionExpected life in Years25Hand Platform Trolley1026Bench Arbor Press27Anvil28Torque Wrench529Swage Block30Vehicle Stands31Compressor TesterWell Pump733Automatic Tyre inflators34Ralli-wolf end mill kit35Dial gauge with magnetic base36Spring Cambering M/c37Diamond Glass cutter38Smoke Meter
56 A separate Log book is maintained for each plant & machinery and the entries are made in the Log book as and when repairs and maintenance are carried out.It is the responsibility of Mechanical Supervisors to ensure preventive maintenance to the Plants & Equipment at the prescribed intervals
57 The Mechanical Supervisors ensure periodical calibration of certain T&P items like Dial gauges, Injector testers, Wall gauges, Torque wrenches etc, as per the stipulated periodicity.The worn out and defective T&P are replaced in time so that the work is not hampered.Additional requirement of T&P owing to increased number schedules or introduction of new models are submitted to the Dy.CME concerned for obtaining the same.
58 Mechanic Tools for TATA Depots D.E.FlatRingTubularSocket6x7 mm6 x 7 mm8 x 9mm10mm8x9 mm10 x 11 mm10x11 mm13mm8x10 mm12x 13mm12x13 mm14mm9x10 mm17x19 mm12x14 mm17mm21 x 23 mm19mm10x13 mm22 x 24 mm22mm12x 14 mm27 x 32 mm24mm14x17 mm41 x 46 mm27mm3/8’’Other Tools55mm single end FlatTommy bar 125mm longTommy bar 250mm longExtension 6Extension 12"Cutting Plier 8"Cutting plier 10”Hammer Ball pane 1/2Kg.File round smooth 8"File flat smooth 6"Feeler Gauge SetTorque wrench(4 to 20 m-Kgs)Circlip Plier 6’’Screw Driver 6’’ & 12’’Nose Plier 6’’
59 Mechanic Tools for LEYLAND Depots D.E.FlatRingSocket3/16’’x1/4’’½’’¼’’x5/16’’10mm5/16’’x3/8’’11mm7/16’’x1/2’’12mm9/16’’ x 5/8’’13mm11/16’’x3/4’’14mm6 x 7mm17mm8 x 9mm19mm10 x 11mm21mm12 x 13mm22mm14x 15mm24mm16 x 17mm46mm18 x 19mm20 x 21mm22 x 23mm24 x 27mmOther Tools55mm single end Flat wrenchTommy bar 125mm longTommy bar 250mm longExtension 6Extension 12"Cutting Plier 8"Cutting plier 10”Hammer Ball pane 1/2Kg.File round smooth 8"File flat smooth 6"Feeler Gauge SetTorque wrench(4 to 20 m-Kgs)Circlip Plier 8’’Screw Driver 8’’ & 12’’Nose Plier 6’’MalletAllen Key set
60 Fast moving Mechanic Tools ASHOK LEYLANDTATADERingSocket10 x 1114 x 1512,1319 x 2214, 178 x 919BSF3/16” X ¼”5/16 X 3/8”Feeler gaugeDERingSocket17 x 199, 1013 x 1413, 1419 x 2217, 199 x 10Feeler Gauge
61 Special tools for Tata vehicles Crow foot spanner for cylinder Head Nut tightening with rocker assemblyCheck nut spanner on front hubCheck nut spanner on rear hubFront Hub pullerRear Hub PullerWater pump flange pullerDrift for oil seal on Hub (outer)Steering ball joint pullerDrift for oil seal on hub (inner)Holders for coupling flangeDrift for removal of Rear hub inner oil sealPuller for clutch release bearingAdopter for checking engine compressionPuller for spigot bearing in crank shaftPuller for C.J. BearingPuller for Rear hub Bearing outer racePuller for water pump inner bearingDrift for oil seal in timing caseSpanner for wheel nutSocket wrench for removal of InjectorsPiston ring compressorStrap wrench for Spin-on filters
62 Special tools for Leyland vehicles Retainer for Liners (for Hino)Cylinder Head Bolt wrench(for Hino)Cylinder liner pullerInjector ExtractorPiston Ring CompressorDrift King Pin bush bottomDrift King Pin Bush bottomCentre bearing Nut SpannerPuller steering wheelSpanner set rocket shaftSpanner spring clamp nutClutch alignment toolClutch Height setting gauge(Z-gauge)Dial gauge (for hub setting with Magnetic base)Strap wrench for Spin-on filtersDrop arm puller ZFDrop arm puller RaneDrift for Rear hub oil sealDrift for F.Hub inner bearingDrift for Bearing outer raceRear Hub nut spannerFront Hub nut SpannerGuide F.Hub inner bearingPuller Stub axle inner brg
63 Delegation of Powers Pertaining to T&P S.NoNature of PowerAuthorityExtent of powers32.i)Standardization of depot equipment, inclusion of new items, fixation of norms, classification of T&P value-wise fixation of guidelines, expectancy etcMDFull powers with the concurrence of FA/CAO on the recommendations of ED(E)/CCOS/CME/ CFMii)Inclusion of new equipment on experimental basisED(E)Powers upto Rs 1.00 lakh per occasion with the concurrence of FA/CAOCMEPowers upto Rs 50,000 per annum with the concurrence of Dy.CAOWM/Dy.CMEPowers upto Rs 10,000 per annum with the concurrence of Dy.CAOContd..
64 Delegation of Powers Pertaining to T&P S.NoNature of PowerAuthorityExtent of powers33.i)Sanction for replacement of T&P equipments including premature replacements at Depots/ W.shopsCME/ED(Z)Full powers on the recommendations of Dy.CME/ WM with the concurrence of DyCAOii)Sanction for replacement of T&P items after their normal utilization for Depots/ W.shops as per guidelines issued from time to timeDyCME/ WMFull powers with concurrence of DyCAODMPowers upto Rs 300/- at a time subject to a limit of Rs 2,000 per annumContd..
65 Delegation of Powers Pertaining to T&P S.NoNature of PowerAuthorityExtent of powers34.i)Sanction for replacement of T&P equipments for New Depots/ W.shopsED(Z)/CMEFull powers as per guidelinesii)Sanction of additional T&P for existing Depots/ W.shops on account of increase in Fleet stength/ acitivity as per guidelinesCME/DyCME/ WMFull powers with concurrence of CFM/ DyCAO as per guidelinesDMPowers upto Rs 300/- at a time subject to a limit of Rs 2,000 per annumContd..
66 Delegation of Powers Pertaining to T&P S.NoNature of PowerAuthorityExtent of powers35Sanction the expenditure incurred for overhaul repairs and maintenance of tools, plant & machinery and replacement of parts thereof in Depots & production units and entering into contract with authorized suppliers or manufacturersED(E)Full powers with concurrence of FA/CAOCME/ ED(Z)Full powers with concurrence of CFM/ DyCAO upto Rs 20,000 at a timeSSOFull powers upto Rs 5,000 at a time with concurrence of Dy.CAOJSOUpto Rs 1,500 at a time
68 Float aggregates are essential resource inputs for depot maintenance. The purpose of providing float aggregates is to make available important units readily available at the depots at all times so that the defective units are replaced immediately and the vehicles are put onroad.Inadequacy/ non-availability of float units affect the Fleet utilization, punctuality of operations and earning potentiality of a depot.Over-provisioning of floats leads to excessive inventory lock-up
69 The requirement of Float aggregates depends on the volume of operations, lead time of supply and the average life of the aggregates.The Mechanical Engineering Department, from time to time; decide the list of float aggregate units to be provided to the depots.Floats are also provided for Workshops as an in-process inventory for uninterrupted supply to the depots and maintain optimum service levels.
70 No.of Float aggregates = (N/n - C) x t x a The following formula is adopted in assessing the requirement of floats for a depot.No.of Float aggregates =(N/n - C) x t x a(Subject to a minimum of 1)Where,N = Operated Kmsn = average life of aggregate in Kmst = Lead time replenishment in days which is the period that elapses between the day of removal of defective unit to the day of replacement being received from workshops or the day of completion of repair in the depot if such repair is within the permissible repairs of depot.C = Complete overhauls demand per daya = Number of units per vehicle
71 Provisioning of Float Units to Depots MAJOR UNITSS.NoUNITNORM1Engine1 for 10,000 KMs.2Front Axle1 for 14,000 KMs.3Rear Axle4Gear Box1 for 8,500 KMs.5Steering Box6FIP1 for 5,000 KMs.7Self Starter1 for 4,000 KMs8Alternator1 for 4,000 KMs.
72 SUB ASSEMBLIESS.NoUNITNORM1Injectors (set)1 for 2,000 KMs.2P. P. Shafts (set)1 for 6,000 KMs.3Air compressor1 for KMs.4Clutch pressure plate1 for 5,000 KMs.5(Leyland)/ Springer (Tata)6Water pump assembly7Cylinder head assembly8Radiator
73 MAJOR SPARES S.No UNIT NORM 1 Front hub 1 for 15,000 KMs. 2 Rear hub 3 Clutch housing4Air cleaner complete1 for 5,000 KMs.5Fuel twin filter assembly6Feed pump7Fly wheel ring gear1 for 10,000 KMs.8Unloader valve1 for 3,000 KMs.9Set (4) of slack adjusters10Set (4) of spring brake chambers11Hand brake valve12A. C. Head
74 MAJOR SPARES S.No UNIT NORM 13 Air tank 1 for 10,000 KMs. 14 Clutch disc1 for KMs.15U. J. Cross1 for 6,000 KMs.16Set of brake drums front (2 off)1 for 5,000 KMs.17Set of brake drums rear (2 off)18Set of spring brackets front (2 off)19Set of spring brackets rear (2 off)20Axle shafts 2 off21H. S. D. Oil Tank22Wiper Machine23Batteries10% of the batteries24Hydraulic jacks1 for 2,000 KMs.
75 All depots send a periodical statement on availability of floats to the concerned Dy.CME once in a year.The Dy.CME of the region reconciliates figures with those maintained by workshops.The Dy.CME concerned processes cases for provision of floats for new models and also for increase of floats on account of increase in schedules, duly recommending the surrender of obsolete models.
76 Provision of Spare Vehicles to Depots Spare vehicles are provided to the Depots to meet the requirements for docking the vehicles for preventive maintenance (Sch.III/IV), FC attention, Complete overhauls, Sundry repairs, Units replacement etc,.Norm for Provision of Spare BusesFleet HeldNormUpto 508%51 to 807%81 & above6%
77 Physical Inspection of Buses by Depot Manager & Maintenance Incharge The Depot Manager shall inspect atleast 30 vehicles (1/3rd Fleet) every month covering 15 vehicles undergone Sch-II maintenance, 10 vehicles undergone Sch-III and 5 vehicles undergone Sch-IV maintenance.This is highly essential to ensure effective execution of preventive maintenance schedules
78 Check-list for inspection of vehicles S.NoSystemItem1EngineAir cleaner maintenance2,,A/c Suction hose3Engine mounting4Engine oil leakages5FuelHSD tank cap seals6Fuel pipe clamping7Fuel leakages8CoolingRadiator Cap9Coolant concentration10Radiator mountingsContd..
79 Tie-rod/ drag link end play ,, ATF oil leakages King pin lubrication S.NoSystemItem1SteeringTie-rod/ drag link end play2,,ATF oil leakages3King pin lubrication4Susp.Broken spring leaves5Spring side clamps/ ferrules6Welded side clamps7Spring brackets/ shackles8Air suspension mounting boltsTightness9Condition of rubber bushesin Air suspensionContd..
80 System Item S.No 1 Transmission Clutch free play 2 ,, Gear lever play 3Gear Box oil leakage4Loose CJ check nuts5CJ bearings condition6UJ Crosses condition7Sleeve yokes condition8CJ rubber beds condition9Slip joint Rubber boot10PP shafts alignment11Missing grease nipples12Chassis greasing13Differential oil leakage14Cleanliness of breathers
81 System Item Brakes Air tank condensate ,, Brake pipe clamps S.NoSystemItem1BrakesAir tank condensate2,,Brake pipe clamps3Air leakage4Air Dryer working5Hand brake condition6Brake dust covers7TyresWheel alignment8Matching of duals9Less than 2mm NSD tyresContd..
82 S.NoSystemItem1ElectricalBattery Maintenance2,,Head Lights3Signal Lights4Self condition5Saloon Illumination6BodyExterior/ Interior cleanliness7Body damages8Painting9Seat Mounting10Seat Upholstery11Inclining mechanism12Shutter glasses13Doors14Window Shutter Knobs15Tightness of body U bolts16Under chassis cleanliness
83 Checklist for Body condition CodeItem DescriptionRemarksEXT-1Body PanelsDents, Scratches, DamagesEXT-2Front/ Rear BumpersBroken/missingEXT-3Front GrillDamages/ missingEXT-4Front CowlsDamagesEXT-5Corner DomesDentsEXT-6Passenger DoorsEXT-7Driver’s DoorDamages/ locksEXT-8LadderEXT-9Rear Luggage Booth (Dicky)EXT-10Exterior PaintFadedEXT-11Roof LeakageArea of LeakageDEST-1Destination Board FrameSize and conditionDEST-2Destination Lettering/PaintDEST-3Destination Board lightingVisibilityDEST-4LED DestinationCondition
84 Checklist for Body condition CodeItem DescriptionRemarksINT-1StepwellDamagesINT-2FlooringConditionINT-3StanchionsBroken/missing/looseINT-4Parcel RackBroken/looseINT-5Grab rails/ Assist railsINT-6Cabin Partition doorINT-7Interior Roof/ side panel FabricINT-8Interior paintingFadedINT-9Saloon CleanlinessDirt & cobwebsGLS-1Window GlassesMissing/ BrokenGLS-2Terene felt/Flock channel RubberWorn out/ missingGLS-3Window shutter knobsMissing/looseGLS-4Windscreen GlassesBrokenGLS-5Top-fixed glassesBroken/missingGLS-6Windows leakageCondition of Rubber flap
86 Checklist for Body condition CodeItem DescriptionRemarksLHT-1Interior LightiningConditionLHT-2Head LightsLHT-3Tail lights/ signal indicatorsSPL-1SpeakersSPL-2TV/Audio SystemSPL-3Cell phone chargersSTR-1Body U BoltsLoose/missingSTR-2Ballata PackingSTR-3Cabin FoundationLooseSTR-4Antisag BarSTR-5Out RiggersSTR-6Battery BoxCondtion
87 Indicators for Quality of Sch-III/IV maintenance Backlog in Sch-III/IV maintenance and failures within 15 days after maintenance are the key indicators for Standards of preventive maintenance at the depot.TypeFleetHeldOptdKmsSch-IIIFailures within15 daysDueDoneBacklog% BacklogNos%ORDEXPTotalTypeFleetHeldOptdKmsSch-IVFailures within15 daysDueDoneBacklog% BacklogNos%ORDEXPTotal
88 Important Registers maintained in Preventive Maintenance Management Daily RG Register RTC-126Vehicle Back History RTC-109Sch-I Maintenance RTC-127Sch-II Maintenance RTC -128Sch-III work done MTD -194Preventive Maintenance Master register RTC-110Unit changes registerRegister for Inspection of vehiclesFC RegisterBreakdowns RTC-129Cancellation of Kms RTC-130
89 Vehicle Replacement Policy APSRTC replaces Mofussil buses at lakh kms and City Buses at lakh kms or 15 years (whichever is earlier) against scrap.Ghat Buses & Super Luxury buses are replaced at 5.50 lakh kms and Volvo Buses at lakh kmsThe other special type buses like Express, Deluxe, Metro Exp etc are replaced at lakh kms
90 Deployment of New Buses from 2010 Type(Jan’12)Aug.Rep.TotalS.Luxury13710924657778835Indra--86169Garuda/ Garuda+30274168Deluxe3289121169238Express2743306041749041078Pallevelugu152547699Sap.Express & Ord1231502279City Ordinary105565City Ord (CNG)138LF A/C Diesel2851LF A/C CNGLF N-A/C Diesel168096314LF N-A/C CNG33SLF Diesel751181939SLF CNG1258705Mini Buses5248653937159067627513427
91 Use of Alternate fuels in APSRTC Green initiatives &Use of Alternate fuels in APSRTC
92 APSRTC’s Environmental Concerns APSRTC always takes lead in sharing the public concern on automobile pollution and climate change.APSRTC is a forerunner in introducing environment friendly vehicles through product upgradation and innovative measures especially in the area of alternate fuels and pollution control.Continued…
93 APSRTC’s Environmental Concerns Sophisticated Electronic Smoke Meters are provided to Depots to check the smoke emission levels of buses at regular intervals.With a commitment towards mitigation of GHG emissions and reduction of smoke levels, APSRTC has started using Biofuels and Compressed Natural Gas on large scale.APSRTC installed 40 Wind Turbines to generate green power to an extent of 10 Mw of Electrical energy
94 APSRTC launched 100 CNG buses in Vijayawada City during the year 2006, which is first of its kind in South India.The number of CNG buses has been increased to 300 in Vijayawada.Introduced 120 CNG buses recently in Hyderabad which include Ultra Low Floor Buses with BS-III/IV compliant CNG rear Engine model is under progress.The Fuel efficiency of CNG buses in VJA is 4.40 km/kg and in Hyd it is 4.49 km/kg
101 Experiences with Biodiesel As a stake holder in promoting the use of biofuels, APSRTC had promptly responded to the call given by the Govt. of Andhra Pradesh and started trials using Biodiesel blended fuel on one City bus, in June’2005.The vehicle was operated with B20 fuel for 8 months to assess the operational feasibility and performance in respect to fuel efficiency and emission reduction. Intermittently the vehicle was also operated with 100% HSD fuel for 2 months for comparison
102 Emission levels of Biodiesel Vehicle during trial period Against the maximum permissible smoke density of 65 Hatridge units, the following emission levels were observed on the vehicle when operated with 20% Bio-diesel.Jun-0541.3Aug-0535.4Sep-0536.2Oct-0532.6Nov-0535.0Dec-0511.8Feb-0625.0Mar-0611.7
103 Emission Levels of trial vehicle When operated with 100% HSD oil During Trial periodBefore TrialJul-0533.3Jan-0634.0Jan-0535.0Feb-0532.6Mar-0511.2Apr-0537.3May-0545.4
104 Comparative Fuel Performance* of Vehicle during trials With 100% HSD oilWith BiodieselJul-054.627Jun-054.355Aug-054.538Sep-054.662Oct-054.778Nov-054.430Dec-054.516Feb-064.797Mar-065.008Jan-065.193* Fuel Performance in Kms/Lit
105 Extended trials with Biodiesel The trial was extended to three more vehicles at the same Depot with 5%, 10% and 20% blends respectively. It was observed during the trials that the vehicle with 20% blend shown improvement in fuel efficiency by 0.27 Km/Lt.The trials were conducted with the Biodiesel supplied by M/S Southern Online Biotechnologies Limited.
107 Several firms like M/s Cleancities Bio-diesel India limited, M/S Naturol Bioenergy Limited and M/S Universal Biofuels Pvt. Limited have come forward to offer Bio-diesel for conducting wider trials.The trials were extended to other regions like Visakhapatnam and East Godavari, where all the vehicles of 4 depots were operated with Biodiesel blended in 1:9 ratio for about one month.
108 With the encouraging trial performance, Corporation has taken a decision to use Bio-diesel at 10% blend on regular basis for all vehicles in the 12 Depots of Hyderabad City Zone in the first phase by procuring the Bio-diesel from M/S Southern Online Biotechnologies LimitedThe supplier had installed a separate overhead tank for biodiesel storage and made necessary arrangements to mix the Biodiesel with the HSD oil in the fixed proportion.
109 In the second phase, tenders were floated in September 2009 for bulk procurement of Bio-diesel at an estimated quantity of 30 Million liters for regular blending at 129 Depots in 14 Regions.The supply contract was awarded to three firms viz, M/S Cleancities Bio-diesel India limited (108 Depots), M/S Southern Online Biotechnologies Limited (12 Depots) and M/S Universal Biofuels Pvt (9 Depots)
110 Biodiesel Stocking & Blending Arrangement at Depots Dip RodTank Level GaugeBiodiesel Storage Tank1 ½’’ MS Line1’’ MS Line1’’ Flexible HoseUnderground HSD Oil TankTruck with Biodesel Transfer PumpGround Level
111 Procedure of Blending Biodiesel with HSD Oil Blending Biodiese with HSD for first timeKnow the quantity of (Q1) of HSD in Ground TankCalculate required qty (Q2) of blend with HSD (Q1x10/90)Transfer calculated qty (Q2) of Biodiesel from Storage tank by gravity using Flowmeter F1Procedure for subsequent replenishmentsIgnore the quantity of B10 blend existing in the storage tank on fresh receipt of HSD oilKnow the fresh quantity (Q3) of HSD that is being decanted into the underground tankCalculate the required quantity (Q4) of Biodiesel to mix by using the formula Q3 x 10/90Transfer the quantity Q4 of Biodiesel from Storage tank to the Underground tank with the help of Flow meter F1
112 Reduction of Pollutants with B20 Fuel The values withPure HSD OilReduction with20% BlendedBio-dieselTotal Unburned Hydrocarbons1.1gms/kwh20%Carbon monoxide4.5 gms/kwh12%Particulate Matter0.36 gms/kwhOxides in Nitrogen8 gms/kwh+ 2%Sulphates--Polycyclic AromaticHydrocarbons (PAH)13%Nitrated PAHs50%Ozone PotentialSpeculated Hydrocarbons10%
114 Comparative Specifications of HSD & Biodiesel ParameterASTMMethodUnitPure Bio-DieselNormal HSD OilCarbon Residue100% SampleD4530% mass0.05 max0.03 max on 10%Acid NumberD664mg KOH/gm0.8 max--Free GlycerinD65840.02 maxTotal Glycerin0.24 maxPhosphorusD49510.001 maxDistillation Temp.AtmosphericEquivalent Temp90% RecoveredD1160Degrees C360 max
115 Some of the barriers in large scale application of Biodiesel Availability and uninterrupted supply of biodiesel is a major constraint for large scale application in APSRTC.Very few firms have come forward to supply the Biodiesel in bulk quantity at a viable priceIt is difficult to assess the quality of the product at the user levelThere is scope for non-adherence to the prescribed specifications by the suppliers in the absence of required testing facilities.Contd…
116 It is difficult to send the samples to the laboratories too frequently. The blending becomes uneconomical if the suppliers quote exorbitant prices due to monopolyPremature clogging of filters is more prevalent while using Biodiesel