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Maintenance Management Fleet Health is secret of our Strength Best Practices in.

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Presentation on theme: "Maintenance Management Fleet Health is secret of our Strength Best Practices in."— Presentation transcript:

1 Maintenance Management Fleet Health is secret of our Strength Best Practices in

2 1st TIER  At depots, preventive maintenance schedules, attention of running repairs, unit changes & fitness work and Coach work & Upkeep 2nd TIER  At workshops - major overhaul of units & buses  At Tyre Retreading shops - retreading and repair of tyres Fleet Maintenance in APSRTC

3 Preventive maintenance to vehicles for roadworthy fleet with good appearance, upkeep & comfort Punctuality Zero Accident Zero Breakdown & Zero Cancellation Minimum operational cost to earn profits Sustainability & growth of organization Lowest emission levels Objectives of Fleet Maintenance

4 PARAMETER Target Upto Jan’12 1HSD KMPL (Total) HSD KMPL (Excl.Spl type) Breakdown Rate % Mech. Cancelation Total Tyre Life % New Tyre Scrap New Tyre Mileage RT Factor Lub KMPL Spring Consumption Fleet Utilization

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 Manpower Tools, Plants & Machinery Spare Parts Fuel & Lub Unit aggregates Infrastructure – Yard, Sheds, Maintenance Pits, Illumination Computers & Software to Provide a Safe, Clean, Comfortable, Environment friendly, Environment friendly, Reliable and Cost effective Bus for Operation Basic Requirements for Effective Fleet Maintenance

7 7 1.Security 2.Vehicle dispatch 3.Gentset 4.Cycle stand 5.Oil Bunk 6.DC(oils) 7.Washing Plant 8.Toilets 9.Smithy 10.Electrical 11.Painter & Trimmer 12.Tyres 13.DC(T&P) 14.Dining hall 15.Stores 16.MF/AMF room 17.Maintenance Pits 18.Sch-III/IV floor STANDARD DEPOT LAY OUT

8 FunctionCustodian/ Incharge Security of Premises, Property & assets Security SI/Head Guard & Security Guards in three shifts Indenting, Receipts, Issues & Accountal of HSD Oil & Lubricants Depot Clerk & Asst.Depot Clerk (Oils) Tools, Plants & Equipment Depot Clerk/ Asst.Depot Clerk (T&P) Tyres indenting, Receipt, issues & Accountal Asst. Depot Clerk (Tyres) Stores & Inventory Stores Supervisor & Asst.Depot Clerk (Stores) Shift Maintenance Superintendent(Mech)/ Dy.Supdt (M)/Leading Hand General ShiftSuperintendent (M)/ Dy.Supdt(M) Maintenance of records, documentation & correspondence Asst.Depot Clerk (Gen) Delegation of various responsibilities in a Depot Garage

9 9 HSD OIL DISPENSING STATION & WASHING PLANT

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13 13 SCHEDULE-I/II MAINTENANCE GARAGE

14 14 PITS FOR VEHICLE INSPECTION & MAINTENANCE

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17 17 TYPICAL SCHEDULE-III/IV MAINTENANCE GARAGE

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21 21 Uppal, Karimnagar, Vijayawada, Vizianagaram, Kadapa, Nellore Tirupathi There are 7 workshops situated at Uppal, Karimnagar, Vijayawada, Vizianagaram, Kadapa, Nellore and Tirupathi The main functions of Workshops are : i) Complete Overhauling of Buses. ii) Sundry repairs of Buses. iii) Reconditioning of aggregates like Engine, Gear box, Front Axle, Rear Axle, FIP etc, and supply to depots on counter exchange basis. OVERHAULING ACTIVITIES AT WORKSHOPS

22 22 Zonal workshops - Uppal

23 23 Zonal workshops – Engine Section Zonal workshops – Body Section

24 24 Tyre Retreading Shop

25 25 Tyre Retreading Process

26 Preventive Maintenance Schedules adopted at Depots S. No Maintenance Schedule Periodicity of Maintenance District OperationCity Operations 1Sch-IDaily 2Sch-IIWeekly 3Sch-III12,000 Kms for Ord 15,000 kms for New & special type 9,000 Kms for all 12,000 kms for New 4Sch-IV36,000 Kms for Ord 45,000 kms for New & special type 27,000 Kms for all 36,000 kms for New 5F.C. Attention Initially after 2 yrs of commissioning & annually thereafter Initially after 2 yrs of commissioning & annually thereafter

27 Oil, Filter & Coolant changes Description of Lubricant LEYLANDTATA Engine Oil Long Life CH4 36,000 for Dist 24,000 for City 36,000 (18,000 for Cummins) Engine oil other than CH415,000/ 16,00018,000 Gear Box oil Ordinary32,00018,000 Gear Box oil Extra Long life40,00072,000 Differential oil Ordinary32,00018,000 Differential oil Extra long life48,00072,000 P.Steering oil & Filter80,000 Clutch Kits & Clutch Fluid40,00072,000 Coolant75, lakhs (or) 2Yrs Contd..

28 Filter Changes Description of Filter LEYALNDTATA Fuel Filter Felt20,00027,000 Fuel Filter Paper 30,000 & 20,000 for BS-II 36,000 & 18,000 for BS-II Spinon Fuel filters25,000 BS-II18,000 TC Fuel Strainers (Baby filters)50,000clean at 9,000 Dry Air Filter element Primary 72,000 Dry Air Filter element Secondary 2,16,000

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 29

30 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 30 Programming of Preventive Maintenance Schedules at Depots

31 A typical VEMAS based report

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33 Sch-I Maintenance Schedule-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 the condition of vehicle Failures Remarks of the Supervisor who supervised the repairs/ maintenance Signature of AE/ DM As per logsheet As per Tyre Mech. Observation VBH 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 Maintenance Every vehicle undergoes Sch-II Maintenance once in a week (Excluding those undergone Sch-III/IV) for about 2-3 hours In addition to all the activities of Sch-I, the following works are taken up in Sch-II  Complete washing through MWP  Lubricating all grease points  Cleaning of Breathers  Air Cleaner maintenance  Battery Maintenance  Tyres rotation  Steering & 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 quality The 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 & unloader  Repairs to Stepwell, stanchions, Passenger Assist rails, Driver partition, flooring, Dashboard, Engine hood, Entrance door & Driver’s door  Dicky doors, locks and gas springs in Special type vehicles Contd..

39 Important Coach works covered during Sch-III/IV  Repairs to broken pillars & cross bearers  Attention to Destination frames & boards  Replacement/ repairs to broken seat frames, torn seat cushions & upholstery  Attention to Seats inclining mechanism, Hand rests, foot rests, pouches, bottle holders etc in special type vehicles  Attention to Driver Seat and adjusting mechanism Contd..

40  Attention to Antisag bar & out riggers  Replacement of damaged window frames, broken shutter glasses, windscreen glasses.  Replacement of terene felt, fitment of shutter knobs  Attention to battery box  Arresting water leakages  Exterior/ 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 depots Filling 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 services Highly 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 Category up to to 4950 to 5455 to 5960 to 6465 to 6970 to 7475 to 7980 to 8485 to 8990 to 9495 to to to & Abv AE(M) SUPDT(M) DY.SUP(M) LH CB/PB TYRE MECH ELEC AC/DC PAINTER WELD/T.S TRIMMER B.SMITH H.MAN

45 Typical Man Power Deployment for maintenance in a Depot with 100 fleet CategoryNormMen Mechanical Foreman Asst. Mechanical Foreman2 Chargeman2 Leading Hands Total Supervisors Mechanics Helpers/ Shramiks Artisans Total

46 Deployment of Mechanics & Helpers for maintenance in a Depot with 100 fleet Norm 0.35 Helper/ Norm 0.50 Sch.I Maintenance1618 Sch.II Maintenance44 Sch.III/IV Maintenance910 Heavy Repairs11 KMPL Attention22 Oil changes22 Vehicle Dispatch13 Tyres preparation2 DGT & Stores2 Battery maintenance2 HSD oil top-up4 Total3550

47 Deployment Artisans for maintenance in a Depot with 100 fleet CategoryNormMen Coach Bulider DC/AC Electrician Tyre Mechanic Welder/ Tinsmith Trimmer Painter Blacksmith Hammerman Total0.2121

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 consideration The 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 maintenance Care 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 outsourcing The records of attendance, details of work done etc, pertaining to outsourcing shall be maintained properly by the Supervisor concerned.

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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 S. No Description Expected life in Years 1 D.G.Set 20 2 Air Compressors 15 3 Car washers 7 4 Automatic Washing Plant 15 5 Arc Welding M/c 20 6 Gas Welding equipment 8 7 HP Greasing equipment 10 8 Bucket type Grease Gun 7 9 Jib Crane 10 Trolley Jack Bench Vice 5 12 Bench Grinder 7 Important T&P required for smooth maintenance Contd..

54 S. No Description Expected life in Years 13 Drilling M/c Sewing M/c Pop rivet guns 5 16 Paint Spray gun Battery Charger 5 18 Cell Tester 3 19 Hydrometer 5 20 Injector Tester Wall gauges 3 22 Electronic gauges 5 23 Hand grinding M/c 7 24 Mechanic’s work bench10 Important T&P required for smooth maintenance Contd..

55 S.No Description Expected life in Years 25 Hand Platform Trolley10 26 Bench Arbor Press10 27 Anvil10 28 Torque Wrench5 29 Swage Block10 30 Vehicle Stands10 31 Compressor Tester10 31 Well Pump7 33 Automatic Tyre inflators 34 Ralli-wolf end mill kit 35 Dial gauge with magnetic base 36 Spring Cambering M/c 37 Diamond Glass cutter 38 Smoke Meter Important T&P required for smooth maintenance

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.FlatRingTubularSocket 6x7 mm 8 x 9mm10mm 8x9 mm 10 x 11 mm 13mm 8x10 mm12x 13mm 14mm 9x10 mm17x19 mm12x14 mm17mm 10x11 mm 21 x 23 mm 17x19 mm19mm 10x13 mm22 x 24 mm 22mm 12x 14 mm27 x 32 mm 24mm 14x17 mm41 x 46 mm27mm 17x19 mm 3/8’’ 22 x 24 mm 27 x 32 mm Other Tools 55mm single end Flat Tommy bar 125mm long Tommy bar 250mm long Extension 6 Extension 12" Cutting Plier 8" Cutting plier 10” Hammer Ball pane 1/2Kg. File round smooth 8" File flat smooth 6" Feeler Gauge Set Torque wrench (4 to 20 m-Kgs) Circlip Plier 6’’ Screw Driver 6’’ & 12’’ Nose Plier 6’’

59 Mechanic Tools for LEYLAND Depots D.E.FlatRingSocket 3/16’’x1/4’’ ½’’ ¼’’x5/16’’ 10mm 5/16’’x3/8’’ 11mm 7/16’’x1/2’’ 12mm 9/16’’ x 5/8’’ 13mm 11/16’’x3/4’’ 14mm 6 x 7mm 17mm 8 x 9mm 19mm 10 x 11mm 21mm 12 x 13mm 22mm 14x 15mm 24mm 16 x 17mm 46mm 18 x 19mm 20 x 21mm 22 x 23mm 24 x 27mm Other Tools 55mm single end Flat wrench Tommy bar 125mm long Tommy bar 250mm long Extension 6 Extension 12" Cutting Plier 8" Cutting plier 10” Hammer Ball pane 1/2Kg. File round smooth 8" File flat smooth 6" Feeler Gauge Set Torque wrench (4 to 20 m-Kgs) Circlip Plier 8’’ Screw Driver 8’’ & 12’’ Nose Plier 6’’ Mallet Allen Key set

60 Fast moving Mechanic Tools DERingSocket 10 x 1114 x 1512,13 14 x 1519 x 2214, x 228 x 919 BSF 3/16” X ¼” 5/16 X 3/8” Feeler gauge DERingSocket 17 x 19 9, x 14 13, x 22 17, 19 9 x 10 Feeler Gauge ASHOK LEYLAND TATA

61 Special tools for Tata vehicles Crow foot spanner for cylinder Head Nut tightening with rocker assembly Check nut spanner on front hub Check nut spanner on rear hub Front Hub puller Rear Hub Puller Water pump flange puller Drift for oil seal on Hub (outer) Steering ball joint puller Drift for oil seal on hub (inner) Holders for coupling flange Drift for removal of Rear hub inner oil seal Puller for clutch release bearing Adopter for checking engine compression Puller for spigot bearing in crank shaft Puller for C.J. Bearing Puller for Rear hub Bearing outer race Puller for water pump inner bearing Drift for oil seal in timing case Spanner for wheel nut Socket wrench for removal of Injectors Piston ring compressor Strap wrench for Spin-on filters

62 Special tools for Leyland vehicles Retainer for Liners (for Hino) Cylinder Head Bolt wrench (for Hino) Cylinder liner puller Injector Extractor Piston Ring Compressor Drift King Pin bush bottom Drift King Pin Bush bottom Centre bearing Nut Spanner Puller steering wheel Spanner set rocket shaft Spanner spring clamp nut Clutch alignment tool Clutch Height setting gauge (Z-gauge) Dial gauge (for hub setting with Magnetic base) Strap wrench for Spin-on filters Drop arm puller ZF Drop arm puller Rane Drift for Rear hub oil seal Drift for F.Hub inner bearing Drift for Bearing outer race Rear Hub nut spanner Front Hub nut Spanner Guide F.Hub inner bearing Puller Stub axle inner brg

63 Delegation of Powers Pertaining to T&P S.NoNature of PowerAuthorityExtent of powers 32.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/ CFM ii)Inclusion of new equipment on experimental basisED(E)Powers upto Rs 1.00 lakh per occasion with the concurrence of FA/CAO CMEPowers upto Rs 50,000 per annum with the concurrence of Dy.CAO WM/Dy.CME Powers upto Rs 10,000 per annum with the concurrence of Dy.CAO Contd..

64 Delegation of Powers Pertaining to T&P S.NoNature of PowerAuthorityExtent of powers 33.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 DyCAO ii)Sanction for replacement of T&P items after their normal utilization for Depots/ W.shops as per guidelines issued from time to time DyCME/ WM Full powers with concurrence of DyCAO DMPowers upto Rs 300/- at a time subject to a limit of Rs 2,000 per annum Contd..

65 Delegation of Powers Pertaining to T&P S.NoNature of PowerAuthorityExtent of powers 34.i)Sanction for replacement of T&P equipments for New Depots/ W.shopsED(Z)/CME Full powers as per guidelines ii)Sanction of additional T&P for existing Depots/ W.shops on account of increase in Fleet stength/ acitivity as per guidelinesCME/ DyCME/ WM Full powers with concurrence of CFM/ DyCAO as per guidelines DMPowers upto Rs 300/- at a time subject to a limit of Rs 2,000 per annum Contd..

66 Delegation of Powers Pertaining to T&P S.NoNature of PowerAuthorityExtent of powers 35Sanction 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/CAO CME/ ED(Z) Full powers with concurrence of CFM/ DyCAO upto Rs 20,000 at a time SSOFull powers upto Rs 5,000 at a time with concurrence of Dy.CAO JSOUpto Rs 1,500 at a time

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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 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 Kms n = average life of aggregate in Kms t = 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 day a = Number of units per vehicle

71 Provisioning of Float Units to Depots S.NoUNITNORM 1Engine1 for 10,000 KMs. 2Front Axle1 for 14,000 KMs. 3Rear Axle1 for 14,000 KMs. 4Gear Box1 for 8,500 KMs. 5Steering Box1 for 10,000 KMs. 6FIP1 for 5,000 KMs. 7Self Starter1 for 4,000 KMs 8Alternator1 for 4,000 KMs. MAJOR UNITS

72 S.NoUNITNORM 1Injectors (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)1 for 5,000 KMs. 6Water pump assembly1 for 5,000 KMs. 7Cylinder head assembly1 for 5,000 KMs. 8Radiator1 for 5,000 KMs. SUB ASSEMBLIES

73 S.NoUNITNORM 1Front hub1 for 15,000 KMs. 2Rear hub1 for 15,000 KMs. 3Clutch housing1 for 15,000 KMs. 4Air cleaner complete1 for 5,000 KMs. 5Fuel twin filter assembly1 for 5,000 KMs. 6Feed pump1 for 5,000 KMs. 7Fly wheel ring gear1 for 10,000 KMs. 8Unloader valve1 for 3,000 KMs. 9Set (4) of slack adjusters1 for 3,000 KMs. 10Set (4) of spring brake chambers1 for 5,000 KMs. 11Hand brake valve1 for 10,000 KMs. 12A. C. Head1 for 5,000 KMs. MAJOR SPARES

74 S.NoUNITNORM 13Air tank1 for 10,000 KMs. 14Clutch 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)1 for 5,000 KMs. 18Set of spring brackets front (2 off)1 for 5,000 KMs. 19Set of spring brackets rear (2 off)1 for 5,000 KMs. 20Axle shafts 2 off1 for 5,000 KMs. 21H. S. D. Oil Tank1 for 6,000 KMs. 22Wiper Machine1 for 5,000 KMs. 23Batteries10% of the batteries 24Hydraulic jacks1 for 2,000 KMs. MAJOR SPARES

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 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,. Fleet HeldNorm Upto 508% 51 to 807% 81 & above6% Norm for Provision of Spare Buses

77 Physical Inspection of Buses by Depot Manager & Maintenance Incharge The Depot Manager shall inspect atleast 30 vehicles (1/3 rd 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.No SystemItem 1 EngineAir cleaner maintenance 2,,A/c Suction hose 3,,Engine mounting 4,,Engine oil leakages 5 FuelHSD tank cap seals 6,,Fuel pipe clamping 7,,Fuel leakages 8 CoolingRadiator Cap 9,,Coolant concentration 10,,Radiator mountings Contd..

79 S.No SystemItem 1 SteeringTie-rod/ drag link end play 2,,ATF oil leakages 3,,King pin lubrication 4 Susp.Broken spring leaves 5,,Spring side clamps/ ferrules 6,,Welded side clamps 7,,Spring brackets/ shackles 8,, Air suspension mounting bolts Tightness 9,, Condition of rubber bushes in Air suspension Contd..

80 S.No SystemItem 1TransmissionClutch free play 2,,Gear lever play 3,,Gear Box oil leakage 4,,Loose CJ check nuts 5,,CJ bearings condition 6,,UJ Crosses condition 7,,Sleeve yokes condition 8,,CJ rubber beds condition 9,,Slip joint Rubber boot 10,,PP shafts alignment 11,,Missing grease nipples 12,,Chassis greasing 13,,Differential oil leakage 14,,Cleanliness of breathers

81 S.No SystemItem 1 BrakesAir tank condensate 2,,Brake pipe clamps 3,,Air leakage 4,,Air Dryer working 5,,Hand brake condition 6,,Brake dust covers 7 TyresWheel alignment 8,,Matching of duals 9,,Less than 2mm NSD tyres Contd..

82 S.NoSystemItem 1ElectricalBattery Maintenance 2,,Head Lights 3,,Signal Lights 4,,Self condition 5,,Saloon Illumination 6BodyExterior/ Interior cleanliness 7,,Body damages 8,,Painting 9,,Seat Mounting 10,,Seat Upholstery 11,,Inclining mechanism 12,,Shutter glasses 13,,Doors 14,,Window Shutter Knobs 15,,Tightness of body U bolts 16,,Under chassis cleanliness

83 Checklist for Body condition CodeItem DescriptionRemarks EXT-1Body PanelsDents, Scratches, Damages EXT-2Front/ Rear BumpersBroken/missing EXT-3Front GrillDamages/ missing EXT-4Front CowlsDamages EXT-5Corner DomesDents EXT-6Passenger DoorsDamages/ missing EXT-7Driver’s DoorDamages/ locks EXT-8LadderDamages/ missing EXT-9Rear Luggage Booth (Dicky)Damages/ locks EXT-10Exterior PaintFaded EXT-11Roof LeakageArea of Leakage DEST-1Destination Board FrameSize and condition DEST-2Destination Lettering/PaintFaded DEST-3Destination Board lightingVisibility DEST-4LED DestinationCondition

84 Checklist for Body condition CodeItem DescriptionRemarks INT-1StepwellDamages INT-2FlooringCondition INT-3StanchionsBroken/missing/loose INT-4Parcel RackBroken/loose INT-5Grab rails/ Assist railsBroken/loose INT-6Cabin Partition doorCondition INT-7Interior Roof/ side panel FabricCondition INT-8Interior paintingFaded INT-9Saloon CleanlinessDirt & cobwebs GLS-1Window GlassesMissing/ Broken GLS-2Terene felt/Flock channel RubberWorn out/ missing GLS-3Window shutter knobsMissing/loose GLS-4Windscreen GlassesBroken GLS-5Top-fixed glassesBroken/missing GLS-6Windows leakageCondition of Rubber flap

85 Checklist for Body condition CodeItem DescriptionRemarks SEAT-1Seat FramesLoose/broken SEAT-2Seat CushionsHard/missing/damaged SEAT-3Seat rexine/fabricTorn SEAT-4Back restsMissing/loose SEAT-5Reclining mechanismCondition SEAT-6Arm RestsBroken/missing/loose SEAT-7Head Rest CoversMissing/dirty SEAT-8Bottle HoldersDamged/missing SEAT-9Magazine PouchesDamaged SEAT-10Foot RestsDamaged CAB-1BonnetDamaged CAB-2Dash BoardDamaged CAB-3Vision MirrorsDamaged CAB-4Cabin CleanlinessDirty

86 Checklist for Body condition CodeItem DescriptionRemarks LHT-1Interior LightiningCondition LHT-2Head LightsCondition LHT-3Tail lights/ signal indicatorsCondition SPL-1SpeakersCondition SPL-2TV/Audio SystemCondition SPL-3Cell phone chargersCondition STR-1Body U BoltsLoose/missing STR-2Ballata PackingLoose/missing STR-3Cabin FoundationLoose STR-4Antisag BarLoose STR-5Out RiggersLoose STR-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. Type Fleet Held Optd Kms Sch-III Failures within 15 days DueDoneBacklog% BacklogNos% ORD EXP Total Type Fleet Held Optd KmsSch-IV Failures within 15 days DueDoneBacklog% BacklogNos% ORD EXP Total

88 88 Important Registers maintained in Preventive Maintenance Management  Daily RG Register RTC-126  Vehicle Back History RTC-109  Sch-I Maintenance RTC-127  Sch-II Maintenance RTC -128  Sch-III work done MTD -194  Preventive Maintenance Master register RTC-110  Unit changes register  Register for Inspection of vehicles  FC Register  Breakdowns RTC-129  Cancellation 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 kms The other special type buses like Express, Deluxe, Metro Exp etc are replaced at 6.50 lakh kms

90 Type (Jan’12) Aug.Rep.TotalAug.Rep.Total S.Luxury Indra Garuda/ Garuda Deluxe Express Pallevelugu Sap.Express & Ord City Ordinary City Ord (CNG) LF A/C Diesel LF A/C CNG LF N-A/C Diesel LF N-A/C CNG SLF Diesel SLF CNG Mini Buses Total

91 Green initiatives & Use of Alternate fuels in APSRTC

92 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 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

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101 101 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

102 102 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 Aug Sep Oct Nov Dec Feb Mar

103 103 Emission Levels of trial vehicle When operated with 100% HSD oil During Trial period Jul Jan Jan Feb Mar Apr May Before Trial

104 104 Comparative Fuel Performance* of Vehicle during trials With 100% HSD oil Jul Jan With Biodiesel Jun Aug Sep Oct Nov Dec Feb Mar * Fuel Performance in Kms/Lit

105 105 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.

106 106 Vehicle No Bend % Before TrialsDuring Trials % Emission Reduction Mar 2006 Apr 2006 May 2006 Avg of three Months Jun 2006 Jul 2006 Aug 2006 Avg of three months AP11Z % AP11Z % AP11Z % Vehicle NoBend % Avg Km/Lit Before Trial Avg Km/Lit During Trial % Improvement AP11Z 38455% % AP11Z % % AP11Z % % Comparative Emission Levels Comparative Fuel Efficiency

107 107 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.

108 108 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 Limited The 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.

109 109 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)

110 110 Dip Rod Tank Level Gauge Biodiesel Storage Tank 1 ½’’ MS Line 1’’ MS Line 1’’ Flexible Hose Underground HSD Oil Tank Truck with Biodesel Transfer Pump Ground Level Biodiesel Stocking & Blending Arrangement at Depots

111 111 Procedure of Blending Biodiesel with HSD Oil Blending Biodiese with HSD for first time 1.Know the quantity of (Q1) of HSD in Ground Tank 2.Calculate required qty (Q2) of blend with HSD (Q1x10/90) 3.Transfer calculated qty (Q2) of Biodiesel from Storage tank by gravity using Flowmeter F1 Procedure for subsequent replenishments 1.Ignore the quantity of B10 blend existing in the storage tank on fresh receipt of HSD oil 2.Know the fresh quantity (Q3) of HSD that is being decanted into the underground tank 3.Calculate the required quantity (Q4) of Biodiesel to mix by using the formula Q3 x 10/90 4.Transfer the quantity Q4 of Biodiesel from Storage tank to the Underground tank with the help of Flow meter F1

112 112 Reduction of Pollutants with B20 Fuel POLLUTANT The values with Pure HSD Oil Reduction with 20% Blended Bio-diesel Total Unburned Hydrocarbons1.1gms/kwh20% Carbon monoxide4.5 gms/kwh12% Particulate Matter0.36 gms/kwh12% Oxides in Nitrogen8 gms/kwh+ 2% Sulphates--20% Polycyclic Aromatic Hydrocarbons (PAH) --13% Nitrated PAHs--50% Ozone Potential Speculated Hydrocarbons --10%

113 113 Comparative Specifications of HSD & Biodiesel Parameter ASTM Method Unit Pure Bio- Diesel Normal HSD Oil Flash PointD93 OCOC130 min66 min Water & SedimentD2709% Volume0.05 max Kinematic Viscosity 40 o cD445mm/Sec1.9 – Sulphated AshD874% mass0.02 max0.01 max SulphurD5453% mass0.05 max0.035 max Copper Strip CorrosionD130No.3 max Not worse than No.1 Cetane NumberD61347 min46 min Cloud PointD2500 OCOCReport Continued…

114 114 Comparative Specifications of HSD & Biodiesel Parameter ASTM Method Unit Pure Bio- Diesel Normal HSD Oil Carbon Residue 100% Sample D4530% mass0.05 max 0.03 max on 10% Acid NumberD664 mg KOH/gm 0.8 max-- Free GlycerinD6584% mass0.02 max-- Total GlycerinD6584% mass0.24 max-- PhosphorusD4951% mass0.001 max-- Distillation Temp. Atmospheric Equivalent Temp 90% Recovered D1160Degrees C360 max--

115 115 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 price It is difficult to assess the quality of the product at the user level Contd… There is scope for non-adherence to the prescribed specifications by the suppliers in the absence of required testing facilities.

116 116 It is difficult to send the samples to the laboratories too frequently. The blending becomes uneconomical if the suppliers quote exorbitant prices due to monopoly Premature clogging of filters is more prevalent while using Biodiesel

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