1. IMPROVING UTILIZATION OF SMALL TRACK MACHINES
By Suresh Gupta, Dean/IRICEN

2. Overall scenario Complete mechanization by 2012
3-tier system of track maintenance
On-track machines (OMU)
Mobile maintenance units (MMU)
Sectional gangs
IRPWM gives a list of equipments for MMU which includes many STMs
MMU-I : one for each PWI section
Communication equipment
Rail cutting /Drilling equipments
Rail/Welding equipment
Spot tamping with lifting lining
Inspection gadgets, material handling equipment & safety and protection equipments

3. Overall scenario (Cont’d..)
MMU-II : one for each sub-division
Points and crossing reconditioning equipment
For minor repairs to equipments
STM manual also gives a scale of stms
There is a difference in machines as given in STM manual & that given in for MMU-I and MMU-II in IRPWM
We should review requirement of type of machines and their scale
Should have minimum but reliable & sturdy machines, which do-not fail frequently

4. Review of Usage of Small Track Machine
Some track machines are popular amongst field staff
(Abrasive rail cutter, Rail cutting machine saw type, drilling machine, Mechanical & Hydraulic track jack, Light weight rail (mono) cum road trolley)
A few machines have been found to be less useful
(Hydraulic -Rail tensor, Rail bender, TRALIS, Concrete sleeper breaker, Concrete sleeper drilling machine)
A few machines have not been procured/tried because their need has not yet been felt by field staff
(Hydraulic sleeper spacer, Portable ballast cleaner)
In general the utilization of STM remains poor

5. Reasons for Poor Utilization
Resistance to change: Transition always brings extra effort, tension, insecurity
Need to conduct more seminars at grass root level
Old system should not be allowed to run parallel to new system
Incentive for adopting new system
But resistance to change is not the main reason for poor utilization.

6. Reliability of STM
Reliability of machines: poor, resulting in frequent break down of machines
Fault lies in design
Whole system of approval of small track machines is defective
We should use machine modules/assemblies readily available in market by standard manufacturer with proven track record.

7. Difficulties in transportation
Work sites are remote and mostly inaccessible by Road and loading/unloading of these machines is cumbersome.
Provision of sufficient trucks with winch arrangement for loading/unloading.
Hiring of tractors
Provision of sufficient heavy duty material trollies.

8. Problem of consumable
Non Availability of Petrol & Other Consumable Stores
Sufficient Imprest need to be provided with SE/P Way Concerned.

9. Lack of trained manpower
Cadre under every SE/PWay or ADEN should be fixed in terms of Technicians and helpers as per norms of small track machines per PWI or ADEN.
The minimum qualification for them should be ITI.
As a immediate measure some interested trackmen may be trained at DETS by manufacturers

10. Problems of Repair No norms for critical inventory of spares exist.
No separate cadre for repair. one SE
PWI should have staff for repair and maintenance .
Powers for repair given in the manual are not adequate
Manufacturer to submit Operational and trouble shooting manual as well as list of spare parts with details of source along with every machine.
As far as possible AMC of equipment for a period of three to five years should be part of procurement tender.
Separate posts of Technicians to be created and filled by at least ITI qualified candidates.

11. Powers in procurements of STM
Procurement of Track machines
Limited provision under revenue.
Funds Need to be provided in CTR estimates.

12. YARDSTICK OF VARIOUS SMALL TRACK MACHINES
Type of Machine
Quantity
Manpower
Manpower proposed
Skilled
Unskilled 1
Abrasive Rail Cutter
3 per SE (Suburban) 2
1 per SE (Other than suburban)
1 per ART
Abrasive Rail Cutting Wheel
As required 3
Rail Cutting Machine (Saw Type)
2 nos. per SE (other than Suburban) 4
Hacksaw Blade for cutting rails

13. YARDSTICK OF VARIOUS SMALL TRACK MACHINES5
Rail Drilling Machine
2 per Se (Suburban) 1
1 per SE (other than suburban)
1 per ART 6
Chamfering Kit
1 per SE 7
Portable DC Welding Generator 8
Double Action Weld Trimmer for AT Welding (Power Pack Version)
1 per welding unit 9
Rail Profile Weld Grinder
1 per Welding unit 10
Light Weight Rail (Mono) cum Road Trolley
2 per gang 2 11
Heavy Duty Hydraulic Extractor for Jammed ERCs

14. YARDSTICK OF VARIOUS SMALL TRACK MACHINES12
Mechanical Track Jack 1 2 8 13
Hydraulic Track Jack
4 per gang/unit gangs 14
Portable track lifting & slewing device (TRALIS)
2 per SE 15
Hand held off track tamper
3 per SE gangs 6 10 16
Hydraulic Rail Tensor (non-infringing type), 70t capacity 3 17
Hydraulic Rail Bender (Jim Crow), Heavy duty
1 per SE 18
Hydraulic Rail Joint Straightner
1 per sub division 19
Toe Load Measuring Device (Mechanical) 20
Powered Material Trolley 7
2 per gang/unit

15. YARDSTICK OF VARIOUS SMALL TRACK MACHINES21
Rail Creep Adjuster
1 per SE 1 22
Hydraulic Sleeper Spacer
2 per SE 23
Concrete Sleeper Breaker with Angle Grinder
1 per ART 24
Concrete Sleeper Drilling Machine
1 per Division 25
Electronic Toe Load Measuring Device 26
Portable ballast cleaner (Semi-mechanised)
1 per gang 2 27
Potable shoulder ballast compactor 28
Self propelled light weight trolley
1 per AEN 29
Jib Crane attachable to BFR-BRH for handling concrete sleeper
As required 30
Attachment for Rail Dolly for PRC sleeper
4 per SE 31
Powered Rail Hauling System
1 per PQRS site
TOTAL

16. System of MMU in KRCL Every SSE maintaining approx. 100 kms track
Assisted by two JE/SE
Each JE/SSE having one miscellaneous gang of 11 track man
One RMV (Rail maintenance vehicle) given to each SSE, headed by JE/SE and following staff
a) MSM (multi skilled man-ITI pass) – 6
b) Track men – 4
Note- MSM will also drive the RMV

17. Small track Machines in RMV
Abrasive rail cutting machine - 1no
Drilling machine – 1 no
Off track tampers – 1 set (four tampers)
Mechanical track lifting jacks – 2 nos.
Tralis – 1 set
Rock splitter – 1 no.
SKV welding equipments – 1 set
One rail piece of about 6m is also loaded on RMV

18. Conclusion
Adoption of small track machines is a must to supplement heavy on line track machines so as to achieve complete mechanisation of track maintenance.
To make it a success a multi pronged approach is required right from design stage to solving problems at field level so that utilisation of STMs can be improved and we are ready for complete mechanisation by 2012