Amrs

Modernization of Stores Depot Modernization of Stores Depot Lower Parel Lower Parel

through through

Intelligent Warehousing Intelligent Warehousing with with

Automated Storage and retrieval Automated Storage and retrieval SystemSystem

Jogendra YadvenduJogendra YadvenduDy.CMM-II,CCG, WRDy.CMM-II,CCG, WR0989232748109892327481

Modernization of Carriage Stores Depot at Modernization of Carriage Stores Depot at Carriage Repair Workshop, Lower Parel, Western Carriage Repair Workshop, Lower Parel, Western

RailwayRailway Carriage Stores Depot at Lower Parel is the biggest

Stores Depot on Western Railway.

Annual material issues value of Rs. 600 Million.

Accounts for approximately 25 % of the annual issues on Western Railway.

Caters to Carriage Workshop & Divisional Consignees (29).

It stocks around 1200 stock items out of which 167 are safety, 257 are vital, 38 passenger amenity items .

LHB Coach is a new technology with many items being imported and limited indigenous vendors

Major activity at Parel Major activity at Parel WorkshopWorkshop

Activity Type 2006-07 07-08 (estimate)

POH ICF 1531 1550

LHB 62 36

RSP ICF Refurbishment of toilets, Laying of Stainless Steel Inlay, changing LP Sheet, Limpet Sheet

LHB Refurbishment of toilets, changing the main door

What does modernization involve ?

Pragmatic mix of IW-ASRS, Drive in Pallet System, Selective Pallet System, conveyor systems etc.

Structurally strong building with adequate free height for vertical storage.

Adequate material handling equipments and transportation facilities such as platform trucks, forklifts , LMV, HMV .

RDBMS based IT application for purchase & Inventory management with adequate Hardware resources.

Estimated cost of the Estimated cost of the projectproject

Sanctioned in M&P Program for the year 2007-08 under plan head 42.

Cost: Rs. 138 Million. Components involved;Components involved; IW-ASRS; Drive in Pallet & Selective Pallet System. 3 & 5 Ton Forklift 5 Ton Road Crane Truck 9 & 16 Ton Multi-utility Vehicle Platform Trucks & Others. 3 Ton EOT Crane.

Why use IW-ASRS at Parel Depot Parel workshop has one of the smallest footprint

to Coach POH ratio. Located in the heart of Metropolitan city-

Mumbai with costly land where lateral expansion is not an option.

POH target of ICF, LHB increasing. Area can be released for workshop

modernization & expansion activities only by releasing the dead space being occupied by multifarious stores godowns.

This is where IW-ASRS comes into play. IW-ASRS utilizes vertical storage capacity

leading to efficient storage & retrieval

Proposed site at Lower Parel Central ward of Parel Depot Measures 50m * 45 m 50% area with mezzanine floor Max. free height available 6 m. Free height available in mezzanine

area is 3 m. Cemented flooring.

General Specifications of IW-ASRSGeneral Specifications of IW-ASRS S/R Machine: Construction: Modular component design. All parts

designed for 100% duty cycle. Welded steel frame. Single mast tube, strut braced. Structural steel base.

Drive and Idler Wheels: Flanged forged alloy steel. Case Hardened to 55 Rockwell C. Reground for concentricity. Heavy-duty pillow block bearing support.

Fork Extractor Mechanism: • Construction: Precession fabricated steel • Load Capacity: 1500 Kg. • Load Support: Industrial Standard Forks • Extractor Drive: Patented ball screw and rotator

with variable frequency drives, industrial gear reducers, and    brake.

Crane Rail with V-H DrivesCrane Rail with V-H Drives Crane Rail:Crane Rail: • Floor mounted , Rail mounted .

Vertical & Horizontal Drives:Vertical & Horizontal Drives:

High performance sine-coded, pulse width modulated AC vector motor drives which generates an adjustable voltage/ frequency three phase output for complete speed control.

Automatic stall prevention and voltage boost prevents nuisance tripping during load or line side transient conditions.

The drives will not induce any voltage or distortion back into the utility line and maintains a displacement power factor of not less than 0.98 throughout its speed range.

Communication & ControlsCommunication & Controls Communication:Communication: • • Infrared Modem

S/R Machine Controls:S/R Machine Controls: Electrical Components: IEEE code compliance

throughout. IEEE rated enclosure, sensors, and wiring. Panel-mounted diagnostic indicator lights. Panel-mounted maintenance controls.

Logistics and Positioning: Onboard programmable controller A-B SLC-500® communication by infrared modem. Steel code bar, optical address readers. Fine positioning, motor-mounted resolvers with 1/16'' accuracy or 1 deg. Accurate positioning on start-up.

Rack & PalletsRack & Pallets Safeguards:Safeguards: Front and rear aisle-obstruction detectors. Onboard

and off-board emergency stops. Load and centering sensors and interlocks.

Rack Structure: Virtually any post and beam (conventional) existing or

new racks capable of safely bearing the pallet loads (pushback and flow rack). Continuity of vertical shelf distance from floor not required. Common depth dimension recommended, but differing depths can often be accommodated. Racks must be attached to the floor but no shimming is needed except with extreme floor conditions.

Maximum Height: 100 ft. Pallets:Pallets: Any two or four way pallet capable of being used.

Activities involved in Activities involved in ASRSASRS

Civil Engineering work of site preparation Leveled flooring with adequate bearing

capacity Adequate free height for 15-20 m for

vertical storage & movement of vertical crane.

New light weigh roof Power requirements

Modus Operandi of execution Prepare detailed sub estimate of electrical, civil &

mechanical portion . Obtain sanction of respective HOD. Prepare STR & DPR. Obtain sanction of GM. Prepare material schedules for purchase components . Prepare tender schedule for works portion. Obtain dispensation from COFMOW. Float only one works tender to take care of mechanical,

civil as well as electrical work to be carried out by a single agency on a turn key basis.

Have provision for operation for 2 years by the contracting agency along with training to be followed by five years comprehensive AMC.

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Series1

Series2

Management of stores functions during Management of stores functions during construction in central wardconstruction in central ward

Shift the employees to the new office Shift the employees to the new office building coming up under GM’s Power.building coming up under GM’s Power.

Shift bogie items to bogie sub stores.Shift bogie items to bogie sub stores. Create sub stores in paint shop for Create sub stores in paint shop for

paint items & use the released space paint items & use the released space for bogie components.for bogie components.

Create sub store in furnishing for Create sub store in furnishing for furnishing items.furnishing items.

Use timber ward for large & costly Use timber ward for large & costly stores.stores.

Use jumbo siding for heavy, big stores.Use jumbo siding for heavy, big stores.

!!

PLAN, ELEVATION & SECTION OF PLAN, ELEVATION & SECTION OF

PAREL STORES DEPOTPAREL STORES DEPOT

FRONT VIEW OF IW-ASRS AT FRONT VIEW OF IW-ASRS AT PAREL STORES DEPOTPAREL STORES DEPOT

TOP VIEW OF PAREL STORES DEPOT TOP VIEW OF PAREL STORES DEPOT WITH IW-ASRSWITH IW-ASRS

PALLET & SECTION AT “C”PALLET & SECTION AT “C”

Generation of Barcode at Purchaser’s PremisesGeneration of Barcode at Purchaser’s Premises

Barcode ComponentsBarcode Components

•Vendor IDVendor ID

•Item CodeItem Code

•Consignee Consignee CodeCode

•Order No, DateOrder No, Date

ADC TechnologiesADC Technologies

Voice systemsVoice systems RFIDRFID OCROCR pick-to-lightpick-to-light laser scannerslaser scanners Bar-codingBar-coding CCD scannersCCD scanners hand-held batch and RF terminalshand-held batch and RF terminals vehicle-mounted computersvehicle-mounted computers wearable computers wearable computers