Reduce Rake Cycle Times with A Category Problems

J S P L,
RAIGARH
STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

MATERIALS
CHAPTER 4
CASE ANALYSIS
4.1 TOOLS AND TECHNIQUES
We have collected data of various problems at wagon tippler from Feb11 to
june11. Generally 34 problems occur at that area. Some problems impact
more and some problem impact less. But, We have further categorized that
problem into three category these are A, B and C. In category A we take
those problems which are only 20% in number but their impact in process is
80%. Similarly, In category B we take that problems which In number are 30%
but in weight age
only 15%. In category C we take that problem which
weight age is only 5% but in number 50%. Our main target is to reduce the A
category problem and this will result in the maximum reduction in the overall
impact and will help as the weightage of the A category problem is around
80%. Thus the unloading management of the organization should concentrate
on these A category problem and hence will help in reducing the Rake-in to
Rake-out cycle time of inward raw materials.
INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD
32

MATERIALS
6%
17
565
43
9%
26
25
27
12%
28
150
260
15
15%
23
638
24
670
25
18%
12
390
15
895
21%
10
695
24%
24
30
26%
11
10
29%
25
11
32%
12
Overall Delay
% of Delay
9101
341
27%
4645
129
14%
3188
62
10%
2560
18
8%
800
2108
72
6%
19
695
1980
41
6%
295
260
1250
18
4%
280
28
935
1245
35
4%
120
24
675
95
890
38
3%
75
11
295
11
395
765
25
2%
105
445
165
715
19
2%
35%
23
330
375
705
2%
13
38%
10
375
155
145
675
15
2%
14
41%
20
150
215
220
585
13
2%
15
44%
13
14
425
140
565
20
2%
16
47%
14
20
150
225
395
10
1%
17
50%
21
11
205
35
95
335
14
1%
346
0
182
0
131
5
147
69
34
366
1
226
0
184
8
215
0
910
1
137
46
169
34
194
94
216
02
235
82
248
32
260
77
269
67
277
32
284
47
291
52
298
27
304
12
309
77
313
72
317
07
% of cum duration
135
Duration (min)
198
0
Cumulative
Total Delay Frequency
59
Duration
(min)Total Delay Duration
Overall
Delay
Durati
on (A+
B+ C)
(min)
Frequency
3%
Delay code
% of sl. No.
Sl.No.
Table No. 4.1 : OVERALL DELAY DURATION AT WAGON TIPPLER # 1, 2 ,3

Wagon
Wagon
Wagon
tippler #
tippler #
tippler #
1
2
3
27%
41%
51%
58%
65%
71%
74%
78%
81%
83%
85%
87%
89%
91%
93%
94%
95%
33
Delay per Frequency
J S P L,
RAIGARH
27
36
51
14
2
29
48
69
36
23
B
31
38
78
45
45
28
40
24
J S P L,
RAIGARH

MATERIALS
18
53%
30
210
96
306
1%
19
56%
31
160
80
240
1%
20
59%
17
195
195
1%
21
62%
32
145
145
0%
22
65%
18
130
130
0%
23
68%
33
125
125
0%
24
71%
15
35
20
35
90
0%
25
74%
22
10
80
90
0%
26
76%
29
85
85
0%
27
79%
40
40
80
0%
28
82%
19
75
75
0%
29
85%
15
45
60
0%
30
88%
25
25
0%
31
91%
16
25
25
0%
32
94%
34
20
20
0%
33
97%
27
15
15
0%
34
100
%
10
10
0%
Table
No.
4.2
Flow
process
chart
of
320
13
322
53
324
48
325
93
327
23
328
48
329
38
330
28
331
13
331
93
332
68
333
28
333
53
333
78
333
98
334
13
334
23
96%
96%
97%
98%
98%
98%
99%
99%
99%
99%
100
%
100
%
100
%
100
%
100
%
100
%
100
%
51
60
98
48
13
0
31
15
13
85
27
75
15
13
25
20
15
10
wagon
placement to unloading
Flow Process Chart
Chart No.
Sheet No.
.
Of
Subject Charted:
Wagon Placement to
unloading
position (Tippler)
Worker
Material / Equipment type

Summary
Activity
Present
Propos
ed
Operation
Transport
34
Savi
ng
J S P L,
RAIGARH
Activity:

MATERIALS
Delay
Inspection
Storage
Method:
Present /
Proposed
Location:
Operative
(s):
Clock Nos.
Cost
Labor
Date:
Material
Date:
Total
Qty Distan
.
ce (m)
Charted
by:
Approved
by:
Description
Distance(m)
Time(workmin./sec)
Time
(min)
Symbol
Remarks
1. Rake-in at line # 1 to 7
(any)
2. Pressure release of first

20 wagons lot
20
one man
working(in day
I man & in
night 2 man)
3. Wagon attach to the

JSPL loco
4. First 20 wagon detach
from full rake
5. Track positioning to
wagon tippler
6. Moving from full rake to

wagon tippler 1, 2, 3
7. JSPL loco detach tippler

position
Total
Table No. 4.3 : Flow process chart of wagon

unloading
35
J S P L,
RAIGARH
Flow Process Chart

MATERIALS
Worker
Material / Equipment type
36
J S P L,
RAIGARH
Chart No. .

MATERIALS
Sheet No.
Of
Summary
Subject Charted:
Activity
Wagon unloading
Operation
Present
Propos
ed
Savi
ng
Transport
Activity:
Delay
Inspection
Method:
Location:
Operative(s):
Present / Proposed
Charted by:
Approved
by:
Date:
Clock Nos.
Date:
Description
Storage
Distance(m)
Time(work-min./sec)
Cost
Labour
Material
Total
Qty Distan
.
ce (m)
Time
(sec)
1. SAC travel
30
2. SAC connect to wagon and

ready to pull and travel
positioning at unloading point
25
3. SAC decouple
90
4. Empty wagon push out
35
Symbol
Remarks
Parallel
activity
5. SAC to his positioned empty

side
10
6. Wagon Unloading
55
Total
Excluding
parallel
37
J S P L,
RAIGARH

MATERIALS
4.2 DATA COLLECTION OF INWARD RAKE OF RAW MATERIAL THROUGH RAIL

AND ITS ANALYSIS (FEB11 TO JUN11)
To assess the quantum of inward rake of raw material through rail, we have
collected month-wise data of Rakes from Apr08 till Dec12. The summary of
inward rakes of raw material Rail is shown below:
TABLE NO. 4.4: Average Monthly Inward Rake of Raw Material

(2008-09 to 2011-12)
AVERAGE MONTHLY INWARD RAKE OF RAW MATERIAL

MONTH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
NOVEMBER
DECEMBER
JANUARY
FEBRUARY
MARCH
TOTAL
Avg/Month
YEAR 08 - 09
174
179
492
139
148
154
453
151
147
150
433
136
139
115
408
154
YEAR 09- 10
180
149
472
143
152
152
470
166
186
168
563
209
186
163
549
200
YEAR 10- 11
185
204
556
167
183
178
545
184
195
182
561
184
178
174
543
191
YEAR 11- 12
148
190
514
176
171
185
490
134
180
183
575
212
1786
2054
2205
1579
149
171
184
175
38
J S P L,
RAIGARH

MATERIALS
From the above data,the average Rake of inward raw material
increased
from 149 Rake during 2008-09 to 175 Rake in 2011-12 (upto Dec11) i.e.
increase of around 9%.
39
J S P L,
RAIGARH

MATERIALS
TABLE NO. 4.5: Data Collection Of Inward Rake Of Different Raw Material
Through Rail And Its Analysis. (Feb11 To Jun11)
(See Annexure 1)
MATERIAL
SARADA (BF)
PELLETS
TENSA (S-16 + BF 1)
TENSA - FINES ORE
COKING COAL
MANGANEESE ORE
LIME STONE
NUT COKE
LIME STONE
COKE FINES
DOLOMITE
DOLOMETRIC
L.STONE
MANGANEESE ORE
CLINKLER
TOTAL
MONTH
FEB'11
MAR'11
APR'11
MAY'11
JUN'11
15
49
25
43
21
46
27
45
26
46
17
18
10
14
13
29
39
0
2
0
7
3
13
33
44
0
2
0
12
2
8
27
24
0
4
0
9
1
3
32
47
3
0
0
9
2
7
34
27
3
6
2
11
1
5
0
0
174
1
3
191
1
2
148
2
2
190
1
1
176
40
J S P L,
RAIGARH

MATERIALS
41
J S P L,
RAIGARH

MATERIALS
42
J S P L,
RAIGARH

MATERIALS
4.3 DATA COLLECTION OF RAKE-IN TO RAKE-OUT CYCLE TIME & ITS

ANALYSIS
We have collected details of inward Rakes of Raw material received during

April09 to Aug09; Rake in to Rake out time for each rake and analyzed the
time spent on various activities viz. from Rake placement (by railway loco) to
Unloading start time in Tippler 1, 2 & 3, Rake Unloading time at Tippler 1, 2 /
3, Rake formation time & Rake release time. Depending upon the materials,
Tippler availability and space available in different yards, full or part Rakes
are placed near the wagon tippler 1, 2 or and 3. Generally, a set of 20
wagons are placed at a tippler and this process of wagon placement is called
lot placement. The summary of the time spent for different activities for
Unloading full rake of material is as follows:
(See Annexure 1)
43
J S P L,
RAIGARH

MATERIALS
Table no.4.6: Material wise In ward Rake movement data ( April '09 to Aug'09)
Placement to
unloading
start duration
(A)
Unloading
start to
unloading
completion
duration (B)
Unloading
completion to
Rake
formation
duration (C )
Rake
formation
to rake
release
duration
(D)
Rake- in to
rake -out
time (E) =
(A) + (B) +
(C ) + (D)
MIN
0:20:00
1:35:00
0:05:00
0:00:00
5:25:00
MAX
19:30:00
24:00:00
5:25:00
0:55:00
44:05:00
AVERAGE
2:45:57
6:58:58
0:58:05
0:06:46
10:49:46
Commodity
COAL
COKE
Details
COUNT
130
PERCENTAGE
WRT OVERALL
MIN
17%
1:00:00
5:05:00
0:30:00
0:00:00
7:05:00
MAX
10:05:00
7:40:00
1:40:00
0:15:00
18:55:00
AVERAGE
4:46:26
6:14:17
0:59:17
0:04:17
12:04:17
COUNT
DOLOMIT
E
IRON ORE
LIME
STONE
OVER ALL
PERCENTAGE
WRT OVERALL
MIN
0:30:00
2:55:00
0:15:00
0:00:00
5:00:00
MAX
10:00:00
7:30:00
4:45:00
0:35:00
17:10:00
AVERAGE
3:07:40
5:02:20
1:03:15
0:10:14
9:23:29
1%
COUNT
43
PERCENTAGE
WRT OVERALL
MIN
6%
0:15:00
1:10:00
0:00:00
0:00:00
3:50:00
MAX
19:55:00
18:25:00
12:30:00
2:10:00
31:05:00
AVERAGE
2:28:47
4:54:07
1:05:14
0:12:05
8:40:13
COUNT
542
PERCENTAGE
WRT OVERALL
MIN
71%
0:30:00
2:45:00
0:20:00
0:00:00
5:20:00
MAX
16:35:00
12:30:00
5:15:00
1:00:00
24:30:00
AVERAGE
3:34:33
5:07:23
1:07:10
0:10:27
9:59:33
COUNT
44
PERCENTAGE
WRT OVERALL
MIN
6%
0:15:00
1:10:00
0:00:00
0:00:00
3:50:00
MAX
19:55:00
24:00:00
12:30:00
2:10:00
44:05:00
AVERAGE
2:38:55
5:17:16
1:03:58
0:10:55
9:11:03
COUNT
766
44
J S P L,
RAIGARH

MATERIALS
PERCENTAGE
WRT OVERALL
100%
The data of time spent on different activities for individual rake for the above
said period is shown in the enclosed Annexure-I
From the above table we observe as follows:
On an average around 154 rakes of Raw material unloaded per month

i.e. around five rake per day. Out of these, 0.9 Rake/ day are of coal &
coke, 0.3 Rake/ day of Dolomite, 0.3 Rake/ day of limestone, and 3.5
Rake/ day of Iron ore.
The average Rake-in to Rake-out Cycle time is around 9 hours 11

Minute per rake against the free time of only 7 hours given by Railways
during these months. Hence, on an average there is a demurrage of 2
hour 11 Minutes per rake. Now the free time has been relaxed from 7
hours to 8 hours w.e.f. from Aug 09. But still our Rake in to Rake out
cycle time is beyond 8 hours.
The average Rake-in to Rake-out cycle time of Iron ore, Dolomite, Lime
stone, Coal and Coke is 8 hrs. 40 min., 9 hrs. 24 min., 10 hrs., 10 hrs.
50 min., and 12 hrs. 4 min respectively (During April09 to Aug09).
45
J S P L,
RAIGARH

MATERIALS
overall average Rake-in to Rake-out cycle time of all raw material is 9

hrs. 11 min (During April09 to Aug09).
The frequency distribution for number of rakes against Time interval of RakeIn to Rake-out time is shown below:
Table no.4.7: Rake-in To Rake-out Duration (April'09 to Aug'09)
Time Interval (hrs.)
No. of Rake
Cum. Frequency
Percentage of
cum. Freq.
<3
0%
3-4
0%
4-5
21
22
3%
5-6
106
128
17%
6-7
182
310
40%
7-8
93
403
53%
8-9
84
487
64%
9 - 10
69
556
73%
10 - 11
39
595
78%
11 - 12
34
629
82%
12 - 13
25
654
85%
13 - 14
22
676
88%
14 - 15
21
697
91%
15 - 16
16
713
93%
16 - 17
11
724
95%
17 - 18
731
95%
18 - 19
734
96%
19 - 20
741
97%
20 - 21
743
97%
21 - 22
748
98%
22 - 23
751
98%
46
J S P L,
RAIGARH

MATERIALS
> 23
15
766
100%
Average
line
The above Frequency Distribution table indicates that only 53% of rakes take
up to 8 Hours of Rake-in to Rake-out time and 22% of rakes take more than
11 hours of the time.
The average Rake placement to unloading start time is 2 hours 39

minutes with the variation from 15 minutes to 19 Hours 55 minutes per
rake. This clearly indicates huge variation in the Rake placement to
unloading start duration.
47
J S P L,
RAIGARH

MATERIALS
The frequency distribution for number of rakes against Time interval of Rake
Placement to Unloading start time is shown below:
Table 4.8: Rake Placement to Unloading Start Duration ( April

09 to Aug' 09)
Time Interval (min)
No. of Rake
Cum. Frequency
Percentage of cum.
Freq.
< 30
38
38
5%
30 - 60
233
271
35%
60 - 90
137
408
53%
90 - 120
62
470
61%
120 - 150
43
513
67%
150 - 180
26
539
70%
180 - 210
32
571
75%
210 - 240
28
599
78%
240 - 270
19
618
81%
270 - 300
25
643
84%
300 - 330
12
655
86%
330 - 360
21
676
88%
360 - 390
14
690
90%
390 - 420
11
701
92%
420 - 450
13
714
93%
450 - 480
721
94%
480 - 510
726
95%
510 - 540
731
95%
540 - 570
736
96%
48
J S P L,
RAIGARH

MATERIALS
570 - 600
742
97%
> 600
24
766
100%
The above Frequency Distribution table indicates that about 67% of rakes
take up to 150 minutes (2.5 Hrs.) of Rake Placement to Unloading Start time
and 16% of rakes take more than 300 minutes (5 Hrs.) of the time.
The average unloading time per rake is 5 Hours 17 minutes with the
variation of 1 hour 10 min. to 24 hours for 59 wagons per rake at
49
J S P L,
RAIGARH

MATERIALS
different tippler. This indicates the average unloading time per rake is
very high.
The frequency distribution for number of rakes against Time interval of

unloading duration is shown below:
Table 4.9:Unloading Duration (April 09 to Aug 09)

Time Interval (hrs.)
No. of Rake
Cum. Frequency
Percentage of cum.
Freq.
<1
0%
1-2
1%
2-3
49
53
7%
3-4
120
173
23%
4-5
264
437
57%
5-6
136
573
75%
6-7
91
664
87%
7-8
42
706
92%
8-9
17
723
94%
9 - 10
13
736
96%
10 - 11
745
97%
>11
21
766
100%
50
J S P L,
RAIGARH

MATERIALS
The above Frequency Distribution table indicates that only 7% of rakes are
unloaded within 3 hours, 75% of rakes are unloaded within 6 Hrs. and 8% of
rakes take more than 8 hours.
The average unloading completion to Rake formation time is around 1

hour 3 minutes with the variation of 5 minutes to 12 hours 30 minutes
for one complete Rake. This is a huge variation.
Formation time is shown below:
TABLE 4.10: UNLOADING COMPLETION TO RAKE FORMATION TIME
(APRIL09 AUG 09)
Time Interval (min)
No. of Rake
Cum. Frequency
Percentage of cum.
Freq.
< 30
149
149
19%
51
J S P L,
RAIGARH

MATERIALS
30 - 60
314
463
60%
60 - 90
196
659
86%
90 - 120
42
701
92%
120 - 150
23
724
95%
150 - 180
16
740
97%
180 - 210
746
97%
210 - 240
749
98%
240 - 270
753
98%
270 - 300
759
99%
> 300
766
100%
The above Frequency Distribution table indicates that 19% of rakes formation
is done within 30 minutes, 86% of rakes formation is done within 90 minutes
52
J S P L,
RAIGARH

MATERIALS
(1.50 Hrs.) and 5% of rakes take more than 150 minutes (2.50 hours) for rake
formation.
The average Rake formation to Rake release time is around 11 minutes

with the variation of 0 minutes to 2 hours 10 minutes for one complete
Rake.
release time is shown below:
TABLE NO: 4.11: RAKE FORMATION TO RAKE RELEASE TIME (APRIL09

AUG09)
Time Interval
(min.)
No. of Rake
Cum. Frequency
Percentage of cum.
Freq.
< 20
618
618
81%
20 - 40
112
730
95%
40 - 60
25
755
99%
60 - 80
761
99%
80 - 100
764
100%
100 - 120
765
100%
> 120
766
100%
53
J S P L,
RAIGARH

MATERIALS
The above Frequency Distribution table indicates that 81% of rakes are
released within 20 min and 5% of rakes take more than40 min.
Out of 766 rakes of raw material during this period ( April09 to

Aug09), 130 rakes were of Coal, 7 rakes coke, 43 rake dolomite, 542
rakes Iron ore and 44 rakes lime stone. (see Annexure 1)
The average Rake-in to Rake-out time of coal is 10 hrs. 50 min, coke is

12 hrs 4 min, Dolomite is 9 hrs 24 min, Iron ore is 8 hrs 40 min and
Lime stone is 10 hrs.
We have further analyzed and observed that the nos. of rakes unloading
during different period of the month has vide variation as shown in the
following table:
54
J S P L,
RAIGARH

MATERIALS
Table 4.12: Nos. of Rakes inward raw material in month

Month
Nos. of Rakes inward raw material in month during

1st to 10th days
11th to 20th days
21st to 30th/ 31st days
April'09
56
62
61
May'09
50
48
50
Jun'09
53
46
41
July'09
47
44
61
Aug'09
47
44
56
Overall
253
244
269
Avg. / Month
50.6
48.8
53.8
Avg./ Day
5.1
4.9
5.4
Number of inward rakes on an average is almost same for the consecutive 10

days gaps of 5 analyzed months viz. April09 August09. The same analysis
55
J S P L,
RAIGARH

MATERIALS
was done further for 5 days gap and that too has been observed to be the
same as shown in table below.
Table no.4.13: NO.OF INWARD RAKES DURING PERIOD OF MONTH
(APRIL'09 TO AUG'09)
Nos. of Rakes inward raw material in month during
Month
1st to 5th
days
6th to 10th
days
11st to
15thdays
16st to
20thdays
21st to
25thdays
26st to
30th/
31stdays
28
28
31
31
34
27
April'09
25
25
Rake May'09
Placement time
starts when
the
23
25
27
23
Carriage
& Wagon
(C&W)
staff
27 No.
Rake Jun'09
is placed at Line
22
24 fit memo
19 to Asst.22
gives
Station
July'09 7 and Railway

19
1/2/3/4/5/6/
loco28is
21
23
39
Master
- KDTR 22
for withdrawal
of
detached
Aug'09
unloaded
Rake25
17
Rly.
TOTAL
Liasoning
Avg. / Detail
Month
Rake
26
22
25
27
121
132
informs
124
120
127
142
26.4
Control,
24.8
24
25.4
28.4
5.3
5.0
4.8
5.1
5.7
Supervisor
to24.2 Plant
Avg./ Daylogistics4.8
Unloading
section
31
4.4: EXISTING FLOW PROCESS CHART OF RAKE PLACEMENT
Unloading Logistics section asks for
TO RAKE DRAWN OUT (INWARDS TRAFFIC)
JSPL loco for placement of Rake (part

For Raw material unloading from Rake, the various
In steps
case,between
some wagons
or full). In the mean while, brake
are
identified
pressure
is released.to The
is
Rake placements
rake rake
handover
to railways have
been unfit
shownor sick, it is
repaired, if possible. Otherwise,
placed at Wagon Tippler.

below:
detached
from
the
Rake.
Marshalling is done by C & W

When the unloading starts, time is
staff, if required.
noted by unloading Logistics section

& informs Railway Logistics
unloading
completion
time
is
informed by unloading Logistics to
Inspection done by Railway C &

W staff after Engine on Train
Railway Logistics
Release memo is issued to CGS,
56
Rake formation
wagonsOF
is MINES
done by
INDIANof
SCHOOL
UNIVERSITY, DHANBAD
KDTR by Siding Supervisor of
loco section at nominated line by
Rly. Liasoning.
Railway Logistics
J S P L,
RAIGARH

MATERIALS
4.5: EXISTING RAILWAY TRACK & RAKE UNLOADING AREA LAYOUT
Presently, there are seven railway tracks in inward unloading side and these
lines merge to single line towards the Kirorimal railway Station. line no.1, 2,
3 , 4, 5,6,7 have no overhead electrified line so that railway electric loco cant
move in either of these lines. As per present practice, Railway Electric Loco
push the loaded Rake from Kirorimal Station and after placing the full loaded
rake in Line no.1 to 7. The railway loco moves away. Full loaded rake of raw
material is handed over to JSPL at these lines and the time of rake supply is
noted by Railway.
57
J S P L,
RAIGARH

MATERIALS
There are three unloading tipplers namely Tippler #1, Tippler #2 and Tippler
#3. Tippler #1 is connected with line no4, Tippler #2 is connected with line
no.1 and Tippler #3 is connected with line no.2.
LOCATION AT TIPPLER &

STOCK YARD
TIPPLE
R NO.
LOCATED AT
HOPPER
CAPACITY
LINE NO.4
3 WAGONS
LINE NO.1
6/7
WAGONS
LINE NO.2
6 /7
WAGONS
CONNECTED
TIPPLER TO
STOCK YARD
DRI - 1 ,DRI - 2,
RMH-3
DRI - 2, RMH-3
There are three stock yard in JSPL, Raigarh namely DRI-1 or RMH-1, DRI-2 and
RMH-3 (A, B and C, D) yard. Each yard have a capacity is around 1,00,000
ton. (see Annexure.).
After the unloading of wagons placed at empty lines. On completion of empty
rake formation the railway is informed for taking out the unloaded rake and
the time of information is recorded. The time between the empty rake
handover by railway to JSPL and the information to railway that rake is ready
to be taken out is called the Rake-in to Rake-Out time and this duration is
taken for computation of railway demurrages. During our study the Railway
has permitted 7 hours as free time and beyond this time, they will charge
demurrage @ Rs. 100/- per hour per wagon.
58
J S P L,
RAIGARH

MATERIALS
4.6: FIELD OBSERVATIONS & GAP IDENTIFICATION

We have conducted field studies during Sep09 to observe the actual process
& time taken for different activities viz. Pressure release time of rake, Wagon
unloading time for tippler #1, Wagon unloading time for tippler #2, Wagon
unloading time for tippler#3for different inward raw material, Rake formation
for empty rake and rake release time.
The summary of field observations of time taken for different activities is as
follows:
Activity
Pressure release
time per lot or per
set ( 20 wagons)
Wagons Placement
of first 20 wagons at
Tippler 1 / 2 / 3
Actual Unloading
time per wagon
through Wagon
Tippler 1/ 2/3.
Cleaning time for
one
wagon( remaining
material)
Rake formation for
empty wagon(59
wagons)
Field Observation Time

Minimu
Maximu
Averag
m
m
e
Remarks
0:15:00
0:25:00
0:20:00
1 man in day,2 Men

gang working in
night at Line No.
1/2/3/4/5/7
0:10:00
0:20:00
0:15:00
1 Loco operator & 1

Ground staff
0:03:50
1 wagon Tippler
operator,3 Men
gang working per
wagon tippler
0:04:00
0:08:00
0:06:00
4 Men gang working
0:30:00
0:40:00
0:35:00
Line No. 1/2/3/4/5/7

and Rake Release
memo
Based on the field observation time for different activities, the Rake- in to
Rake- out cycle time without delay of Full Rake of a only single tippler has
been computed & compared with the average actual time taken during
April09 to Aug09 and shown below:
Full Loaded Rake Unloaded at single tippler

59
Activities
Pressure release
time per lot or 1st
set ( 20 wagons)
Wagons Placement
of first set 20
wagons at Tippler 1
/2/3
Actual Unloading
time per 1st set (20
wagons) through
Wagon Tippler 1/ 2/3.
Cleaning time for

last one
wagon( remaining
material)
Actual Unloading
time 2nd set (20
wagons) through
Cleaning time for

last one
wagon( remaining
material)
Actual Unloading
time 3rd SSset (20
wagons) through
Cleaning time for

last one
wagon( remaining
material)
Rake formation for
empty wagon(59
wagons)

MATERIALS
No of box
Sl. No.
J S P L,
RAIGARH
Duration (in minute)

Min.
Time
Max
Time
Avera
ge
Time
Total
time per
Rake
20
0:15:
00
0:25:
00
0:20:0
0
0:20:00
1 man in day,2 Men gang

working in night at Line
No. 1/2/3/4/5/7
20
0:10:
00
0:20:
00
0:15:0
0
0:15:00
1 Loco operator & 1

Ground staff
0:03:
30
0:03:
30
0:03:3
0
20
1:10:00
1 wagon Tippler operator,3

Men gang working per wagon
tippler
0:06:00
4 Men gang working
(Per wagon)
1:10:00

tippler
0:04:
00
0:08:
00
0:06:0
0
0:06:00
4 Men gang working
0:03:
30
0:03:
30
0:03:3
0
1:06:30

tippler
(Per wagon)
1
20
19
0:04:
00
0:08:
00
0:06:0
0
0:03:
30
0:03:
30
0:03:3
0
(Per wagon)
1
Remarks
0:04:
00
0:08:
00
0:06:0
0
0:06:00
4 Men gang working
0:30:
00
0:40:
00
0:35:0
0
0:35:00
Line No. 1/2/3/4/5/7 and Rake

Release memo
Rake-in Rake-out Time (excluding delay as Per Field

observations)
Rake-in Rake-out Time ( Including delay as per past
data)
Gap or Excess Time due to various Delays
4:54:30
i.e. 5 Hrs. 55 min.
9 Hrs.
11 min.
3 Hrs.
16 min
Based on the field observation time for different activities, the Rake- in to
Rake- out cycle time without delay of Full Rake of a Multiple tippler has
60
J S P L,
RAIGARH

MATERIALS
been computed & compared with the average actual time taken during
April09 to Aug09 and shown below:
Full Loaded Rake Unloaded at multiple Tippler

Sl.
N
o.
Activities
Pressure release
time per lot or 1st
set ( 20 wagons)
Wagons Placement
of 1st, 2nd, 3rd set
20 wagons at
Tippler 1 / 2 / 3
Actual Unloading
time full loaded rake
(59 wagons) through
Wagon Tippler 1/
2/3.
Cleaning time for

last one
wagon( remaining
material)
Rake formation for
empty wagon(59
wagons)
No
of
bo
x
Duration (in minute)

Min.
Time
Max
Time
Avera
ge
Time
20
0:15:
00
0:25:
00
0:20:0
0
0:20:00
1 man in day,2 Men

gang working in night at
Line No. 1/2/3/4/5/7
59
0:10:
00
0:20:
00
0:15:0
0
0:45:00
1 Loco operator & 1

Ground staff
0:03:
30
0:03:
30
0:03:3
0
59
(Per wagon)
Total
time per
Rake
Remarks
1:10:00

Men gang working per
wagon tippler
0:04:
00
0:08:
00
0:06:0
0
0:18:00
4 Men gang working
59
0:30:
00
0:40:
00
0:35:0
0
0:35:00
Line No. 1/2/3/4/5/7 and

Rake Release memo
Rake-in Rake-out Time (excluding delay as Per Field

observations)
Rake-in Rake-out Time ( Including delay as per past
data)
Gap or Excess Time due to various Delays
3:08:00
i.e. 3 Hrs. 08 min.
9 Hrs.
11 min.
6 Hrs.
03 min
CAUSE EFFECT DIAGRAM & IDENTIFICATION OF PROBLEMS

61
J S P L,
RAIGARH

MATERIALS
To find the Root cause for the excess time taken, we tried to get the delay
data from the various unloading yards & sections. Since the department do
not maintain the delay data as required,
the possible reasons of delay at
each unloading yard assessed by discussing with the shift in charge and other
staffs of the unloading yards. To know the relation between various reasons of
delays, the cause-effect diagram for High time of Rake-in to Rake-out has
been drawn and shown below:
62
J S P L,
RAIGARH

MATERIALS
63

Reduce Rake Cycle Times with A Category Problems

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J S P L,

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

only 15%. In category C we take that problem which

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

Total Delay Frequency

(min)Total Delay Duration

Total Delay Frequency

(min)Total Delay Duration

Total Delay Frequency

(min)Total Delay Duration

Table No. 4.1 : OVERALL DELAY DURATION AT WAGON TIPPLER # 1, 2 ,3

Delay per Frequency

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

Material / Equipment type

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

2. Pressure release of first

3. Wagon attach to the

6. Moving from full rake to

7. JSPL loco detach tippler

Table No. 4.3 : Flow process chart of wagon

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

Material / Equipment type

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

2. SAC connect to wagon and

4. Empty wagon push out

5. SAC to his positioned empty

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

4.2 DATA COLLECTION OF INWARD RAKE OF RAW MATERIAL THROUGH RAIL

TABLE NO. 4.4: Average Monthly Inward Rake of Raw Material

AVERAGE MONTHLY INWARD RAKE OF RAW MATERIAL

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

From the above data,the average Rake of inward raw material

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

4.3 DATA COLLECTION OF RAKE-IN TO RAKE-OUT CYCLE TIME & ITS

We have collected details of inward Rakes of Raw material received during

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

From the above table we observe as follows:

On an average around 154 rakes of Raw material unloaded per month

The average Rake-in to Rake-out Cycle time is around 9 hours 11

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

overall average Rake-in to Rake-out cycle time of all raw material is 9

Table no.4.7: Rake-in To Rake-out Duration (April'09 to Aug'09)

Time Interval (hrs.)

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD

STUDY OF RAKE-IN TO RAKE-OUT CYCLE TIME OF INWARD

The average Rake placement to unloading start time is 2 hours 39