1. Inspection by
(Sh.)
11th Feb., 2012

2. Introduction
 Stores Depot came into existence in 1962 to cater the material requirement of
Workshop.
 During initial years, Kota Stores depot was primarily responsible for supply of
raw materials like Steel and Lubricants for in-house manufacturing.
 Targeted POH of Kota Workshop increased from 250 FW units per month in
1960 to 400 Vehicle Units over a period of 50 years in a gradual manner.
 This has been made possible by outsourcing of more and more shop
manufactured items to trade.

3. Key Activities
 Feeding wagon components to Wagon repair shop Kota and Kota division.
 Centralized scrap disposal depot for Wagon Repair shop Kota, Kota division
and Jabalpur Division.
 Apart from centralized scrap yard, this depot is also operating two wagon
cutting yards – cutting up Yard and POH yard.

4. Challenges faced
 Increased workload
 Increase in number of stock items and their AAC value
 Receipt & Issue : approx 10000 MT of steel/ other material
(approx)
 Increase in scrap disposal activity
 Handling of scrap in scrap yard: approx 40000 MTs per
annual (incoming outgoing).
 Shortage of manpower
 40% staff retirements in next 5 years

5. Increase in receipt and issue
of materials
 Increased work load in past few years is reflected by
increase in number of stock items and their AAC values.
Year Total No of items Stocked AAC Value
2010 796 60 cr
2012 1027 81 cr

6. Manpower Position

7. Initiatives
 Mechanisation of material handling
 Better use of manpower
 Improvement in infrastructure
 Use of IT tools

8. Improvements in Material Handling
in depot
 Handling multifold increase in workload without increase
in manpower was made possible through mechanisation of
material handling activity at stores depot. In view of above,
following improvements in material handling are started in
depot :

9. Palletisation
Hand Pallet trucks : 08 Pallets : 50
Forklifts : 3 Tipper : 1

10. Receipt & Stocking Wards
At, present man power is used for loading and unloading
of Railway material received from various sources in
Receiving section at this depot and movement to stocking
wards. Now these works are dealt with palletisation to
reduce multiple handling of material and for safety of
workers.
Past Present

11. Palletisation

12. Scrap yard
 Lot of un accounted material lying in mixed condition
 Disputes in scrap delivery
 Weighbridge of 30 Mt capacity undergoing frequent
breakdowns

13. Depot Modernization
 Kota Stores Depot has been planned to be modernized along with
Wagon Repair workshop. Following machines and works have been
sanctioned in the workshop modernization project:-
M& P Sanctioned under Modernisation Works sanctioned under Modernisation
Program Program
• Goliath crane cap. 10 MT -286.62 Lakhs • Construction of 03 Nos asbestos sheds for
stocking CBC items=25 Lakhs work has
• Adjustable Racking System -30.00 Lakhs
been completed
• Tri Stacker -29.58 Lakhs
• Up gradation of stores office= 6.51 Lakhs
• Mini truck – 3.78 Lakhs
• Upgradation of ward 80= 4.47 lakhs
• Lister Truck-2.57 Lakhs

14. M&P and Works Programme:
Machines Proposed under M& P Program Status
05 MT Road mobile crane Sanctioned by GM in 2009-10 M& P
Program. Under Procurement with
COS/JBP
Apart from above M&Ps, GM/WCR has sanctioned following works
for improvement in material stocking and its protection.
Works Proposed Status
Provision of safety wall of wagon cutting Sanctioned by GM for cost of 13 lakhs.
up yard Work completed
Improvement in infrastructure of Kota Sanctioned by GM/WCR at cost of 47
store depot for faster turnover of scrap lakhs. Tender under finalisation
sale activity

15. Implementation of MMIS
 Kota stores depot is first depot to achieve 100%
reconciliation of stocks in MMIS.
 All material receipt, issue and scrap sale activities are
being done through MMIS in this depot.
 Online availability of information of any item.

16. Mechanisation of material handling activities
Sr. No Description Quantity Date of
Nos commissioning
1 Diesel Tripper cap 6.3 MT 01 2010
2 Hydraulic Road Mobile TIL Crane 01 2009
18 MT
3 Diesel Fork Lift Cap. 03 MT 03 2009
4 Diesel Hydraulic Road Mobile 01 2008
Crane cap. 5 MT
5 Ashok Leyland Truck cap 10 MT 01 2005
6 Diesel Lister Truck cap 03 MT 01 1999

17. Steel Yard
Presently unloading of steel items viz. heavy sheet plates, channels etc
unloaded from wagons and trucks by road mobile crane which need
more man power and consume lot of time.
Future: Goliath crane cap. 10 MT
Present : road mobile
Progress:-sanctioned by railway
crane cap 16 MT
Bd under modernization program
Under tender stage.

18. Improvement in layout of depot
To improve efficiency of material transportation, A new 100 ton
capacity weighbridge is to be installed with approach road and a
separate entre gate to scrap yard.
•increase output of scrap delivery team(Stores, Account, RPF)
as capacity to deliver material to scrap purchasers at a time
would increase from 20 MT per truck to 60 MT per lorry

19. Results

20. Availability of Items
Out of stock
Item As on 31.07.2011 As on 31.07.12
O/S Total O/S O/S
O/S Total Item O/S
Target items % %
Safety <2% 169 6 3.55 169 3 1.77
vital <2% 129 2 1.58 129 2 1.58
Others 729 15 2.05 729 15 2.06
Total <5% 1027 23 2.24 1027 20 1.94

21. Inventory control
Apart from smooth supply of material, depot has managed
its inventory to low levels. This depot achieved target
TOR of 20% in the last two financial years

22. Year Cum. Receipt Cum. Issues Closing Balance T.O.R.
05-06 67.16 51.74 32.43 63%
06-07 98.37 98.86 30.16 31%
07-08 52.41 61.64 20.00 32%
08-09 65.86 67.60 18.26 27%
09-10 61.17 67.24 12.19 18%
10-11 81.90 79.39 15.20 19%
11-12 (upto Jan.- 75.50 70.86 19.08 22%
2012)

23. Inventory control
Apart from smooth supply of material, depot has managed its
inventory to low levels. This depot achieved target TOR of 20% in
the last three financial years.
(Figs. In Crores of Rs.)
Cum. Closing
Year Cum. Issues T.O.R.
Receipt Balance
08-09 65.86 67.60 18.26 27%
09-10 61.17 67.24 12.19 18%
10-11 81.90 79.39 15.20 19%
11-12 87.81 87.63 14.62 17%

24. Sale of scrap
Kota stores depot achieved highest sale of scrap
during its history in financial Year 2011-12 with sales
of 207.10 Crs. The year-wise position of scrap disposal
is as under:
* Sales for current year is 25 cr against annual target of Rs 150 Cr

25. THANKS!
/kU;okn!