Maintenance Management

1
Best Practices in
Maintenance Management
Fleet Health is secret of our Strength
2
Fleet Maintenance in APSRTC

• 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

3
Objectives of Fleet Maintenance

• 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

4
INDICATORS OF EFFECTIVE FLEET MAINTENANCE
PARAMETER 2010-11 2011-12 Target Upto Jan12
1 HSD KMPL (Total) 5.17 5.30 5.13
HSD KMPL (Excl.Spl type) 5.26 5.40 5.26
2 Breakdown Rate 0.10 0.07 0.08
3 Mech. Cancelation 0.23 0.11 0.19
4 Total Tyre Life 1.68 1.84 1.70
5 New Tyre Scrap 2.37 1.30 3.17
6 New Tyre Mileage 62897 -- 67282
7 RT Factor 2.70 -- 2.58
8 Lub KMPL 1117 1189 1174
9 Spring Consumption 78 50 55
10 Fleet Utilization 99.45 99.60 95.40
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
Basic Requirements for Effective Fleet
Maintenance
7
STANDARD DEPOT LAY OUT

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(TP)
14. Dining hall
15. Stores
16. MF/AMF room
17. Maintenance Pits
18. Sch-III/IV floor

8
Delegation of various responsibilities in a Depot
Garage
Function Custodian/ 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 (TP)
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 Shift Superintendent (M)/ Dy.Supdt(M)
Maintenance of records, documentation correspondence Asst.Depot Clerk (Gen)
9
HSD OIL DISPENSING STATION WASHING PLANT
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13
SCHEDULE-I/II MAINTENANCE GARAGE
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PITS FOR VEHICLE INSPECTION MAINTENANCE
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TYPICAL SCHEDULE-III/IV MAINTENANCE GARAGE
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21
OVERHAULING ACTIVITIES AT WORKSHOPS

• 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.

22
Zonal workshops - Uppal
23
Zonal workshops Engine Section
Zonal workshops Body Section
24
Tyre Retreading Shop
25
Tyre Retreading Process
26
Preventive Maintenance Schedules adopted at
Depots
S. No Maintenance Schedule Periodicity of Maintenance Periodicity of Maintenance
S. No Maintenance Schedule District Operation City Operations
1 Sch-I Daily Daily
2 Sch-II Weekly Weekly
3 Sch-III 12,000 Kms for Ord 15,000 kms for New special type 9,000 Kms for all 12,000 kms for New
4 Sch-IV 36,000 Kms for Ord 45,000 kms for New special type 27,000 Kms for all 36,000 kms for New
5 F.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 LEYLAND TATA
Engine Oil Long Life CH4 36,000 for Dist 24,000 for City 36,000 (18,000 for Cummins)
Engine oil other than CH4 15,000/ 16,000 18,000
Gear Box oil Ordinary 32,000 18,000
Gear Box oil Extra Long life 40,000 72,000
Differential oil Ordinary 32,000 18,000
Differential oil Extra long life 48,000 72,000
P.Steering oil Filter 80,000 80,000
Clutch Kits Clutch Fluid 40,000 72,000
Coolant 75,000 3.00 lakhs (or) 2Yrs
Contd..
28
Filter Changes
Description of Filter LEYALND TATA
Fuel Filter Felt 20,000 27,000
Fuel Filter Paper 30,000 20,000 for BS-II 36,000 18,000 for BS-II
Spinon Fuel filters 25,000 BS-II 18,000 TC
Fuel Strainers (Baby filters) 50,000 clean at 9,000
Dry Air Filter element Primary 72,000 72,000
Dry Air Filter element Secondary 2,16,000 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

30
Programming of Preventive Maintenance Schedules
at Depots

• 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

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
Date Complaints on the condition of vehicle Complaints on the condition of vehicle Failures Remarks of the Supervisor who supervised the repairs/ maintenance Signature of AE/ DM
Date As per logsheet As per Tyre Mech. Observation Failures Remarks of the Supervisor who supervised the repairs/ maintenance Signature of AE/ DM

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 Ubolts, 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 Drivers 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 Maintenanceat
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 44 45 to 49 50 to 54 55 to 59 60 to 64 65 to 69 70 to 74 75 to 79 80 to 84 85 to 89 90 to 94 95 to 99 100 to 109 120 to 149 150 Abv
AE(M) 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1
SUPDT(M) 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2
DY.SUP(M) 0 0 0 1 1 2 2 2 2 2 2 2 2 2 2
LH 2 2 2 2 2 2 2 2 2 2 3 3 4 4 4

CB/PB 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4
TYRE MECH 1 2 2 2 2 2 2 2 3 3 3 3 3 4 5
ELEC AC/DC 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5
PAINTER 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2
WELD/T.S 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
TRIMMER 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2
B.SMITH 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2
H.MAN 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2
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Typical Man Power Deployment for maintenance in a
Depot with 100 fleet
Category Norm Men
Mechanical Foreman 0.049 1
Asst. Mechanical Foreman 0.049 2
Chargeman 0.049 2
Leading Hands 0.037 4
Total Supervisors 0.086 9
Mechanics 0.35 35
Helpers/ Shramiks 0.50 50
Artisans 0.21 21
Total 1.15 115
46
Deployment of Mechanics Helpers for maintenance
in a Depot with 100 fleet
Activity Mechanics _at_ Norm 0.35 Helper/ Shramik _at_ Norm 0.50
Sch.I Maintenance 16 18
Sch.II Maintenance 4 4
Sch.III/IV Maintenance 9 10
Heavy Repairs 1 1
KMPL Attention 2 2
Oil changes 2 2
Vehicle Dispatch 1 3
Tyres preparation 2
DGT Stores 2
Battery maintenance 2
HSD oil top-up 4
Total 35 50
47
Deployment Artisans for maintenance in a Depot
with 100 fleet
Category Norm Men
Coach Bulider 0.039 4
DC/AC Electrician 0.047 5
Tyre Mechanic 0.034 3
Welder/ Tinsmith 0.010 1
Trimmer 0.024 2
Painter 0.024 2
Blacksmith 0.022 2
Hammerman 0.022 2
Total 0.21 21
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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.

51
Tools, Plants Machinery
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 TP Return shall be
  maintained properly indicating the locality of
  each every item of the Garage.

53
Important TP required for smooth maintenance
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
10 Trolley Jack 10
11 Bench Vice 5
12 Bench Grinder 7
Contd..
54
Important TP required for smooth maintenance
S. No Description Expected life in Years
13 Drilling M/c 10
14 Sewing M/c 10
15 Pop rivet guns 5
16 Paint Spray gun 10
17 Battery Charger 5
18 Cell Tester 3
19 Hydrometer 5
20 Injector Tester 10
21 Wall gauges 3
22 Electronic gauges 5
23 Hand grinding M/c 7
24 Mechanics work bench 10
Contd..
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Important TP required for smooth maintenance
S.No Description Expected life in Years
25 Hand Platform Trolley 10
26 Bench Arbor Press 10
27 Anvil 10
28 Torque Wrench 5
29 Swage Block 10
30 Vehicle Stands 10
31 Compressor Tester 10
31 Well Pump 7
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
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 TP items like Dial
  gauges, Injector testers, Wall gauges, Torque
  wrenches etc, as per the stipulated periodicity.
• The worn out and defective TP are replaced in
  time so that the work is not hampered.
• Additional requirement of TP owing to increased
  number schedules or introduction of new models
  are submitted to the Dy.CME concerned for
  obtaining the same.

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Mechanic Tools for TATA Depots
D.E.Flat Ring Tubular Socket
6x7 mm 6 x 7 mm 8 x 9mm 10mm
8x9 mm 10 x 11 mm 10x11 mm 13mm
8x10 mm 12x 13mm 12x13 mm 14mm
9x10 mm 17x19 mm 12x14 mm 17mm
10x11 mm 21 x 23 mm 17x19 mm 19mm
10x13 mm 22 x 24 mm 22 x 24 mm 22mm
12x 14 mm 27 x 32 mm 27 x 32 mm 24mm
14x17 mm 41 x 46 mm 27mm
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
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Mechanic Tools for LEYLAND Depots
D.E.Flat Ring Socket
3/16x1/4 3/16x1/4 ½
¼x5/16 ¼x5/16 10mm
5/16x3/8 5/16x3/8 11mm
7/16x1/2 7/16x1/2 12mm
9/16 x 5/8 9/16 x 5/8 13mm
11/16x3/4 11/16x3/4 14mm
6 x 7mm 6 x 7mm 17mm
8 x 9mm 8 x 9mm 19mm
10 x 11mm 10 x 11mm 21mm
12 x 13mm 12 x 13mm 22mm
14x 15mm 14x 15mm 24mm
16 x 17mm 16 x 17mm 46mm
18 x 19mm 18 x 19mm
20 x 21mm 20 x 21mm
22 x 23mm 22 x 23mm
24 x 27mm 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
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Fast moving Mechanic Tools
ASHOK LEYLAND
TATA
DE Ring Socket
10 x 11 14 x 15 12,13
14 x 15 19 x 22 14, 17
19 x 22 8 x 9 19
BSF BSF BSF
3/16 X ¼ 3/16 X ¼
5/16 X 3/8 5/16 X 3/8
Feeler gauge Feeler gauge
DE Ring Socket
17 x 19 17 x 19 9, 10
13 x 14 13 x 14 13, 14
19 x 22 19 x 22 17, 19
9 x 10 9 x 10
Feeler Gauge Feeler Gauge Feeler Gauge
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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
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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 TP
S.No Nature of Power Authority Extent of powers
32.i) Standardization of depot equipment, inclusion of new items, fixation of norms, classification of TP value-wise fixation of guidelines, expectancy etc MD Full powers with the concurrence of FA/CAO on the recommendations of ED(E)/CCOS/CME/ CFM
ii) Inclusion of new equipment on experimental basis ED(E) Powers upto Rs 1.00 lakh per occasion with the concurrence of FA/CAO
ii) Inclusion of new equipment on experimental basis CME Powers upto Rs 50,000 per annum with the concurrence of Dy.CAO
ii) Inclusion of new equipment on experimental basis WM/ Dy.CME Powers upto Rs 10,000 per annum with the concurrence of Dy.CAO
Contd..
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Delegation of Powers Pertaining to TP
S.No Nature of Power Authority Extent of powers
33.i) Sanction for replacement of TP equipments including premature replacements at Depots/ W.shops CME/ ED(Z) Full powers on the recommendations of Dy.CME/ WM with the concurrence of DyCAO
ii) Sanction for replacement of TP 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
ii) Sanction for replacement of TP items after their normal utilization for Depots/ W.shops as per guidelines issued from time to time DM Powers upto Rs 300/- at a time subject to a limit of Rs 2,000 per annum
Contd..
65
Delegation of Powers Pertaining to TP
S.No Nature of Power Authority Extent of powers
34.i) Sanction for replacement of TP equipments for New Depots/ W.shops ED(Z)/ CME Full powers as per guidelines
ii) Sanction of additional TP for existing Depots/ W.shops on account of increase in Fleet stength/ acitivity as per guidelines CME/ DyCME/ WM Full powers with concurrence of CFM/ DyCAO as per guidelines
ii) Sanction of additional TP for existing Depots/ W.shops on account of increase in Fleet stength/ acitivity as per guidelines DM Powers upto Rs 300/- at a time subject to a limit of Rs 2,000 per annum
Contd..
66
Delegation of Powers Pertaining to TP
S.No Nature of Power Authority Extent of powers
35 Sanction 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 manufacturers ED(E) Full powers with concurrence of FA/CAO
35 Sanction 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 manufacturers CME/ ED(Z) Full powers with concurrence of CFM/ DyCAO upto Rs 20,000 at a time
35 Sanction 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 manufacturers SSO Full powers upto Rs 5,000 at a time with concurrence of Dy.CAO
35 Sanction 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 manufacturers JSO Upto Rs 1,500 at a time
67
FLOAT UNITS
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
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Provisioning of Float Units to Depots
MAJOR UNITS
S.No UNIT NORM
1 Engine 1 for 10,000 KMs.
2 Front Axle 1 for 14,000 KMs.
3 Rear Axle 1 for 14,000 KMs.
4 Gear Box 1 for 8,500 KMs.
5 Steering Box 1 for 10,000 KMs.
6 FIP 1 for 5,000 KMs.
7 Self Starter 1 for 4,000 KMs
8 Alternator 1 for 4,000 KMs.
72
SUB ASSEMBLIES
S.No UNIT NORM
1 Injectors (set) 1 for 2,000 KMs.
2 P. P. Shafts (set) 1 for 6,000 KMs.
3 Air compressor 1 for 5.000 KMs.
4 Clutch pressure plate 1 for 5,000 KMs.
5 (Leyland)/ Springer (Tata) 1 for 5,000 KMs.
6 Water pump assembly 1 for 5,000 KMs.
7 Cylinder head assembly 1 for 5,000 KMs.
8 Radiator 1 for 5,000 KMs.
73
MAJOR SPARES
S.No UNIT NORM
1 Front hub 1 for 15,000 KMs.
2 Rear hub 1 for 15,000 KMs.
3 Clutch housing 1 for 15,000 KMs.
4 Air cleaner complete 1 for 5,000 KMs.
5 Fuel twin filter assembly 1 for 5,000 KMs.
6 Feed pump 1 for 5,000 KMs.
7 Fly wheel ring gear 1 for 10,000 KMs.
8 Unloader valve 1 for 3,000 KMs.
9 Set (4) of slack adjusters 1 for 3,000 KMs.
10 Set (4) of spring brake chambers 1 for 5,000 KMs.
11 Hand brake valve 1 for 10,000 KMs.
12 A. C. Head 1 for 5,000 KMs.
74
MAJOR SPARES
S.No UNIT NORM
13 Air tank 1 for 10,000 KMs.
14 Clutch disc 1 for 5.000 KMs.
15 U. J. Cross 1 for 6,000 KMs.
16 Set of brake drums front (2 off) 1 for 5,000 KMs.
17 Set of brake drums rear (2 off) 1 for 5,000 KMs.
18 Set of spring brackets front (2 off) 1 for 5,000 KMs.
19 Set of spring brackets rear (2 off) 1 for 5,000 KMs.
20 Axle shafts 2 off 1 for 5,000 KMs.
21 H. S. D. Oil Tank 1 for 6,000 KMs.
22 Wiper Machine 1 for 5,000 KMs.
23 Batteries 10 of the batteries
24 Hydraulic jacks 1 for 2,000 KMs.
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
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,.

Norm for Provision of Spare Buses
Fleet Held Norm
Upto 50 8
51 to 80 7
81 above 6
77
Physical Inspection of Buses by Depot Manager
Maintenance Incharge

• The Depot Manager shall inspect atleast 30
  vehicles (1/3rd 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 System Item
1 Engine Air cleaner maintenance
2 ,, A/c Suction hose
3 ,, Engine mounting
4 ,, Engine oil leakages
5 Fuel HSD tank cap seals
6 ,, Fuel pipe clamping
7 ,, Fuel leakages
8 Cooling Radiator Cap
9 ,, Coolant concentration
10 ,, Radiator mountings
Contd..
79
S.No System Item
1 Steering Tie-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 System Item
1 Transmission Clutch 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 System Item
1 Brakes Air tank condensate
2 ,, Brake pipe clamps
3 ,, Air leakage
4 ,, Air Dryer working
5 ,, Hand brake condition
6 ,, Brake dust covers
7 Tyres Wheel alignment
8 ,, Matching of duals
9 ,, Less than 2mm NSD tyres
Contd..
82
S.No System Item
1 Electrical Battery Maintenance
2 ,, Head Lights
3 ,, Signal Lights
4 ,, Self condition
5 ,, Saloon Illumination
6 Body Exterior/ 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
Code Item Description Remarks
EXT-1 Body Panels Dents, Scratches, Damages
EXT-2 Front/ Rear Bumpers Broken/missing
EXT-3 Front Grill Damages/ missing
EXT-4 Front Cowls Damages
EXT-5 Corner Domes Dents
EXT-6 Passenger Doors Damages/ missing
EXT-7 Drivers Door Damages/ locks
EXT-8 Ladder Damages/ missing
EXT-9 Rear Luggage Booth (Dicky) Damages/ locks
EXT-10 Exterior Paint Faded
EXT-11 Roof Leakage Area of Leakage
DEST-1 Destination Board Frame Size and condition
DEST-2 Destination Lettering/Paint Faded
DEST-3 Destination Board lighting Visibility
DEST-4 LED Destination Condition
84
Checklist for Body condition
Code Item Description Remarks
INT-1 Stepwell Damages
INT-2 Flooring Condition
INT-3 Stanchions Broken/missing/loose
INT-4 Parcel Rack Broken/loose
INT-5 Grab rails/ Assist rails Broken/loose
INT-6 Cabin Partition door Condition
INT-7 Interior Roof/ side panel Fabric Condition
INT-8 Interior painting Faded
INT-9 Saloon Cleanliness Dirt cobwebs
GLS-1 Window Glasses Missing/ Broken
GLS-2 Terene felt/Flock channel Rubber Worn out/ missing
GLS-3 Window shutter knobs Missing/loose
GLS-4 Windscreen Glasses Broken
GLS-5 Top-fixed glasses Broken/missing
GLS-6 Windows leakage Condition of Rubber flap
85
Checklist for Body condition
Code Item Description Remarks
SEAT-1 Seat Frames Loose/broken
SEAT-2 Seat Cushions Hard/missing/damaged
SEAT-3 Seat rexine/fabric Torn
SEAT-4 Back rests Missing/loose
SEAT-5 Reclining mechanism Condition
SEAT-6 Arm Rests Broken/missing/loose
SEAT-7 Head Rest Covers Missing/dirty
SEAT-8 Bottle Holders Damged/missing
SEAT-9 Magazine Pouches Damaged
SEAT-10 Foot Rests Damaged
CAB-1 Bonnet Damaged
CAB-2 Dash Board Damaged
CAB-3 Vision Mirrors Damaged
CAB-4 Cabin Cleanliness Dirty
86
Checklist for Body condition
Code Item Description Remarks
LHT-1 Interior Lightining Condition
LHT-2 Head Lights Condition
LHT-3 Tail lights/ signal indicators Condition
SPL-1 Speakers Condition
SPL-2 TV/Audio System Condition
SPL-3 Cell phone chargers Condition
STR-1 Body U Bolts Loose/missing
STR-2 Ballata Packing Loose/missing
STR-3 Cabin Foundation Loose
STR-4 Antisag Bar Loose
STR-5 Out Riggers Loose
STR-6 Battery Box Condtion
87
Indicators for Quality ofSch-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 Sch-III Sch-III Sch-III Failures within 15 days Failures within 15 days
Type Fleet Held Optd Kms Due Done Backlog Backlog Nos
ORD
EXP
Total
Type Fleet Held Optd Kms Sch-IV Sch-IV Sch-IV Sch-IV Failures within 15 days Failures within 15 days
Type Fleet Held Optd Kms Due Done Backlog Backlog Nos
ORD
EXP
Total
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 11.00 lakh kms
  and City Buses at 11.50 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 10.00 lakh kms
• The other special type buses like Express,
  Deluxe, Metro Exp etc are replaced at 6.50 lakh
  kms

90
Deployment of New Buses from 2010
Type 2010-11 2010-11 2010-11 2011-12 (Jan12) 2011-12 (Jan12) 2011-12 (Jan12)
Type Aug. Rep. Total Aug. Rep. Total
S.Luxury 137 109 246 57 778 835
Indra -- -- -- 8 61 69
Garuda/ Garuda 0 30 30 27 41 68
Deluxe 32 89 121 169 69 238
Express 274 330 604 174 904 1078
Pallevelugu -- -- -- 152 547 699
Sap.Express Ord 27 123 150 22 57 79
City Ordinary -- -- -- 10 55 65
City Ord (CNG) -- -- -- 0 138 138
LF A/C Diesel 28 0 28 51 0 51
LF A/C CNG 0 0 0 8 0 8
LF N-A/C Diesel 16 80 96 3 1 4
LF N-A/C CNG 0 0 0 33 0 33
SLF Diesel 75 118 193 9 0 9
SLF CNG 12 58 70 5 0 5
Mini Buses 52 0 52 48 0 48
Total 653 937 1590 676 2751 3427
91
Green initiatives Use of Alternate fuels in
APSRTC
92
APSRTCs 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
APSRTCs 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
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 June2005.

• 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
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.

103
Emission Levels of trial vehicleWhen operated
with 100 HSD oil

• During Trial period

• Before Trial

104
Comparative Fuel Performance ofVehicle during
trials

• With 100 HSD oil

• With Biodiesel

Fuel Performance in Kms/Lit
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
Comparative Emission Levels
Vehicle No Bend Before Trials Before Trials Before Trials Before Trials During Trials During Trials During Trials During Trials Emission Reduction
Vehicle No Bend  Mar 2006 Apr 2006 May 2006 Avg of three Months  Jun 2006 Jul 2006 Aug 2006 Avg of three months Emission Reduction
AP11Z 3845 5 44.3 55 30.4 43.23 35.4 41 30.6 35.67 17.49
AP11Z 4045 10 29.3 33.7 40.1 34.37 32.7 22.1 20.1 24.97 27.35
AP11Z 4037 20 27.7 31.9 20.9 26.63 11.7 21.6 16.67 16.67 59.75
Comparative Fuel Efficiency
Vehicle No Bend Avg Km/Lit Before Trial Avg Km/Lit During Trial Improvement
AP11Z 3845 5 5.29 5.33 0.76
AP11Z 4045 10 5.20 5.38 3.46
AP11Z 4037 20 4.91 5.21 5.47
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 19 ratio for about one month.

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

• 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
Biodiesel Stocking Blending Arrangement at
Depots
111
Procedure of Blending Biodiesel with HSD Oil

• Blending Biodiese with HSD for first time
• Know the quantity of (Q1) of HSD in Ground Tank
• Calculate required qty (Q2) of Biodiesel _at_10
  blend with HSD (Q1x10/90)
• Transfer calculated qty (Q2) of Biodiesel from
  Storage tank by gravity using Flowmeter F1

• Procedure for subsequent replenishments
• Ignore the quantity of B10 blend existing in the
  storage tank on fresh receipt of HSD oil
• Know the fresh quantity (Q3) of HSD that is being
  decanted into the underground tank
• Calculate the required quantity (Q4) of Biodiesel
  to mix by using the formula Q3 x 10/90
• Transfer the quantity Q4 of Biodiesel from
  Storage tank to the Underground tank with the
  help of Flow meter F1

112
Reduction of Pollutants with B20 Fuel
POLLUTANT The values with Pure HSD Oil Reduction with 20 Blended Bio-diesel
Total Unburned Hydrocarbons 1.1gms/kwh 20
Carbon monoxide 4.5 gms/kwh 12
Particulate Matter 0.36 gms/kwh 12
Oxides in Nitrogen 8 gms/kwh 2
Sulphates -- 20
Polycyclic Aromatic Hydrocarbons (PAH) -- 13
Nitrated PAHs -- 50
Ozone Potential Speculated Hydrocarbons -- 10
113
Comparative Specifications of HSD Biodiesel
Parameter ASTM Method Unit Pure Bio-Diesel Normal HSD Oil
Flash Point D93 OC 130 min 66 min
Water Sediment D2709 Volume 0.05 max 0.05 max
Kinematic Viscosity 40oc D445 mm/Sec 1.9 6.0 2 - 5
Sulphated Ash D874 mass 0.02 max 0.01 max
Sulphur D5453 mass 0.05 max 0.035 max
Copper Strip Corrosion D130 No.3 max Not worse than No.1
Cetane Number D613 47 min 46 min
Cloud Point D2500 OC Report
Continued
114
Comparative Specifications of HSD Biodiesel
Parameter ASTM Method Unit Pure Bio-Diesel Normal HSD Oil
Carbon Residue 100 Sample D4530 mass 0.05 max 0.03 max on 10
Acid Number D664 mg KOH/gm 0.8 max --
Free Glycerin D6584 mass 0.02 max --
Total Glycerin D6584 mass 0.24 max --
Phosphorus D4951 mass 0.001 max --
Distillation Temp. Atmospheric Equivalent Temp 90 Recovered D1160 Degrees C 360 max --
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

• There is scope for non-adherence to the
  prescribed specifications by the suppliers in the
  absence of required testing facilities.

Contd
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

117
Thank You