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

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 Tools, Plants & Machinery Spare Parts Fuel & Lub Manpower to Provide a Safe, Clean, Comfortable, Environment friendly, Reliable and Cost effective Bus for Operation Unit aggregates Computers & Software Infrastructure – Yard, Sheds, Maintenance Pits, Illumination

7. STANDARD DEPOT LAY OUT • Security • Vehicle dispatch • Gentset • Cycle stand • Oil Bunk • DC(oils) • Washing Plant • Toilets • Smithy • Electrical • Painter & Trimmer • Tyres • DC(T&P) • Dining hall • Stores • MF/AMF room • Maintenance Pits • Sch-III/IV floor

8. Delegation of various responsibilities in a Depot Garage

9. HSD OIL DISPENSING STATION & WASHING PLANT

13. SCHEDULE-I/II MAINTENANCE GARAGE

14. PITS FOR VEHICLE INSPECTION & MAINTENANCE

17. TYPICAL SCHEDULE-III/IV MAINTENANCE GARAGE

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

27. Oil, Filter & Coolant changes Contd..

28. Filter Changes

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

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 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 U’bolts, 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 & Driver’s 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

45. Typical Man Power Deployment for maintenance in a Depot with 100 fleet

46. Deployment of Mechanics & Helpers for maintenance in a Depot with 100 fleet

47. Deployment Artisans for maintenance in a Depot with 100 fleet

48. 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.