DRIVERS AND BARRIERS TO ENERGY CONSERVATION IN RAILWAY

WORKSHOPS: A CASE STUDY OF TWO MAJOR CENTRES IN

SOUTH INDIA

Suresh D. Mane & Dr. N. Nagesha

OutlineIntroductionLiterature reviewObjective and ScopeStatistical MethodologyResults & DiscussionsConclusionsAcknowledgementReferences

INTRODUCTION

Energy Supplies – Finite & DwindlingEnvironmental Issues, Costs – On the riseCO2 – 350 ppmIndia – Annually10,48,533 Million Units (MU)

supply is 9,78,301 MU a deficit of 6.7%. Peak requirement - 1, 44,225 MW, Deficit

6.2%Installed Capacity ConstraintsOil Imports @ 80% of requirementOutflow of foreign exchange Rs 5 lakh

Crores p.a.

INDIAN RAILWAYS

India's largest energy consumer - 2.5% of nation’s total electricity and 40% of diesel.

2012-13, 17.15 billion units of electricity and 2.35 billion liters of diesel

2014-15 – Rs 35,474 Crores i.e. 20% World's third largest network Resource Crunch – FDI, PPP11 National EC Awards, the highest

ever by any industry, BEE in 2012

11 Departments R&D infrastructure, Expenses marginal

Electricity Diesel TotalBillion Units Amount in

Crores of Rs Billion litres Cost in Crores of Rupees

Cost in Crores of Rupees

17.15 9,619 2.35 16,848 26,467

Railway Energy Management Company formed in 2013 + PTC

RAILWAY WORKSHOPS

Workshops – Maintenance of Locomotives, coaches and wagons

41 Workshops , 20 Coach maintenance

Study relates to – Carriage Repair Workshop, (UBLS) Hubli and Central Workshops, Mysore (MYSS)

Established in 1885 and 1924

Abbreviations

PoH – Periodical Overhaul ( 18 months periodicity)

IoH – Intermediate Overhaul ( 9 months , only Bogie)

RSP – Rolling Stock ProgrammeFA – Factor AnalysisPCA – Principal Component Analysis

Suresh D. Mane & Dr. N. Nagesha 8

Scope of Study

1.Carriage Repair Workshop – Hubli (UBLS) Est. in 1885, 3400 Workforce (ISO-9001)

2. Central Workshop – Mysore (MYSS) Est. in 1924, 1800 Workforce ( ISO 9001,14001,18001)

MG, Steam Era, Wooden Coaches, 4 Wheel Stock

N

Suresh D. Mane & Dr. N. Nagesha 10

UBLS as on 1.1.13

AREA 1,05,200 SQ MT

COVERED AREA 40,000 SQ MT

TRACK 6 KM

AVERAGE MONTHLY ELECTRICITY CONUMPTION

1,35,000 UNITS

D.G. SET 500 KVA 2 No,s

STAFF 3095

MACHINERY & PLANT 590 No’s

Wooden Bodied Coach

Steel bodied Coach

LHB Coach (SS)

Suresh D. Mane & Dr. N. Nagesha 12

MYSS on 1.1.13

AREA 1,01,171 SQ MTR

COVERED AREA 30,565 SQ MTR

TRACK 7.2 KM

AVERAGE MONTHLY ELECTRICITY CONUMPTION

63,500 UNITS

D.G. SET 250 KVA 2 Nos

STAFF 1990

MACHINERY & PLANT 220

UBLS Activities

Mfg of BogiePoH, IoH, RSP

Mfg of brake van

MYSS Activities

PoH, IoH

Mfg of Toy train

LHB Coach Maintenance

Brake Block Mfg

Suresh D. Mane & Dr. N. Nagesha 15

TECHNICAL STAFF DEPLOYMENT

ACTIVITY UBLS MYSS

COACH IOH,POH,RFB 1341 1161

FABRICATION/MFG ACTIVITY 701 0

COMPOSITE BRAKE BLOCK MFG 0 26

OUTSTATION, SERVICE ACTIVITY 243 133

TOTAL 2285 1320

Organisational Structure of IR

LITERATURE REVIEW

Nagesha and Balachandra (2006) found that Financial & Economic barrier was the top barrier group followed by Behavioral & Personal barrier in the SSI sector.

Patrick Thollander et al (2013) driving forces were found to be financially related followed by organizational driving forces. EC potential - 7.5%.

Somashekar and Nagesha (2010) -10 factors influencing domestic household energy consumption in India using FA

Gunther Ellwanger (UIC, 2013) Average external cost of transport per passenger (in Euros per 1000 km) was least for Rail. The results in Euros per 1000 km for others are; Car – 72, Aviation 52, Bus 32, and Rail -18.

Jenny Palm and Patrik Thollander (2010) Cost effective EETs - lack of information, procedural impediments and routines not favouring energy efficiency. (LCC)

Weber (1997), consumption belongs to the realm of technology but EC to the realm of society. Social factors are relevant, in addition to technology.

Baranzi and Giovannini (1996) link energy consumption to four major factors viz. technological, economic and financial, institutional and cultural.

METHODOLOGY

Drivers – 7 drivers identified. Forced ranking methodology was adopted using the weighted average method.

Barriers – 25 variables , Factor analysis was applied using SPSS software version 20.

BARRIERS- FACTOR ANALYSIS SAMPLE & POPULATION

Total -124 respondents 5 Point Likert Scale

25 variables, UBLS has 235 supervising engineers

and seven technical officers MYSS has 157 supervising engineers

and six technical officers 82 from UBLS and 42 from MYSS Sample - 34 % of population at UBLS Sample - 26 % population at MYSS.

Chief Workshop Manger (CWM)

Dy. Chief Workshop Manager (Dy. CWM)

Workshop Personnel

Officer (WPO)

Sr. Material

Manager (SMM)

Sr. Asst. Finan. Advisor

(Sr. AFA)

Works Manager (WM)

Production Engineer

(PE)

Divisional Elec. Engr. (DEE)

Asst. Electrical Engr. (AEE)

Asst. Workshop Mgr (AWM)

Asst. Workshop (AWM)

Asst. Workshop

Mgr (AWM)

Senior Section Engineer (SSE)

Junior Engineer (JE)

Technicians

Support Staff

Factor AnalysisMultivariate Statistical approach to

analyze interrelationships among variable

Common dimensions/factors/components

Data reductionSample adequacy – 100 acceptable

( Min 50)Overall Significance of Correlation

matrix – KMO & Bartlett test

Kaiser Meyer Olkin (KMO) &Bartlett’s test for sphericity

Compares the magnitude of observed correlation coefficients with the magnitude of partial correlation coefficient.

Higher the better correlation between variables can be explained by other variables.

The Bartlett’s test of sphericity takes the determinant of the correlation matrix into consideration.

KMO value for the combined responses at 0.770 (should be > 0.50),

Bartlett’s test for sphericity - 0.000 level (Should be < 0.05) Meeting the requirements.

PCA methodologySearches for the weight or factor score

coefficient so that the first factor explains the largest population of variance.

This explained variance is subtracted from the original input matrix so as to yield a residual matrix.

A second principal factor is extracted from the residual matrix in such a way that the second takes care of most of the residual variance and so on, and this procedure is repeated until there is a very little variance to be explained.

Factor loading Correlation coefficient between the factor score and

variable is called factor loading. Factor loadings are used to compute Eigen values for

each factor and the communalities of each variable. For the interpretation of factor, the factor loading

matrix is rotated. The main purpose of rotation is to bring the smallest

loadings close to zero and its largest loading towards unity.

Varimax method for rotation. After completing the rotation, a cut off point for factor

loading is selected. > 0.5, and the same is adopted Thus, variables with a loading of > 0.5 naming the

factor appropriately.

VARIABLES

Employee Motivation Technology of Machines

Attitude Prompt Decisions

Optimum Utilisation Finance Department

EC Capability Awards for Motivation

Inventory Management Focus on quality

Monitoring Health Machine Handling

Regular Meetings Procurement process

Increasing Awareness Centralized Decision-Making

Preventive Maintenance Least Cost Procurement Policy

Periodical Training Ego/Feeling of Insignificance

Role of Trade Unions

Transfer Policy

Total Variance explained for combined data from workshops

Component

Initial Eigen Value Extracted Sum of LoadingsRotation Sums of Squared

Loadings

Total

% Varian

ce

Cumulative % Total

% Varian

ce

Cumulative % Total

% Varian

ce

Cumulative %

1 6.7 25.7 25.7 6.7 25.7 25.7 3.8 14.7 14.7

2 1.9 7.5 33.2 1.9 7.5 33.2 2.4 9.4 24.1

3 1.8 6.9 40.1 1.8 6.9 40.1 2.3 8.8 32.9

4 1.5 5.7 45.8 1.5 5.7 45.8 1.9 7.5 40.4

5 1.4 5.4 51.2 1.4 5.4 51.2 1.9 7.2 47.6

6 1.3 4.8 56.0 1.3 4.8 56.0 1.6 6.2 53.7

7 1.1 4.4 60.4 1.1 4.4 60.4 1.6 6.1 59.8

8 1.1 4.3 64.7 1.1 4.3 64.7 1.3 4.8 64.7

Rank

VariablesCo-

relationMean

Variable Score

Average Factor Score

Factor Name

1 Employee Motivation 0.80 4.36 4.36 Motivation

2

Attitude 0.75 4.324.27

Knowledge & AttitudeOptimum Utilisation 0.64 4.30

EC Capability 0.55 4.39

3

Inventory Management 0.74 4.184.27

PreventiveMeasures

Monitoring Health 0.72 4.19Regular Meetings 0.72 4.05Increasing Awareness 0.67 4.37Preventive Maintenance 0.61 4.35

Periodical Training 0.58 4.41Technology of Machines 0.53 4.32

4Prompt Decisions 0.73 4.23

3.88Timely

Decision- Making

Finance Department 0.60 3.54

5Awards for Motivation 0.73 4.06

3.86 RecognitionFocus on quality 0.70 3.66

6Machine Handling 0.68 4.09

3.85 Management Agility

Procurement process 0.66 3.79Centralized Decision-Making 0.56 3.68

7Least Cost Procurement Policy 0.73 3.78

3.51Procurement

PolicyEgo/Feeling of Insignificance 0.61 3.25

8Role of Trade Unions 0.85 2.90

3.06Human

Resource FactorTransfer Policy 0.53 3.22

DRIVERS TO EC

1. Dedication of Management, Supervisors and Staff towards EC.

2. Awareness of Associates for Adoption of latest Technologies.

3. Capacity Utilization of Machinery and equipment. 4. Top Management viz. Zonal Head Quarters and

Railway Boards drive for EC.5. Education of Associates, Training provided, and

Skill developed due to experience.6. Recognition, Motivation by Management for EC

activities. 7. Concern for planet earth, and Environment

protection.

Respondents Profile Shop ( UBLS) No. of

respondents

Carriage Shop 23

Production Shop

15

Maintenance & Training

18

Electrical & Officers

16

Total 82

Shop ( UBLS) Respondents

MYSS

PG in Engg 2 0

Engg Graduates

18 14

Engg Diploma 62 28

82 42

Total Population

242 163

Respondents Designation

MYSS UBLS Average Age

Average Experience in

Years

Junior Engineer 6 38 38 16

Senior Section Engineer

31 40 48 24

Officers 5 4 50 25Total Experience in Years

868 2379

Average Experience

20 29

Results & Discussions

Weighted Average Scores of Drivers by various groups at UBLS

Nomenclature

DDedication of Management

AAwareness of Associates

CCapacity Utilisation

TTop Management drive

EEducation of Associates

RRecognition

PConcern for planet earth

Comparative weighted Average Scores of Drivers by UBLS and MYSS

Nomenclature

D Dedication of Management

A Awareness of Associates

C Capacity Utilisation

T Top Management drive

E Education of Associates

R Recognition

P Concern for planet earth

Suresh D. Mane & Dr. N. Nagesha 37

Acknowledgement

The authors also warmly thank all the Officers and Engineers of the

Carriage Repair Workshop Hubli and Central Workshops Mysore

who have freely given their valuable time for this study.

Thank You and

have a good day

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