Best Practices in Maintenance Management Fleet Health is

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

Fleet Maintenance in APSRTC 1 st TIER Ø At depots, preventive maintenance schedules, attention of running repairs, unit changes & fitness work and Coach work & Upkeep 2 nd TIER Ø At workshops - major overhaul of units & buses Ø At Tyre Retreading shops - retreading and repair of tyres

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

INDICATORS OF EFFECTIVE FLEET MAINTENANCE PARAMETER 1 2010 -11 2011 -12 Target Upto Jan’ 12 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 99. 45 99. 60 95. 40 10 Fleet Utilization

Ø APSRTC has established very precise Preventive Maintenance Policies which are flexible in design and rigid in implementation. Ø The Maintenance Policies are primarily designed based on the manufacturers’ recommendations, product duty cycles and application environment. Ø 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

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

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(T&P) 14. Dining hall 15. Stores 16. MF/AMF room 17. Maintenance Pits 18. Sch-III/IV floor 7

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 (T&P) 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)

HSD OIL DISPENSING STATION & WASHING PLANT 9

SCHEDULE-I/II MAINTENANCE GARAGE 13

PITS FOR VEHICLE INSPECTION & MAINTENANCE 14

TYPICAL SCHEDULE-III/IV MAINTENANCE GARAGE 17

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. 21

Zonal workshops - Uppal 22

Zonal workshops – Engine Section Zonal workshops – Body Section 23

Tyre Retreading Shop 24

Tyre Retreading Process 25

Preventive Maintenance Schedules adopted at Depots S. Maintenance No Schedule Periodicity of Maintenance District Operation City Operations 1 Sch-I Daily 2 Sch-II 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

Oil, Filter & Coolant changes Description of Lubricant LEYLAND TATA Engine Oil Long Life CH 4 36, 000 for Dist 24, 000 for City 36, 000 (18, 000 for Cummins) Engine oil other than CH 4 15, 000/ 16, 000 18, 000 Gear Box oil Ordinary Gear Box oil Extra Long life Differential oil Ordinary Differential oil Extra long life P. Steering oil & Filter Clutch Kits & Clutch Fluid 32, 000 40, 000 32, 000 48, 000 80, 000 40, 000 Coolant 75, 000 18, 000 72, 000 80, 000 72, 000 3. 00 lakhs (or) 2 Yrs Contd. .

Filter Changes Description of Filter Fuel Filter Felt Fuel Filter Paper Spinon Fuel filters Fuel Strainers (Baby filters) Dry Air Filter element Primary Dry Air Filter element Secondary LEYALND TATA 20, 000 27, 000 30, 000 & 36, 000 & 20, 000 for BS-II 18, 000 for BS-II 25, 000 BS-II 50, 000 18, 000 TC clean at 9, 000 72, 000 2, 16, 000

• 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 29

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 30

A typical VEMAS based report

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.

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

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 Ø Complete washing through MWP Ø Lubricating all grease points Ø Cleaning of Breathers Ø Air Cleaner maintenance Ø Battery Maintenance Ø Tyres rotation Ø Steering & Brake test

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

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

Important Coach works covered during Sch-III/IV Ø Tightening of all Body U’bolts, cabin foundation bolts. Ø Repairs to damaged body panels, exterior & interior roof panels, parcel racks, Luggage carrier, ladder & unloader Ø Repairs to Stepwell, stanchions, Passenger Assist rails, Driver partition, flooring, Dashboard, Engine hood, Entrance door & Driver’s door Ø Dicky doors, locks and gas springs in Special type vehicles Contd. .

Important Coach works covered during Sch-III/IV Ø Repairs to broken pillars & cross bearers Ø Attention to Destination frames & boards Ø Replacement/ repairs to broken seat frames, torn seat cushions & upholstery Ø Attention to Seats inclining mechanism, Hand rests, foot rests, pouches, bottle holders etc in special type vehicles Ø Attention to Driver Seat and adjusting mechanism Contd. .

Ø Attention to Antisag bar & out riggers Ø Replacement of damaged window frames, broken shutter glasses, windscreen glasses. Ø Replacement of terene felt, fitment of shutter knobs Ø Attention to battery box Ø Arresting water leakages Ø Exterior/ Interior paint touch up

Manpower Planning for Preventive Maintenance at Depots

• 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

• 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.

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) SUPDT(M) DY. SUP(M) LH 0 1 0 2 0 1 1 2 2 1 1 2 3 1 1 2 3 1 2 2 4 CB/PB TYRE MECH ELEC AC/DC PAINTER WELD/T. S TRIMMER B. SMITH H. MAN 2 1 1 1 1 1 2 2 3 1 1 1 3 2 3 2 1 2 1 1 3 2 4 2 1 2 2 2 3 3 4 2 1 2 2 2 4 3 5 2 1 2 2 2 4 4 5 2 1 2 2 2 4 5 5 2 1 2 2 2

Typical Man Power Deployment for maintenance in a Depot with 100 fleet Category Norm Mechanical Foreman Asst. Mechanical Foreman Men 1 0. 049 Chargeman 2 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

Deployment of Mechanics & Helpers for maintenance in a Depot with 100 fleet Activity Mechanics Helper/ Shramik @ Norm 0. 35 @ 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

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

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 disproportionate 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.

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.

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.

• 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 ‘T&P Return’ shall be maintained properly indicating the locality of each & every item of the Garage.

Important T&P required for smooth maintenance S. Description No 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. .

Important T&P required for smooth maintenance S. Description No 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 Mechanic’s work bench 10 Contd. .

Important T&P 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

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

The Mechanical Supervisors ensure periodical calibration of certain T&P items like Dial gauges, Injector testers, Wall gauges, Torque wrenches etc, as per the stipulated periodicity. The worn out and defective T&P are replaced in time so that the work is not hampered. Additional requirement of T&P owing to increased number schedules or introduction of new models are submitted to the Dy. CME concerned for obtaining the same.

Mechanic Tools for TATA Depots D. E. Flat Ring Tubular Socket 6 x 7 mm 6 x 7 mm 8 x 9 mm 10 mm 8 x 9 mm 10 x 11 mm 10 x 11 mm 13 mm 8 x 10 mm 12 x 13 mm 14 mm 9 x 10 mm 17 x 19 mm 12 x 14 mm 17 mm 10 x 11 mm 21 x 23 mm 17 x 19 mm 19 mm 10 x 13 mm 22 x 24 mm 22 mm 12 x 14 mm 27 x 32 mm 24 mm 14 x 17 mm 41 x 46 mm 17 x 19 mm 22 x 24 mm 27 x 32 mm 27 mm 3/8’’ Other Tools 55 mm single end Flat Tommy bar 125 mm long Tommy bar 250 mm long Extension 6 Extension 12" Cutting Plier 8" Cutting plier 10” Hammer Ball pane 1/2 Kg. 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’’

Mechanic Tools for LEYLAND Depots D. E. Flat Ring Socket Other Tools 3/16’’x 1/4’’ ¼’’x 5/16’’x 3/8’’ 7/16’’x 1/2’’ 9/16’’ x 5/8’’ 11/16’’x 3/4’’ 6 x 7 mm 8 x 9 mm 10 x 11 mm 12 x 13 mm 14 x 15 mm 16 x 17 mm 18 x 19 mm 20 x 21 mm 22 x 23 mm 24 x 27 mm ½’’ 10 mm 11 mm 12 mm 13 mm 14 mm 17 mm 19 mm 21 mm 22 mm 24 mm 46 mm 55 mm single end Flat wrench Tommy bar 125 mm long Tommy bar 250 mm long Extension 6 Extension 12" Cutting Plier 8" Cutting plier 10” Hammer Ball pane 1/2 Kg. 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

Fast moving Mechanic Tools ASHOK LEYLAND DE Ring 10 x 11 14 x 15 19 x 22 8 x 9 BSF 3/16” X ¼” 5/16 X 3/8” Feeler gauge Socket 12, 13 14, 17 19 TATA DE Ring 17 x 19 13 x 14 19 x 22 9 x 10 Feeler Gauge Socket 9, 10 13, 14 17, 19

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

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

Delegation of Powers Pertaining to T&P S. No Nature of Power 32. i) ii) Standardization of depot equipment, inclusion of new items, fixation of norms, classification of T&P value-wise fixation of guidelines, expectancy etc Inclusion of new equipment on experimental basis Authority Extent of powers MD Full powers with the concurrence of FA/CAO on the recommendations of ED(E)/CCOS/CME/ CFM ED(E) Powers upto Rs 1. 00 lakh per occasion with the concurrence of FA/CAO CME Powers upto Rs 50, 000 per annum with the concurrence of Dy. CAO WM/ Powers upto Rs 10, 000 Dy. CME per annum with the concurrence of Dy. CAO Contd. .

Delegation of Powers Pertaining to T&P S. No Nature of Power 33. i) ii) Sanction for replacement of T&P equipments including premature replacements at Depots/ W. shops Authority Extent of powers CME/ ED(Z) Full powers on the recommendations of Dy. CME/ WM with the concurrence of Dy. CAO Sanction for replacement of T&P Dy. CME/ Full powers with items after their normal utilization WM concurrence of Dy. CAO for Depots/ W. shops as per DM Powers upto Rs 300/- at guidelines issued from time to a time subject to a limit time of Rs 2, 000 per annum Contd. .

Delegation of Powers Pertaining to T&P S. No Nature of Power 34. i) ii) Sanction for replacement of T&P equipments for New Depots/ W. shops Sanction of additional T&P for existing Depots/ W. shops on account of increase in Fleet stength/ acitivity as per guidelines Authority Extent of powers ED(Z)/ CME Full powers as per guidelines CME/ Full powers with Dy. CME/ concurrence of CFM/ Dy. CAO as per WM guidelines DM Powers upto Rs 300/- at a time subject to a limit of Rs 2, 000 per annum Contd. .

Delegation of Powers Pertaining to T&P S. No Nature of Power 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 Authority Extent of powers ED(E) Full powers with concurrence of FA/CAO CME/ ED(Z) Full powers with concurrence of CFM/ Dy. CAO upto Rs 20, 000 at a time SSO Full powers upto Rs 5, 000 at a time with concurrence of Dy. CAO JSO Upto Rs 1, 500 at a time

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

• 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.

• 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

Provisioning of Float Units to Depots S. No 1 2 3 4 5 6 7 8 MAJOR UNITS UNIT NORM Engine 1 for 10, 000 KMs. Front Axle 1 for 14, 000 KMs. Rear Axle 1 for 14, 000 KMs. Gear Box 1 for 8, 500 KMs. Steering Box 1 for 10, 000 KMs. FIP 1 for 5, 000 KMs. Self Starter 1 for 4, 000 KMs Alternator 1 for 4, 000 KMs.

SUB ASSEMBLIES S. No 1 2 3 4 5 6 7 8 UNIT Injectors (set) P. P. Shafts (set) Air compressor Clutch pressure plate (Leyland)/ Springer (Tata) Water pump assembly Cylinder head assembly Radiator NORM 1 for 2, 000 KMs. 1 for 6, 000 KMs. 1 for 5, 000 KMs.

MAJOR SPARES S. No UNIT NORM 1 2 3 Front hub Rear hub Clutch housing 1 for 15, 000 KMs. 4 5 6 7 8 9 10 11 12 Air cleaner complete Fuel twin filter assembly Feed pump Fly wheel ring gear Unloader valve Set (4) of slack adjusters Set (4) of spring brake chambers Hand brake valve A. C. Head 1 for 5, 000 KMs. 1 for 10, 000 KMs. 1 for 3, 000 KMs. 1 for 5, 000 KMs. 1 for 10, 000 KMs. 1 for 5, 000 KMs.

MAJOR SPARES S. No UNIT NORM 13 14 15 Air tank Clutch disc U. J. Cross 1 for 10, 000 KMs. 1 for 5. 000 KMs. 1 for 6, 000 KMs. 16 17 18 19 20 21 22 23 24 Set of brake drums front (2 off) Set of brake drums rear (2 off) Set of spring brackets front (2 off) Set of spring brackets rear (2 off) Axle shafts 2 off H. S. D. Oil Tank Wiper Machine Batteries Hydraulic jacks 1 for 5, 000 KMs. 1 for 6, 000 KMs. 1 for 5, 000 KMs. 10% of the batteries 1 for 2, 000 KMs.

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.

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% 76

Physical Inspection of Buses by Depot Manager & Maintenance Incharge The Depot Manager shall inspect atleast 30 vehicles (1/3 rd 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

Check-list for inspection of vehicles S. No System 1 2 3 4 5 6 7 8 9 10 Item Engine Air cleaner maintenance , , A/c Suction hose , , Engine mounting , , Engine oil leakages Fuel HSD tank cap seals , , Fuel pipe clamping , , Fuel leakages Cooling Radiator Cap , , Coolant concentration , , Radiator mountings Contd. .

S. No System 1 2 3 4 5 6 7 8 9 Item Steering Tie-rod/ drag link end play , , ATF oil leakages , , King pin lubrication Susp. Broken spring leaves , , Spring side clamps/ ferrules , , Welded side clamps , , Spring brackets/ shackles Air suspension mounting bolts , , Tightness Condition of rubber bushes , , in Air suspension Contd. .

S. No System 1 Item 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

S. No System 1 2 3 4 5 6 7 8 9 Brakes , , , , , Tyres , , Item Air tank condensate Brake pipe clamps Air leakage Air Dryer working Hand brake condition Brake dust covers Wheel alignment Matching of duals Less than 2 mm NSD tyres Contd. .

S. No System 1 Item Electrical Battery Maintenance 2 , , Head Lights 3 , , Signal Lights 4 , , Self condition 5 , , Saloon Illumination 6 Body 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 Exterior/ Interior cleanliness

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 Driver’s 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

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

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

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

Indicators for Quality of Sch-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. Fleet Optd Type Held Kms Failures within 15 days Due Done Backlog % Backlog Nos % Sch-III ORD EXP Total Failures within Sch-IV Fleet Optd Type 15 days Held Kms Due Done Backlog % Backlog Nos % ORD EXP Total

Important Registers maintained in Preventive Maintenance Management Ø Daily RG Register RTC-126 Ø Vehicle Back History RTC-109 Ø Sch-I Maintenance RTC-127 Ø Sch-II Maintenance RTC -128 Ø Sch-III work done MTD -194 Ø Preventive Maintenance Master register RTC-110 Ø Unit changes register Ø Register for Inspection of vehicles Ø FC Register Ø Breakdowns RTC-129 Ø Cancellation of Kms RTC-130 88

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

Deployment of New Buses from 2010 Type 2010 -11 2011 -12 (Jan’ 12) Aug. Rep. Total 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 LF A/C Diesel 28 0 28 51 0 51 LF A/C CNG 0 0 0 8 LF N-A/C Diesel 16 80 96 3 1 4 LF N-A/C CNG 0 0 0 33 SLF Diesel 75 118 193 9 0 9 SLF CNG 12 58 70 5 Mini Buses 52 0 52 48 0 48 Total 653 937 1590 676 2751 3427 S. Luxury

Green initiatives & Use of Alternate fuels in APSRTC

APSRTC’s 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… 92

APSRTC’s 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 93

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

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 June’ 2005. The vehicle was operated with B 20 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 101

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. Jun-05 41. 3 Nov-05 35. 0 Aug-05 35. 4 Dec-05 11. 8 Sep-05 36. 2 Feb-06 25. 0 Oct-05 32. 6 Mar-06 11. 7 102

Emission Levels of trial vehicle When operated with 100% HSD oil During Trial period Before Trial Jul-05 33. 3 Jan-05 35. 0 Jan-06 34. 0 Feb-05 32. 6 Mar-05 11. 2 Apr-05 37. 3 May-05 45. 4 103

Comparative Fuel Performance* of Vehicle during trials With 100% HSD oil With Biodiesel Jul-05 4. 627 Jun-05 4. 355 Jan-06 5. 193 Aug-05 4. 538 Sep-05 4. 662 Oct-05 4. 778 Nov-05 4. 430 * Fuel Performance in Kms/Lit Dec-05 4. 516 Feb-06 4. 797 Mar-06 5. 008 104

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. 105

Comparative Emission Levels Before Trials Vehicle Bend No % AP 11 Z 3845 AP 11 Z 4037 Mar Apr May 2006 During Trials Avg of Jun Jul three 2006 Months 41 Aug 2006 Avg of three months % Emission Reduction 30. 6 35. 67 17. 49 5% 44. 3 55 30. 4 43. 23 35. 4 10% 29. 3 33. 7 40. 1 34. 37 32. 7 22. 1 20. 1 24. 97 27. 35 20% 27. 7 31. 9 20. 9 26. 63 11. 7 21. 6 16. 67 59. 75 Comparative Fuel Efficiency Avg Km/Lit % Improvement Before Trial During Trial Vehicle No Bend % AP 11 Z 3845 5% 5. 29 5. 33 0. 76% AP 11 Z 4045 AP 11 Z 4037 10% 20% 5. 20 4. 91 5. 38 5. 21 3. 46% 5. 47% 106

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 1: 9 ratio for about one month. 107

With the encouraging trial performance, Corporation has taken a decision to use Biodiesel 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. 108

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) 109

Biodiesel Stocking & Blending Arrangement at Depots Biodiesel Storage Tank 1 ½’’ MS Line Dip Rod Tank Level Gauge 1’’ Flexible Hose 1’’ MS Line Truck with Biodesel Transfer Pump Ground Level Underground HSD Oil Tank 110

Procedure of Blending Biodiesel with HSD Oil Blending Biodiese with HSD for first time 1. Know the quantity of (Q 1) of HSD in Ground Tank 2. Calculate required qty (Q 2) of Biodiesel @10% blend with HSD (Q 1 x 10/90) 3. Transfer calculated qty (Q 2) of Biodiesel from Storage tank by gravity using Flowmeter F 1 Procedure for subsequent replenishments 1. Ignore the quantity of B 10 blend existing in the storage tank on fresh receipt of HSD oil 2. Know the fresh quantity (Q 3) of HSD that is being decanted into the underground tank 3. Calculate the required quantity (Q 4) of Biodiesel to mix by using the formula Q 3 x 10/90 4. Transfer the quantity Q 4 of Biodiesel from Storage tank to the Underground tank with the help of Flow meter F 1 111

Reduction of Pollutants with B 20 Fuel POLLUTANT Reduction with The values with 20% Blended Pure HSD Oil Bio-diesel Total Unburned Hydrocarbons 1. 1 gms/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% 112

Comparative Specifications of HSD & Biodiesel Parameter ASTM Method Flash Point D 93 Water & Sediment D 2709 Kinematic Viscosity 40 oc D 445 Unit Pure Bio. Diesel Normal HSD Oil OC 130 min 66 min % Volume 0. 05 max mm/Sec 1. 9 – 6. 0 2 -5 0. 01 max Sulphated Ash D 874 % mass 0. 02 max Sulphur D 5453 % mass 0. 05 max 0. 035 max Copper Strip Corrosion D 130 Cetane Number D 613 Cloud Point D 2500 Not worse No. 3 max than No. 1 47 min OC 46 min Report Continued… 113

Comparative Specifications of HSD & Biodiesel Parameter ASTM Method Unit Pure Bio. Diesel Normal HSD Oil Carbon Residue 100% Sample D 4530 % mass 0. 05 max 0. 03 max on 10% Acid Number D 664 mg KOH/gm 0. 8 max -- Free Glycerin D 6584 % mass 0. 02 max -- Total Glycerin D 6584 % mass 0. 24 max -- Phosphorus D 4951 % mass 0. 001 max -- Distillation Temp. Atmospheric Equivalent Temp 90% Recovered D 1160 Degrees C 360 max -114

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… 115

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 116