One-Day Refresher Training Module (On-the-Job Training) For Technicians &

Workshop Assistant Working in Various Shops of Alambagh Workshop

1. Objective:

To refresh and upgrade the technical knowledge, practical skills, and safety awareness
of technicians & Workshop Assistant working in various shops of Carriage Workshop,
Alambagh with emphasis on standard practices, quality workmanship, safety, and
productivity.

2. Duration: 8 Hrs

3. Training Methodology
• Classroom briefing
• Demonstration at workplace
• Hands-on practical exposure (OJT)
• Interaction and experience sharing
• Audio-visual aids (where available)

4. Course Structure & Schedule

A. Session I: Inaugural & Overview (30 Minutes)

• Introduction to refresher OJT programme
• Importance of skill upgradation and adherence to SOPs
• Expectations from technicians

B. Session II: Safety & Statutory Compliance (1 Hours)

• General safety rules in workshop
• Use of Personal Protective Equipment (PPE)
• Electrical safety, fire safety, and first aid
• Safe handling of tools, machinery, lifting tackles, and chemicals
• Accident prevention and reporting procedure

C. Session III: On-the-Job Practical Training (2 Hours 30 Minutes)

• Demonstration of correct working methods at shop floor
• Proper use of tools, jigs, fixtures, and measuring instruments
• Good housekeeping practices (5S concept)
• Energy conservation and material economy
• Practical problem-solving at workplace

D. Session IV: Digital Initiatives & Documentation (30 Minutes)

• Awareness about WISE / IT-enabled systems used in workshop

• Importance of correct data entry and job documentation
• Role of technicians in digital monitoring and transparency

E. Session V: Shop-wise Customized Technical Modules (3 Hours each shop)

(i) Paint Shop

• Surface preparation: cleaning, de-rusting, sanding
• Use of primers, putty, and top coats as per specification
• Spray painting techniques and defect control (runs, sagging, peeling)
• Paint booth safety, ventilation, and fire precautions
• Waste disposal and environmental safety

(ii) Bogie Shop

• Bogie overhauling sequence and critical checkpoints
 • Inspection of frames, bolster, and suspension components
• Fitment and tightening of fasteners with correct torque
• Safety during handling and turning of bogies
• Common bogie defects and corrective measures

(iii) Air Brake Shop

• Air brake system overview and safety precautions
• Inspection and testing of brake cylinders, distributor valves, hoses
• Leakage testing and functional testing procedures
• Correct routing and clamping of air pipes
• Importance of brake power certificate parameters

(iv) Lifting Shop

• Safe lifting practices and load assessment
• Use and inspection of cranes, hoists, slings, and jacks
• Do’s and Don’ts during coach lifting and lowering
• Communication and signaling during lifting operations
• Periodic inspection and certification of lifting tackles

(v) Wheel Shop

• Wheel set overhauling and safety precautions
• Inspection of wheel profile, axle, and press fit
• Wheel pressing parameters and record keeping
• Handling and storage of wheel sets
• Common wheel defects and rejection criteria

(vi) Roller Bearing Shop

• Types of roller bearings used in coaches
• Cleaning, inspection, and greasing procedures
• Bearing mounting and dismounting practices
• Temperature and noise monitoring
• Causes of bearing failure and preventive measures

(vii) CBC & Draft Gear Shop

• Components of CBC and draft gear assembly
• Inspection of knuckle, lock, yoke, and follower
• Assembly sequence and functional checks
• Safety during compression and handling of draft gear
• Common failures and corrective actions

(viii) Screw Coupling & Buffing Gear Shop

• Inspection of screw coupling components
• Measurement of wear limits and thread condition
• Buffing gear overhauling and spring inspection
• Correct assembly and testing
• Safety during handling of compressed springs

(ix) Corrosion / Furnishing Shop

• Identification of corrosion-prone areas in coaches
• Surface preparation: de-scaling, grinding, chemical treatment
• Repair / replacement of corroded panels and members
• Application of anti-corrosive primers, sealants, and coatings
• Quality checks and long-term corrosion prevention measures

(x) Welding Shop

• Types of welding used in carriage workshop (ARC, MIG, TIG as
applicable)
 • Selection of electrodes / filler materials
• Joint preparation and welding parameters
• Welding defects, causes, and rectification
• Welding safety: PPE, gas cylinder handling, fire prevention

(xi) Furnishing Shop

• Interior furnishing components: berths, seats, partitions, panels
• Correct fitment practices and alignment checks
• Use of approved materials, fasteners, and adhesives
• Aesthetic finish, passenger safety, and comfort aspects
• Common furnishing defects and rectification methods

(xii) Plumbing Shop

• Coach plumbing system overview (water supply, drainage, toilets)
• Inspection and replacement of pipes, valves, traps, and fittings
• Leakage testing and pressure checks
• Safe handling of chemicals and sealants
• Hygiene, sanitation standards, and environmental safety

(xiii) Millwright Shop

o EOT Cranes & Critical Machines
• EOT crane types and applications in workshops
• Statutory safety requirements, SWL, load charts & inspections
• Preventive maintenance schedules (daily/weekly/monthly)
• Critical components: wire ropes, hooks, brakes, gearboxes,
bearings
• Alignment & leveling of heavy machines (wheel lathes, presses,
etc.)
• Safe isolation (LOTO) and coordination with electrical staff
• Load testing, documentation & failure analysis
• Working at height and material handling safety

o Air Compressors & Compressed Air System

• Types of compressor used in workshops
• Pre-start checks, safety valves & pressure settings
• Lubrication, filters, belts, intercoolers/aftercoolers
• Moisture traps, air dryers & condensate drainage
• Receiver tank inspection, hydro testing & safety
• Leakage control, energy conservation & common faults

(xiv) Motor Section

• Overview of mobile equipment used in workshop and their applications
• Pre-start checks and daily inspection checklist for vehicles
• Safe driving practices within workshop premises (speed limits, blind
spots, signaling)
• Load handling principles: SWL, stability, center of gravity and tipping
prevention
• Fork lifter operations: fork positioning, pallet handling, stacking and de-
stacking
• JCB operations: excavation, lifting attachments, swing safety and
ground stability
• Hydra crane operations: outriggers deployment, load charts and lifting
radius control
• Shunter operations: coupling/uncoupling, braking system checks and
communication protocols
• Fuel, battery and hydraulic system inspection and maintenance
• Routine preventive maintenance: lubrication, filters, belts and hoses
 • Parking, shutdown procedures and key control
• Breakdown handling, reporting procedure and coordination with
maintenance staff
• Common operational failures, accidents causes and preventive
measures
• Safety precautions: PPE, reversing alarms, fire safety and emergency
response

F. Session VI: Interaction, Feedback & Assessment (30 Minutes)

• Interaction with trainees
• Sharing of experiences and difficulties faced at shop floor
• Short assessment / verbal feedback
• Suggestions for improvement

5. Training Faculty
• SSE/BTC and SSE / JE of concerned shops
• Safety Officer / Nominated Safety Supervisor
• Experienced technicians / subject experts