7. Coach Holding of Parel Workshop TYPE ICF ICF-SHATABDI LHB Holding 3000 60 110

9. Major activity at Parel Workshop 36 62 LHB 15 5 0 1531 ICF POH 07-08 (estimate) 2006-07 Type Activity Refurbishment of toilets, changing the main door LHB Refurbishment of toilets, Laying of Stainless Steel Inlay, changing LP Sheet, Limpet Sheet ICF RSP

10. Divisional Feeding points of Parel Stores Depot Division Carriage Repair Depots BCT BCT, BDTS, BL, ST BRC ANND ADI ADI, KKF, NBVJ, GIM RJT RJT, OKA, HXP RTM RTM, IND, BVP BVP,VRL,PBR

11. Feeding Points Stores Depot Lower Parel Carriage Repair Workshop WR Divisions CWS-ADI-BG (165) CWS-ADI-MG(150) CWS-RTM-P (54) CWS-BCT (56) CWS-BDTS(121) CWS-TRS-BAMY(5) CWS-BL (114) CWS-ST (128) CWS-BRCP (20) CWS-ANND (73) CWS-SBI-MG(2) CWS-BVJ (122) CWS-GIM (125) CWS-IND (163) CWS-MHW (24) CWS-UJN (13) CWS-COR (13) CWS-BVC (117) CWS-PBR (123) Mumbai Baroda Ratlam Ahmedabad Bhavnagar Rajkot CWS-RJT (115)

12. Annual issues & closing Balance YEAR ISSUES ( in 10 Million) BALANCE ( in 10 Million) TOR ( %) 2004-05 42.33 10.22 24.14 2005-06 46.01 10.11 21.97 2006-07 58.71 10.97 19.34

13. Annual usage value of various category of stores

14. Category of items at Parel depot

16. Present Status

20. Works Program May 2009 Railway Board > 50 Million June-July 09 Railway Board > Rs. 20 Million but < Rs 50 Million Pink Book June-July 09 Railway Board > Rs. 3 Million but < Rs. 20 Million Feb 2009 GM < Rs. 3 Million LAW BOOK Commencing Yaer Sanctioning Authority Value of Works Plan Head 42

21. Machinery & Plants Program May 2008 Railway Board >Rs. 10 Million Sept/Oct 08 Railway Board > Rs. 1 Million but < Rs 10 Million Pink Book Sept/Oct 08 Railway Board Any Vehicles Sept/Oct 08 GM < Rs. 1 Million LAW BOOK Commencing Year Sanctioning Authority Value of Works Plan Head 41

37. Other storage & retrieval systems Storage carousel Push-back rack Shelves/bins/drawers Flow-through rack Mezzanine Stacking frame Drive-in rack Split case order picking system Cantilever rack Selective pallet rack Automatic storage/retrieval systems (AS/RS Unit load AS/RS Miniload AS/RS Man-on-board AS/RS Sliding rack Block stacking (no equipment)

46. Shelves/Bins/Drawers

57. Loading/ Unloading Area RAIL RAIL RAIL

58. Vertical crane of IW-ASRS

59. Drive-in-Pallet System 1 2 3

65. !

67. PLAN, ELEVATION & SECTION OF PAREL STORES DEPOT

68. FRONT VIEW OF IW-ASRS AT PAREL STORES DEPOT

69. TOP VIEW OF PAREL STORES DEPOT WITH IW-ASRS

70. PALLET & SECTION AT “C”

72. Layout of C ward Dy.CMM-PL Chamber CA/TA to Dy.CMM lift AMM, Ledger Section & computer cell NF Ward DMS Returned stores & platform Survey Plot & Loading platform

73. LAYOUT FOR THE PROPOSED ASRS AT THE CENTRAL WARD

75. Existing Plan of Roof for Central Ward Existing Elevation of Roof for Central Ward Dy.CMM-PL Chamber CA/TA to Dy.CMM lift AMM, Ledger Section & computer cell NF Ward DMS Returned stores & platform Survey Plot & Loading platform

76. Future elevation of Roof for Central Ward Dy.CMM-PL Chamber CA/TA to Dy.CMM lift AMM, Ledger Section & computer cell NF Ward DMS Returned stores & platform Survey Plot & Loading platform

77. Layout of C ward Dy.CMM-PL Chamber CA/TA to Dy.CMM lift AMM, Ledger Section & computer cell NF Ward DMS Returned stores & platform Survey Plot & Loading platform

81. S/ASRS/LPL/2008/01 DATED 07.07.2008 opening ON 12.11.2008 AT 11.00 HRS SCOPE: Design , fabrication, supply, commissioning and testing of automated storage and retrieval system at carriage repair stores depot, lower Parel, Mumbai EMD: 7.70 Lakhs. Expected time of completion: 12 TO 15 Months from the date of issue of signing of contract Tender Details

83. CIVIL WORK INVOLVES Demolishing /dismantling of existing structure/building and segregation of dismantled debris along with their transportation to nominated Scrap Yards . Construction of concrete platform of approximate height 1 Mtr For supporting entire ASRS structure. Erection of pre-engineered modular steel structure/building for housing the ASRS . Provision of High Rise Racking System with minimum 3840 racking Locations

84. Provision of cage and plain pallets for keeping material. Provision of High rise Fully Automated, Computer Controlled, Stacker Crane and Transfer Car system along with necessary Aisle Equipment0. Provision of comprehensive Warehouse Management System. Provision of Electricals, screened partition and fire protection system for complete ASRS system. CIVIL WORK . CONT.

87. PAYMENT TERMS Payment will be made for the actual work done at site on pro-rata basis. The tendered is free to submit its stage payment schedule based on the activities involved such as dismantling of building, removal of debris, construction of ASRS platform, erection of columns, construction of roof etc. Advance payment of accepted rate/structural steel of bars, HTS wires, neoprene bearings, anchorages, sheathing etc. shall be made after bringing to the site of work and on production of necessary purchase voucher/Test certificates, an insurance policy covering losses due to thefts & floods and against indemnity bond submitted by the contractors and accepted by competent authority. This advance is recoverable from running bills to the extant quantity of above material are consumed up to the running bills stage. Sr.No Work Payment to be made Remarks. (a) Supply of reinforced steel 70% (b) Supply of material other than reinforced steel 60% (c) Fabrication & Erection 90% (d) On commissioning 100%

88. EMD & SD EMD. Deposit Receipt, Pay order, Demand Draft, Guarantee Bonds. Performance Guarantee/Security Deposit To. Be deposited Excise Duty & Modvat

89. Technical Specification 1 One Single Mast Stacker Crane for 1000 mm (W) X 1200 mm (D) X 1200 mm (H) Pallets of one ton capacity and capable of serving a height of 18 meters or more Transfer Car – Racking System Plain Steel Pallets -: Qty 1920 Numbers of Four way entry Plain Steel pallets of size – 1000 mm (W) X 1200 mm(D) X 1200 mm (H) Cage Steel Pallets : Qty. 1920 Numbers of Four way entry four side wire mesh cage steel pallets of size – 1000 mm (W) X 1200 mm(D) X 1200 mm Mechanical Aisle Equipments: Railway railwith adjustable clamps for holding the rails inposition & to ensure alignment. Top rail shall be mounted on the racking system through clamps

90. Electrical Aisle Equipments: The Electrical aisle equipment shall consist of Power rail (fully enclosed Bus Bar), which is mounted on the racking system below the first loading level with necessary protection as feature as per Indian Electricity Act. Controls & Hardware – All necessary controls, PLC, Hardware etc. Software – Warehouse Management System and inverter control system OPERATION CYCLE Technical Specification 2

92. DESIGN STANDARDS 1 The design of the AS/RS should conform to Indian and International standards, ensuring that best of the System is supplied. Following Indian and International Standards should be followed. IS 800 – 1984 General Construction on steel IS 801 – 1975 Code of practice for use of cold formed light gauge steel structural members in general building construction IS 10748 – 1984 Hot-rolled Steel Strip for Welded Tubes and Pipes – Specification IS 3655 – 1966 Recommended practice for electroplating IS 101 – 1964 Methods of Sampling and test for paints, varnishes and related Products

93. DESIGN STANDARDS 2 IS 2074 – 1992 Ready Mixed Paint, Air Drying, Red Oxide Zinc Chrome, Priming – Specification IS 513 : Cold Rolled Low Carbon Steel Sheets & Strips IS 325 : 3-Phase induction motor – specifications. IS 1363 : Hexagon Head Bolts, Screws and Nuts IS 2062 : 1999 Steel for General Structural Purposes – Specification IS 4923 : 1997 Hollow Steel Sections for structural use IS 2266 : Steel Wire Rope for engineering purpose. IS 4923 : Hollow steel section for structural use. FEM 9.311 – 1978: Rules for Design of Storage & retrieval Machines – Structures. 5.1.15 FEM 9.831 – 1995 : Basis of calculation for Storage & retrieval Machines – Tolerances & Clearances within warehouse. 5.1.16 FEM 9.851 – 2003 : Performance Data of S/R Machines – Cycle Time.

102. PEB Design

103. PEB BUILDING

118. PEB TCCS = TAPERED COLUMN CLEAR SPAN

132. Soil test report

135. RFID API Software (Communicates with the RFID Reader) Customer-Specific Application Software Host Computer Host Memory Space Reader Antenna Application Program Interface (API) Application Program Interface (API) Components of an RFID System

136. Antenna Reader Firmware Customer’s MIS Host Application Software API TCP/IP Power ~ Asset Asset/Tag RFID System Components (block diagram) Tag Insert

137. RESPONSES COMMANDS Tag Physical Memory APPLICATIONRESPONSES APPLICATION INTERROGATOR RF TAG APPLICATIONCOMMANDS Command / Response Unit PHYSICAL INTERROGATOR DATA PROTOCOL PROCESSOR ISO/IEC 15961 ISO/IEC 18000 Encoder Logical Memory AIR INTERFACE ISO/IEC 15962 ISO/IEC 15962 Annexes Logical Memory Map Note: The Logical Memory Map in the Tag Physical Memory is given by the Tag architecture and the mapping rules in the Tag Driver. All the information in the Logical Memory is represented in the Logical Memory Map Decoder Tag Driver and Mapping Rules Application Program Interface DEVICE COMMANDS DEVICE RESPONSES

139. RFID Operations

161. Regulations - ITU

163. How far, how fast, how much, how many, attached to what ?

164. Radio Frequency Identification (RFID) Applications

165. Portal Applications Bill of Lading Material Tracking

167. Conveyor / Assembly Line Read / Write Operations Higher Accuracy than Bar Code

169. Hand Held Application Categories Wireless Batch Fixed Station

170. Application Examples Material Handling Inspecting / Maintaining Where is it? What is it? What is inside the box? Where is it going? Where has it been? Should it be here? What have I assembled or disassembled? How many do I have? Do I have enough? Has this been repaired? Is this under warrantee? Has this been inspected? Is this complete? What is the asset’s status or state? Wireless / Batch Inventory Management Material Handling By Destination Material Handling Aggregate / De-aggregate

171. Shipping Validation Tote/Box/Unit Level Inventory

172. Intelligent Labels

173. The HazMat Label

175. Radio Frequency Identification (RFID) Standards

176. The Layers of Logistic Units ( Optically Readable Media) Movement Vehicle (truck, airplane, ship, train) Layer 5 ISO TC 204 (None) AIAG B-15 Container (e.g., 40 foot Sea Container) Layer 4 ISO TC 104 (None) Layer 3 ISO TC 122/WG 4 (15394) ANSI MH10.8.1 AIAG B-10/14 EIA 556-B UCC 6 Layer 2 ISO TC 122/WG 4 (15394) ANSI MH10.8.1 AIAG B-10/14 EIA 556-B UCC 6/EAN Genl Spec Layer 1 ISO TC 122/WG 7 (22742) ANSI MH10.8.6 AIAG B-4 (TBD) EIA 621/624 & IEC TC 91 UCC 1 /EAN Genl Spec Layer 0 ISO TC 122 (TBD) ANSI MH10.8.7 AIAG B-4 EIA SP-3497 UCC 1 /EAN Genl Spec Unit Load “ Pallet” Unit Load “ Pallet” Transport Unit Transport Unit Transport Unit Transport Unit Pkg Pkg Pkg Pkg Pkg Pkg Pkg Pkg Item Item Item Item Item Item Item Item Item Item Item Item Item Item Item Item

177. The Layers of Logistic Units (Radio Frequency Identification - RFID) Container (e.g., 40 foot Sea Container) Movement Vehicle (truck, airplane, ship, train) Layer 5 ISO TC 104 ISO TC 204 (ISO 14816) IATA ISO TC 8 AAR Layer 4 (433 MHz, 860-930 MHz) ISO 122/104 JWG (ISO 10374) ISO TC 104 (ISO 18185) ISO TC 104 (Beyond 18185) ISO 17363 (122/104 JWG) Layer 3 (433 MHz, 860-930 MHz) ISO 17364 (122/104 JWG) ANSI MH10.8.4 AIAG (TBD) EIA (TBD) EAN.UCC GTAG Layer 2 (860-930 MHz) ISO 17365 (122/104 JWG) ANSI MH10.8.8 AIAG (TBD) TCIF (TBD) Layer 1 (860-930 MHz) ISO 17366 (122/104 JWG) Layer 0 (860-930 MHz) ISO 17367 (122/104 JWG) AIAG B-11 Item Item Item Item Item Item Item Item Item Item Item Item Item Item Item Item Pkg Pkg Pkg Pkg Pkg Pkg Pkg Pkg Transport Unit Transport Unit Transport Unit Transport Unit Unit Load “ Pallet” Unit Load “ Pallet”

179. Lads, Dads, & Granddads                                                          

182. The Ideal Setup

183. Often --The Real World

187. Hot Band with Resistance Welded Stainless Tag

188. Thermal Transfer Printed Metal Tags Slot for Band Wire On Holes

189. AIAG Label in Adhesive Pouch

190. Recommended Label in Adhesive Pouch

191. Typical Tag

192. ORDER # DATA IDENTIFIER

193. LPN # DATA IDENTIFIER

194. • Bar Code Basics

195. SYMBOLOGIES: There are several ways that the Bars , Dots and Spaces can encode information. Each way is called a SYMBOLOGY 2 D Codes 1 D (Linear)Codes

196. Typical Code 39 Tag

197. GOOD BARCODES INCLUDE: • BLACK BARS • WHITE SPACES • GOOD CONTRAST ( PCS) • PROPER RATIOS • CLEAR ZONES P rint C ontrast S ignal

198. START SEQUENCE Q U I E T 1 000 1 0 111 0 111 0 1 STOP SEQUENCE 1 000 1 0 111 0 111 0 1 Q U I E T

199. BAR CODE POINTERS “X” DIMENSION • USE LARGEST POSSIBLE “x” DIMENSION FOR THE AVAILABLE SPACE BETTER THAN • BAR CODE CALCULATORS AVAILABLE AT

200. BAR CODE POINTERS “X” DIMENSION • LARGER X MEANS LONGER READ DISTANCE .048”= “x” Reads at 12 to 15 ft. ( Long Range Reader) .012”= “x” Reads at 2 to 3 ft. • LARGER “x” WORKS BETTER DIRTY/ SCUFFED

201. Code 39 Code 128C I 2 of 5 All of these symbologies encode the same decimal digits but look at the much finer (delicate) bars in Code 39 POINTER !! For all decimal digits , use 128 or I 2 of 5 (even # digits)

203. 1. Start by Marking Bar Coded LPN with Check Digit(s) on each coil Verify! License Plate Check Digits

204. 2. Create an LPN Indexed Database--- REAL TIME NETWORK LPN CK HT RCVD THK WT1 ANNEAL LAST 12345681 59 A12345 126@12:30 .0625 IPS7 12345682 63 A12345 126@12:33 .0825 20,200 P1@128@04:58 P28 12345683 67 123467 126@12:38 .0375 14,357 P3@128@05:10 P27

205. 3. Create and Use a Network Mill Computer Scale S2 etc. LPN CK HT RCVD THK WT1 ANNEAL LAST 12345681 59 A12345 126@12:30 .0625 17,425 S2 12345682 63 A12345 126@12:33 .0825 20,200 P1@128@04:58 P28 12345683 67 123467 126@12:38 .0375 14,357 P3@128@05:10 P27

206. Summary • Identify Coils Uniquely (LPN + Check) • Use Automatic Identification (Barcodes Big as Possible) • Create and Use a Networked Database with the coil LPN’s used as a index pointer • Update and USE the Database wherever possible (up to shipping)