Case Studies | Allcargo Logistics

ALLCARGO PROJECTS TEAM ACHIEVED A MAJOR MILESTONE BY CROSSING THE SON RIVER THROUGH BYPASS, WITH GENERATOR STATOR UNIT I WEIGHING 345 TONS – RELIANCE SASAN POWER PROJECT

The Client

Reliance Power Limited, India's leading Power Utility is setting up the Country's first Ultra Mega Power Project (UMPP) at Sasan in the state of Madhya Pradesh. The Project consists of 6 Units, each capable of generating 660 MW (Mega Watts), translating to 3,960 Million Units of Power.

The Business Need

Reliance Power Limited, India's leading Power Utility is setting up the Country's first Ultra Mega Power Project (UMPP) at Sasan in the state of Madhya Pradesh. The Project consists of 6 Units, each capable of generating 660 MW (Mega Watts), translating to 3,960 Million Units of Power.

Key Challenges

Execution of this project entailed transporting individual Cargo, including Reactors (70 Tons), De-Aerators (152 Tons), Transformers (up to 230 Tons) and Generator Stators (345 Tons). It also included 25 SODCs to be transported by barges on the Ganges River up to Zamania (in the state of Uttar Pradesh) located 1,200 km away. And from Zamania by road to the Site which was another 350 Km. The other SODCs, including the De-Aerators (each weighing 152 Tons and 42 m in length) to be transported from Haldia Port by road. These had to be transported across places where there were no proper roads or jetty at the riverside. The biggest challenge was crossing the Son River, which was in spate for the first time in 32 years due to an overflow of the water from the dam located nearby.

Solution

En route, we built Causeways and Bypasses through Rivers, crossed a multitude of Railway Lines, blasted hill sides to take turns with our long Trailers, and moved for over 100 Kms in terrorist infested areas.

The Milestone Crossing which was the Son River, we created a strong bypass made of over 1.4 million sandbags with the help of 300+ laborers, dozers, levelers. It took 4 months to complete this.

The first Generator Stator Unit I weighing 345 Tons, crossed the Son river bypass successfully on May 23, 2012. And the balance two were successfully taken across the river, the next day.

Value Delivered

Thus, with extreme precautionary steps and strategic and systematic planning undertaken by Allcargo, the logistics movement of the Generator Stator and other equipment are being successfully delivered in an efficient and effective manner.

Allcargo has handled 7 of the 9 Power Projects of Reliance Group in the last 6 years, and is proud to be a lead innovative partner in India's infrastructure growth story.

A highly charged logistics team flawlessly executes its strategy

The Client

NTPC (National Thermal Power Corporation) is the largest state-owned power generating company in India, with an installed capacity of 33194 MW. It is currently operating 15 coal-based, 7 gas-based power stations and 6 joint ventures.

The Business Need

The contract for the NTPC Barh 3 x 660 MW project was awarded to Allcargo Logistics Ltd. by M/s Power Machine for the transportation of three Generator Stators and their accessories from Haldia Port / Kolkata Port to NTPC Barh, Bihar.

Key Challenges

The dimensions for the Generator Stator were 9.98 metres x 5.11 metres x 4.73 metres, consisting of an enormous weight of 378 MT each. The Allcargo Logistics Ltd.

Solution

Considering the severe constraints in road transportation to the project site direct from Haldia Port, Multi-modal Transportation option was opted for in order to execute the operation. The Generator Stator was initially transported via waterways up the River Ganges for 902 Km on a flat top barge built by us - from the Haldia Port to Kiroderpur Jetty near Fatwah. The consignment was then transported by road from Kirderpur Jetty to NTPC – Barh Super Thermal Project site (46 Km).

Implementation

Allcargo Logistics Ltd. deployed a flat top barge having dimensions of 60 mtrs length x 15 mtrs width x 2.8 mtrs depth with a carrying capacity of 1000 tons and a loaded draft of 1.2 mtrs along with two tug boats of 900 BHP each for towing the Generator Stator from Haldia port to Kiroderpur Jetty.

We deployed our 12 Axle Goldhofer Hydraulic Modular Trailer in a 1+½ (Total 18 Axles i.e. 36 suspensions) combination for the transportation of Generator Stator by road from Kiroderpur Jetty to the NTPC Project site.

The Generator Stator was received on steel beams and stools pre-positioned on the barge. The beams and stools were specially fabricated and arranged on the barge in such a pattern so as to distribute the entire load of the Generator keeping in mind the deck-loading factor of 5 mt per sq. m. of the barge. The beams were fabricated after calculating the bending movement of the Generator's load.

The package was lashed and secured using tested wire ropes having 19 mm diameter with 5-ton bottle screws and D-shackles, as per insurance surveyor's recommendations.

We selected the Kiroderpur Jetty for constructing a RORO (Roll On, Roll Off) Jetty just 46 Km away from the site. The site was most suitable since there were no bridges en route. Except for a few overhead low-tension electrical lines, tree branches and traffic congestions, the route was considered safe for transportation.

We obtained the required permissions from local administrations like the Police, Electricity Board, Forest and other Government officials.

For smooth and uninterrupted movement, all the potholes on the road which had formed after the monsoons were filled and leveled.

The cargo was escorted by our own staff as well as designated police officers, who assisted us in controlling the traffic during the operation. The State Police Officers also provided us parking slots during the movement.

Value Delivered

Thus, with extreme precautionary steps and strategic and systematic planning undertaken by Allcargo Logistics Ltd., the logistics movement of the Generator Stator and its accessories was successfully delivered in an efficient and effective manner.

THE ONE-STOP ACCOUNTABILITY THAT WON REPEAT BUSINESS FROM VAL

The Customer

Vedanta Aluminium Ltd (VAL) is a leading producer of metallurgical grade alumina and other aluminium products, catering to a wide spectrum of industries. It is an Associate Company of the globally diversified, London Stock Exchange listed, FTSE 100 metals and mining group Vedanta Resources PLC. The Business Need

Allcargo Logistics Ltd. was appointed as the complete logistics provider for the Aluminium Smelter Plant project to be commissioned at Jharsuguda, Orissa by VAL India in December 2008.

The scope of work was

Origin cargo booking & vendor co-ordination – Ex-China
Ocean freight for bulk break & containerized cargo
Custom clearance & handling documentation
In-transit warehousing
On shore transport from port to site
Unloading of cargo at site.

Key Challenges

Allcargo Logistics Ltd. functioned as 3PL, providing End-to-End supply chain management for this project. The scope of work involved

China based Vendors coordination
Origin Consignment booking
Ocean Freight transportation by break bulk and container
Custom Clearance & documentation
In- transit warehousing
On shore transportation from port to site
Unloading of cargo at site.

Solution

Efficient & complex co-ordination was required in order to smoothly execute the operational aspect of sourcing from multiple suppliers in China & to ensure that freight cost was being effectively controlled. Warehousing of material for consolidation was accomplished by Allcargo Logistics Ltd. at China. This helped VAL to control the freight cost during the entire transportation of the project. Implementation

Upon Vessel arrival at the Vishakhapatnam port, the containers were either dispatched to Project site via rail and/or road. At the project site, Allcargo Logistics Ltd. was involved in transportation of containers to project site to pre-determined contractors. This aspect of our service also included destuffing of the containers. The empty containers were then returned back to a nominated liner yard at the discharge port.

Following is an overview of 3PL activities for the VAL project:

Every element of the 3PL activities was set with stringent Timeline KPI's (Key Performance Indicators) & proactive documentation requirements - with Allcargo Logistics Ltd. working closely with the client at every stage.

Value Delivered

Allcargo Logistics Ltd. was able to smoothly execute the project in an effective and efficient manner. Based on our performance in the year 2009 for Phase I, we have been able to secure the service order for Phase II of the project which comprised of 6500 TEU, currently under execution.

A LOGISTICS PARTNER WHO PUT DMRC'S SCHEDULE ON TRACK

The Customer

Delhi Metro Rail Corporation (DMRC), the company that implements and operates the Delhi MRTS.

The Business Need

A coach shell of dimension 22.2 × 3.4 × 4.25 meters, and weighing 14 tons had to be exported from India to Korea for testing, and returned.

Key Challenges

30 days had already been lost in waiting for the BB operators, and any further delay in testing would have adversely affected the time schedule of the DMRC Project. Allcargo Logistics Ltd. had to make up for the delay.

Solution

The shipment was loaded on 4 × 40 flat racks using 8 slots on the twin deck front end.

Implementation

We loaded the containers first to make a bed for the shipment. The entire consignment had to be loaded in 60 minutes or we would be paying high dues for equipment idling and vessel idling at Chennai Port. Bad weather due to a cyclone and strong winds delayed the operation, but we managed to load in 75 minutes.

Value Delivered

The shipment reached the factory in Masan in 18 days. It was re-imported back to India on regular BB service after the testing, and on time! This was the first time CCTPL (a port terminal in Chennai) shipped ODC (Odd Dimension Cargo) in the conventional way.

CONSTRUCTION OF ONSHORE COAL UNLOADING CRANE AT NEW MANGALORE PORT TRUST

The Client

Lanco Infratech Ltd is one of India's top business conglomerates and among the fastest growing. The company has executed many challenging infrastructure projects across India, including Highways.

The Business Need

Construction of onshore coal unloading crane, with a capacity of 30t at single bucket, for unloading coal from vessel at New Mangalore Port Trust (NMPT).

Key Challenge

An accident had occurred here previously due to improper operation and co-ordination.

Solution:

Allcargo Logistics Ltd. provided an expert logistic solution using innovative methods and advanced technology. A detailed study was conducted in

Load distribution calculation according to crane capacity
Movement distribution according to separate crane & capacity
Fixing the ground condition according to cranes
Movement distribution in ratio of 40 % & 60%
Wind speed measurement

And based on the study, a combination of these two cranes was suggested:

LEIBHERR 1400 – 400t
KOBELCO 2500t

Implementation:

A combination of two cranes were pressed into service and the total length of job was divided into two parts.

Total wt according to the ratio of 60% & 40%
Total wt – 85 t
Total length of the job– 28 m
LR Working range – 18 m
Boom length – 63 m
Load – 54 t
CKE working range - 15 m
Boom length – 70 m
Load- 34 t

Among the safety measures taken up at NMPT, Mangalore were

Engineering Control and Applications
Monitoring the Safety of Equipment
Controlling emergency situations in sensitive places near the job site.
Medical Vigilance
Documentation of Defective Equipment
Prevention of injuries and hazardous situations
Use of Personal Protective Equipment
Curbing loss-inducing circumstances through proper analysis of safety requirements of an industry.

EQUIPMENT SOLUTIONS - GIRDER ERECTION AT THERMAL POWER PLANT

Sector	Thermal Power
Crane	Demag CC 2600 (Crawler Crane)
Crane Capacity	500 Ton
Weight	115 Ton
Size	10Mtr. X 0.6Mtr. X 4Mtr.
Location	Mettur (Tamil Nadu)

Allcargo Logistics Ltd. has bagged a number of contracts at various thermal power projects and one of them was the contract for girder erection at Mettur Thermal Power Plant in Tamil Nadu.

This job was carried out using Demag CC 2600 (500 Ton) capacity crane. The heaviest girder erected was 115 ton at a height of 100 meters. Our crew competency and expertise made this execution successful, adhering to stringent safety norms.

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EQUIPMENT SOLUTIONS - COLD BOX ERECTION AT STEEL PLANT

Sector	Cement - Steel
Crane	Demag AC 1600 (Telescopic Crane)
Crane Capacity	650 Ton
Weight	55 Ton
Size	3 Mtr. X 3 Mtr. X 25 Mtr.
Location	Durgapur (West Bengal)

The mission was to place a 55 ton cold box at a height of 25 meters from the ground, at a radius of 22 meters with a boom length of approximate 63 meters. The movement and placement of the crane in a running plant was a challenge due to shortage of space, which we overcame with minor dismantling and skills of the operating crew. This is a good example of similar jobs successfully executed by us.

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Equipment Solutions - Wind Mill Erection

Sector	Wind Power
Crane	Demag CC 2400-1 (Crawler Crane)
Crane Capacity	400 TON
Location	Satara (Maharashtra)

Allcargo Logistics Ltd. has bagged long term contracts with major wind energy companies in India to provide entire equipment consisting of main crane of 400 ton capacity plus 3 support cranes and trailers for the erection of wind turbine towers. We have erected more than 200 complete towers during the past 3 years with total safety.

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Equipment Solutions - Erection at Bhatinda Refinery

Sector	Petrochemical Complex
Crane	Liebherr LR 1750 (Crawler Crane)
Weight	120 Ton & 260 Ton
Location	Guru Govind Singh Refinery – (Bhatinda) Punjab

Allcargo Logistics Ltd. has participated in practically every petro project, providing the 200 to 750 ton heavy cranes for critical erection. In the above picture, our Liebherr LR 1750 (750 ton) crane is in Operation for erection of a Chimney in Hindustan Mittal Energy’s Bhatinda Refinery Project. The same crane has erected vessels ranging from 120 ton to 260 tons.

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Equipment Solutions - Turbine Recovery Job

Sector	Engineering Infrastructure
Crane	Liebherr LR 1650 (Crawler Crane)
Crane Capacity	650 Ton
Weight	280 Ton
Location	Bhavnagar (Gujrat)

Allcargo Logistics Ltd has undertaken a number of recovery jobs. The above picture shows a turbine weighing 280 ton being recovered from a river bed by utilizing our Liebherr LR 1650 (650 ton) crane. The turbine was lying in the river and was recovered successfully without any further damage.

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FORWARD INTEGRATION: AFTER MARKET

One of India’s largest Commercial Vehicle Manufacturers faced the challenges of managing an in-house inventory of after-market spare parts to service their dealers across the country. Their major challenge was to build a reliable production line feeding which required a reduction in inventory variance, management of packing material consumption, packing of goods in special packs and preparation of kits.

Our innovation in stores management and order processing led to a reduction in lead time to delivery of goods to dealers.

The customer also recorded an increase in throughput, an increase in sales of spare parts and a reduction in cost of SPD operations.

Facts and Figures

Allcargo efficiently manages 120,000 sq.ft. Facility

4 years, we have consistently met the SLA/ KPI and we are now into the 5th Year
SKUs & unit quantity handled - 30,000 and 400,000+ respectively
Client Sales increased from INR 216 Cr. per year to INR 360 Cr. in 3 years
Stock gross variance reduced from 10 % to less than 1% in 3 years
Kitting activity introduced: 250 unique types of kits and 50,000 such kits every month
Additional Services added: VOR, Emergency Orders, etc.
Order to Despatch Lead time improved from 3 Days to less than a day

Allcargo Logistics is India’s first & largest integrated logistics company in the private sector. Our services include <a href="http://www.allcargologistics.com/nvocc/">NVOCCs</a>, Container Freight Station & <a href="http://www.allcargologistics.com/cfs-and-icd/">Inland Container Depot</a>, <a href="http://www.allcargologistics.com/projects-and-engineering-solutions/">Project Logistics</a>, <a href="http://www.allcargologistics.com/crane-rental/">Crane Rentals</a>, <a href="http://www.allcargologistics.com/ecommerce-logistics/">E commerce Logistics</a>, <a href="http://www.allcargologistics.com/contract-logistics/">Contract Logistics</a> & <a href="http://www.allcargologistics.com/coastal-shipping/">Coastal Shipping</a>. Know more about what makes us your preferred logistics partner!

BACKWARD INTEGRATION: VMI & LINE FEEDING

A well known manufacturer of consumer durable white goods wished to set up a new facility to manage their raw material by consolidating goods from its vendors. Additionally, they needed to manage their storage capacity and claims.

Allcargo helped them achieve their goal by consolidating the supply of their raw material from suppliers assuring no stoppage in their production line. This led to an overall improved performance of their assembly line and a reduction in their logistics cost.

Allcargo helped them achieve the JIT (Just in time) manufacturing model by preparing bins and trolleys which eliminated line stoppage due to irregularities in supply.

We provided support in managing the inventory on behalf of vendors for the customer resulting in a reduction in cost of damages.

Facts and Figures

Allcargo has been associated with the customer for 5 years and now into the 6th year

Manages inventory on behalf of 10 vendors will bescaled up to 18 in this financial year
100,000 SKU quantity & 3,500 unique line kits
Efficient co-ordination with vendors and the customerwith reliable feed to the line twice a day
Zero Production Line Stoppage on account Stock outs

Forward Integration: After Market

One of India’s largest Commercial Vehicle Manufacturers faced the challenges of managing an in-house inventory of after-market spare parts to service their dealers across the country. Their major challenge was to build a reliable production line feeding which required a reduction in inventory variance, management of packing material consumption, packing of goods in special packs and preparation of kits.

Our innovation in stores management and order processing led to a reduction in lead time to delivery of goods to dealers.

The customer also recorded an increase in throughput, an increase in sales of spare parts and a reduction in cost of SPD operations.

Facts and Figures

Allcargo efficiently manages 120,000 sq.ft. Facility

4 years, we have consistently met the SLA/ KPI and we are now into the 5th Year
SKUs & unit quantity handled - 30,000 and 400,000+ respectively
Client Sales increased from INR 216 Cr. per year to INR 360 Cr. in 3 years
Stock gross variance reduced from 10 % to less than 1% in 3 years
Kitting activity introduced: 250 unique types of kits and 50,000 such kits every month
Additional Services added: VOR, Emergency Orders, etc.
Order to Despatch Lead time improved from 3 Days to less than a day

BACKWARD INTEGRATION: VMI & LINE FEEDING

A well known manufacturer of consumer durable white goods wished to set up a new facility to manage their raw material by consolidating goods from its vendors. Additionally, they needed to manage their storage capacity and claims.

Allcargo helped them achieve their goal by consolidating the supply of their raw material from suppliers assuring no stoppage in their production line. This led to an overall improved performance of their assembly line and a reduction in their logistics cost.

Allcargo helped them achieve the JIT (Just in time) manufacturing model by preparing bins and trolleys which eliminated line stoppage due to irregularities in supply.

We provided support in managing the inventory on behalf of vendors for the customer resulting in a reduction in cost of damages.

Facts and Figures

Allcargo has been associated with the customer for 5 years and now into the 6th year

Manages inventory on behalf of 10 vendors will bescaled up to 18 in this financial year
100,000 SKU quantity & 3,500 unique line kits
Efficient co-ordination with vendors and the customerwith reliable feed to the line twice a day
Zero Production Line Stoppage on account Stock outs