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Traction
(A) Operational issues:
(i) Punctuality loss
Railway-wise and territory wise status is enclosed at Annexure T-1 (A) and T-1 (B). ECR, NR, NCR, NWR & WCR should bring the action plan for improvement as their
performance has deteriorated.
(ii) ICMS: The detailed position of shed outage (Coaching) in ICMS for Jan’12 is enclosed as Annexure T-2. 100+ overall outage indicates that locos are not being properly attached/detached by Railways and certain railways are not meeting the outage target. Railways should investigate the reasons and discuss.
(iii) CMS: A total no. of 339 lobbies have been commissioned till January, 2012.
Out of which 205 are under Mechanical control and only 155 Mechanical lobbies are generating mileage bills through CMS. The Zonal Railways which are not using the facility for mileage calculation of running staff may explain the reasons for not implementing the same.
The new developments in CMS are as below: 1. Running status of freight trains now can be accessed through CMS. This
facility should be utilized for bringing down PDD. 2. Mileage Sheets of Running staff can be printed anywhere through internet on
http//203.176.113.112/CMS reports.
(B) Progress of important RSP items viz. VCD & DPS.
Present status is enclosed at Annexure T-3. The progress of fitment of VCD is slow on ECR, NR, NER, NWR, SR & SWR. These Railways should bring the action plan for achieving the target.
The fitment of DP needs to be expedited. Present Status is enclosed at Annexure T-4. DLW should bring details of ALCO blocks likely to be supplied to Zonal Railways.
DLMW should indicate the progress of procurement of blocks.
(C) Fuel
(i) Line Haul Cost
The tentative figures of Line haul cost for diesel freight and passenger services is enclosed at Annexure T-5. Railways should bring the action plan for improvement.
Maintenance cost of diesel locos is indicated in Annexure T-6. There has been an abnormal increase in NCR, NFR and abnormal reduction in SECR, ECoR. These railways may discuss reasons for the same.
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(ii) Explosive clearance of RCD
Railway-wise status is enclosed at Annexure T-7. Railways should bring the action plan for obtaining the clearance and the likely dates.
(D) SPAD
(i) Railway-wise status of SPAD cases alongwith detailed analysis from April’2009 onwards
is enclosed at Annexure T-8. NR and NER contribute to 25 and 12.5% of the cases respectively.
(ii) Departmental candidates contribute towards 77% of SPAD cases on diesel traction. Board has, therefore, nominated a Committee to look into the additional training required for departmental candidates to bring down SPAD cases. Railways may give suggestions.
(iii) Need for having independent JA grade officer looking after the power organization in every division.
(E) DEMUs
(i) Railway-wise status of DEMU ineffective is enclosed at Annexure T-9. Railways may suggest ways of bringing down POH time as this contributes to nearly 8% of the ineffective.
(ii) IROAF to bring out the progress of CNG conversion of DEMU. (iii) ICF should indicate the progress of supply of RSP items for DEMUs against Board’s bulk
RSP.
(F) Presentations by DLW, RDSO and ICF on new initiatives in diesel technology.
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Annexure T-1 (A) PUNCTUALITY LOSS CASES ON DIESEL LOCO ACCOUNT (BG)
April' 2010-Jan'2011 April' 2011-Jan'2012
No. of PL cases
PL cases/100 Link /month
No. of PL cases
PL cases/100 Link /month
%age Improvement
/100ML /monthRly.
Direct Total
Avg. Mail Link Direct Total Direct Total
Avg. Mail Link Direct Total Direct Total
CR 99 189 80 12.4 23.6 101 158 92 10.9 17.1 11.6 27.5ER 178 328 128 13.9 25.6 122 307 131 9.3 23.5 32.9 8.3EC 156 376 85 18.4 44.2 191 378 92 20.8 41.1 -13.1 7.1ECOR 34 61 32 10.6 19.1 28 50 35 8.1 14.5 23.6 24.0NR 541 968 306 17.7 31.6 608 1170 303 20.1 38.6 -13.5 -22.1NC 264 522 52 50.8 100.4 290 536 54 53.7 99.3 -5.8 1.1NE 212 409 95 22.3 43.1 208 419 98 21.3 42.9 4.5 0.3NF 296 630 111 26.7 56.8 249 497 122 20.4 40.7 23.6 28.3NW 201 285 98 20.5 29.1 216 324 101 21.3 32.0 -4.0 -10.0SR 166 305 143 11.6 21.3 139 239 151 9.2 15.8 20.8 25.9SC 126 224 140 9.0 16.0 114 237 149 7.6 15.9 15.2 0.8SE 57 111 53 10.8 20.9 41 67 62 6.7 10.9 38.0 48.0SECR 10 18 17 5.9 10.6 20 44 18 10.9 23.9 -84.8 -125.8SW 132 230 100 13.2 23.0 116 235 110 10.6 21.4 19.9 6.9WR 105 273 87 12.1 31.4 79 220 92 8.6 23.9 29.0 24.0WC 258 581 129 20.0 45.0 311 595 131 23.8 45.6 -19.1 -1.2KR 1 2 4 4 IR 2836 5512 1656 17.1 33.3 2837 5480 1741 16.3 31.5 4.8 5.4
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Annexure T -1 (B)
Territory Wise Punctuality Cases On DSL account Apr'2011 - Jan'2012
Rly Direct Cases
Lost Trains % Indirect Cases
Lost Trains % Total Cases
Lost Trains %
CR 109 3.8 87 3.3 196 3.6
ER 124 4.4 178 6.7 302 5.5
EC 339 11.9 377 14.3 716 13.1
ECO 35 1.2 25 0.9 60 1.1
NR 684 24.1 655 24.8 1339 24.4
NC 344 12.1 327 12.4 671 12.2
NE 220 7.8 185 7.0 405 7.4
NF 127 4.5 118 4.5 245 4.5
NW 155 5.5 68 2.6 223 4.1
SR 97 3.4 78 3.0 175 3.2
SCR 129 4.5 82 3.1 211 3.9 SE 27 1.0 9 0.3 36 0.7 SEC 16 0.6 22 0.8 38 0.7 SW 92 3.2 103 3.9 195 3.6 WR 82 2.9 89 3.4 171 3.1
WC 210 7.4 210 7.9 420 7.7
KR 47 1.7 30 1.1 77 1.4
IR 2837 100.0 2643 100.0 5480 100.0
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Annexure T -2
ICMS Chg Outage (Shortfall/Excess) (Last 1 month Average)
Railway Cumulative Average
CR 8.30
ER 21.90
ECR -8.07
ECOR 0.90
NR 47.96
NC -4.60
NE 2.95
NF 6.79
NW -5.72
SR 9.92
SC -0.49
SE 5.71
SEC 1.24
SW 11.74
WR -0.34
WC 17.55
Total 115.74
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Annexure‐T3
Diesel Locos VCD Position upto the Month of Dec.' 2011 S. No
Railway Type of locos Total loco holding
Total No. of locos fitted with VCD at the end of the month
Balance to be provided
ALCO Locos 176 174 2
EMD Locos 0 0 0 1 CR
Total 176 174 2
ALCO Locos 270 246 24
EMD Locos 0 0 0 2 ER
Total 270 246 24
ALCO Locos 195 99 96 EMD Locos 0 0 0 3 ECR Total 195 99 96
ALCO Locos 183 183 0 EMD Locos 0 0 0 4 ECoR
Total 183 183 0 ALCO Locos 444 255 189
EMD Locos 58 58 0 5 NR
Total 502 313 189 ALCO Locos 108 100 8 EMD Locos 0 0 0 6 NCR Total 108 100 8 ALCO Locos 193 98 95
EMD Locos 0 0 0 7 NER Total 193 98 95
ALCO Locos 151 147 4 EMD Locos 108 108 0 8 NFR Total 259 255 4 ALCO Locos 123 72 51 EMD Locos 70 70 0 9 NWR Total 193 142 51 ALCO Locos 257 199 58 EMD Locos 4 4 0 10 SR Total 261 203 58
ALCO Locos 401 401 0 EMD Locos 41 41 0 11 SCR
Total 442 442 0 ALCO Locos 254 248 6 EMD Locos 0 0 0 12 SER Total 254 248 6
ALCO Locos 76 76 0 EMD Locos 25 25 0 13 SECR
Total 101 101 0 ALCO Locos 94 71 23
EMD Locos 222 222 0 14 SWR Total 316 293 23
ALCO Locos 207 207 0 EMD Locos 79 79 0 15 WR Total 286 286 0 ALCO Locos 337 297 40
EMD Locos 0 0 0 16 WCR
Total 337 297 40 ALCO Locos 3469 2873 596 IR EMD Locos 607 607 0
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Total 4076 3480 596
Progress of Sanctioned RSP Items Annexure‐T‐4
Distributed Power System (Till Dec' 2011)
Item No. 834/2008‐09,
2010‐11 2011‐12 S. No.
Railways
Alloted Status Alloted Status Status
Remarks
1 CR 0 0 10
2 ER
3 ECR 0 0
4 ECoR 10 0
LOA for 10 nos. issued. P.O. under vetting
5 NR 10 0 Material not recd.
6 NCR 0 0
7 NER 0 0
8 NFR 0 0
9 NWR 20 0 20 Supply is still awaited from DLW.
10 SR 0 0
11 SCR 0 0 20
12 SER 10 0 10 DPS transferred to WR.
13 SECR 0 0 10
14 SWR 20
15 WR 10 2 20 Work in progress
16 WCR 0 0
17 DLW 0 0 160
IR 60 2 260 0
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Annexure T-5 LINE HAUL COST (Source: Summary of end results to be published by Rly Bd)
Goods Diesel
Rly 2009-10 2010-11 Increase %
CR 211.53 232.24 9.79%
ER 138.77 152.44 9.85%
ECR 251.32 224.53 -10.66%
ECOR 162.66 147.47 -9.34%
NR 106.52 130.68 22.68%
NCR 123.31 135.79 10.12%
NER 107.07 133.11 24.32%
NFR 124.39 134.78 8.35%
NWR 82.08 105.12 28.07%
SR 221.71 166.09 -25.09%
SCR 187 165.57 -11.46%
SER 194.02 142.26 -26.68%
SECR 367.61 285.15 -22.43%
SWR 276.82 334.92 20.99%
WR 166.85 203.28 21.83%
WCR 164.03 158.04 -3.65%
IR 158.6 165.37 4.27%
Coaching Diesel
2009-10 2010-11 Increase %
CR 269.84 303.08 12.32%
ER 383.64 366.03 -4.59%
ECR 187.85 213.8 13.81%
ECOR 191.72 278.08 45.04%
NR 169.33 207.03 22.26%
NCR 279.87 289.18 3.33%
NER 210.64 210.78 0.07%
NFR 266.39 299.53 12.44%
NWR 181.62 211.95 16.70%
SR 232.45 174.69 -24.85%
SCR 272.96 304.75 11.65%
SER 252.4 203.69 -19.30%
SECR 321.3 304.67 -5.18%
SWR 327.41 348.04 6.30%
WR 295.04 303.53 2.88%
WCR 227.82 298.56 31.05%
IR 231.41 254.81 10.11%
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Annexure T-6
Rly Repair & Maintenance cost of Diesel
Locos (C-300)
2009-10 2010-2011
% Increase
CR 1179118 1147403 -2.7%
ER 1395335 1455915 4.3%
ECR 785608 724886 -7.7%
ECOR 811203 685612 -15.5%
NR 2490837 2578801 3.5%
NCR 701503 1000927 42.7%
NER 813498 602356 -26.0%
NFR 853152 1030766 20.8%
NWR 803311 812805 1.2%
SR 1324852 1263810 -4.6%
SCR 1807025 1735161 -4.0%
SER 985561 900436 -8.6%
SECR 460811 357512 -22.4%
SWR 1358657 1294762 -4.7%
WR 1083029 1158304 7.0%
WCR 1500944 1457596 -2.9%
IR 18354444 18207052 -0.8%
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Annexure-T-7
RCD Explosive Clearance
Rly Available Awaited Total
CR 11 8 19
ER 2 7 9
ECR 3 9 12
ECOR 10 0 10
NR 10 13 23
NCR 11 0 11
NER 7 1 8
NFR 7 7 14
NWR 2 12 14
SR 15 4 19
SCR 13 8 21
SER 8 4 12
SECR 11 1 12
SWR 10 3 13
WR 25 1 26
WCR 6 1 7
IR 151 79 230
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Diesel SPAD ANALYSIS (Apr'09 - 6 Jan'2012) Annexure T-8
Railway Wise Mode of Rectt. Wise
Railway No. of Cases Departmental RRB
CR 3 37 11
ER 3
ECR 1
ECoR 1 Train Service Wise
NR 12 Service No. of Cases
NCR 2 Coaching 30
NER 6 Freight 17
NFR 4 L/E 1
NWR 2
SR 4 Grading Wise
SCR 4 Grade No. of Cases
SER 2 A' Grade 24
SECR 0 B' Grade 19
SWR 1 C' Grade 5
WR 2
WCR 1
Total 48
Duty Performed Till Accident Rest Availed Before S/On
Time Period No. of Cases Time Period No. of Cases
Up to 4 hrs 14 Up to 6 hrs 1
4-6 hrs 18 6-8 hrs 3
6-8 hrs 6 8-16 hrs 22
> 8 hrs 10 >16 hrs 22
Time of Accident Wise Loco Pilot Age Wise
Time Period No. of Cases Age Group No. of Cases
00-04 hrs 15 30-40 Yrs 5
04-08 hrs 13 40-50 Yrs 16
08-12 hrs 4 50-60 Yrs 27
12-16 hrs 5
16-20 hrs 7
20-24 hrs 4
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Annexure - T-9 Average ineffective position of DMUs November'11-Jan'12
700 HP 1400 HP Overall
Rly Holding as on 30.01.12
Average Ineffective
Holding as on
30.01.12
Average Ineffective
Holding as on 30.01.12
Average Ineffective
SWR 0 0.0 8 26.9 8 26.9
SECR 3 10.3 9 31.6 12 26.3
SR 12 26.9 9 12.0 21 20.5
NR 24 21.5 43 15.7 67 17.8
NCR 0 0.0 5 15.4 5 15.4
SER 0 0.0 8 14.4 8 14.4
WR 12 15.4 6 7.7 18 12.8
ER 7 0.0 18 12.0 25 11.1
SCR 26 2.4 10 33.7 36 9.2
NFR 0 0.0 16 6.7 16 6.7
NER 0 0.0 2 0.0 2 0.0
IR 84 14.0 134 16.1 218 15.3
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Mechanical (Development) SN Agenda Points
Action by
1 Wagon Prototyping Centre: Detailed Estimate sanctioned. Further action is to be taken by SER
SER
2 Centres of Excellence for development & prototyping of various types of Mechatronics systems at RCF/KXH and DMW/Patiala: Detailed estimates are under process in Railway Board
RCF DMW
3 Environment Friendly Toilets: The first lot of 43 IR-DRDO Bio-toilets have completed more than one year in service without any bacteria recharging. ICF- NFR rake in service since October 2011, Five more trains are being turned out by RCF by March 2012. Next year’s target is 2500+ bio-toilets including two rakes of LHB and 100 bio-toilets for retro-fitment in Bhopal Workshop.
RCF ICF NCR NFR NR CR WR NER WCR
4 IT applications in Mechanical Deptt: ERP Material module is live in TKD since 2nd Jan 2012. PM module to go live within next few weeks. Dadri Freight Depot to go live in Feb 2012. ICF-ERP is live since 6th Feb 2012. Coaching Asset Management System is working between BCT-NDLS and Go live for Lucknow is planned in March 2012, WISE Pilot is ON.
NR WR ICF NCR
5 WILD and ABD: Detailed presentation by ED/Research, Report by ED Wagon & Ed Research to be submitted.
RDSO
6 Prototype LHB crashworthy shell has been manufactured and has reached RDSO. Testing to begin in end Feb 2012
RDSO
7 EOTT: Frequency allocation by WPC is expected in Feb 2012. RDSO to conduct testing.
NR, RDSO
8. 9. 10 11
Vision based equipment to be initiated. Oscillation trials of track friendly bogies 32.5/25 T axle load Weighbridges committee to finalise its report Some new development areas are listed below for discussion
NR, RDSO RDSO, WR, WCR, NWR NFR, WR, SR
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S No Description Remarks
1 Heavy Haul Freight Bogies
Features such as low dynamic forces on rails, reduced wheel and rail wear and economical to maintain. Improved availability of wagons for service.
2 Traction and Suspension Development
Distributed Power, REMLOT, Hotel Load etc Superior universal bogie platform for self propelled stock using modular motor configuration including high speed operations Better Predictive maintenance, Combustion & Control of emission and fuel efficiency Improved traction efficiency optimized on a per-passenger basis
3 Green Toilets No discharge on tracks- better with the view point of hygiene and reduced corrosion.
4 Retrofitment of Existing stock for superior interiors
State of art interiors, development of model coaching rakes with enhanced amenities and aesthetics, comparable to best in world for 1000 coaches
5 OMRS – On line monitoring of Rolling Stock:
Safety Implications, Cost of disruption to the traffic and problems faced by the passengers in case of en-route detachment will be reduced, and will help achieving philosophy of zero tolerance for accident.
6 EOTT and other on-board modules
One extra wagon in the same length of train. Detention of rake on account of shunting of brake van avoided.
7 IT for Maintenance of Rolling Stock
Upgrading asset availability and reliability Efficient monitoring and control.
S.No Description Remarks
1 Wagon Prototyping Centres
Fast development of new designs of wagons. The first one is being set up at Kharagpur
2 Centres of excellence in Mechatronics
Prototyping and Capability to handle emerging products effectively. Two being set up in RCF and DMW
3 Green Toilet Centre Prototyping and development of green toilet sub-systems, being set up in Nagpur workshop of SECR
4 Upgrades in Indigenous manufacture
State of Art Foundry facilities for higher axle load bogies
5 Train sets Train sets based on indigenous System Integration aimed at optimized energy consumption on per person basis for super dense crush loads
6 Retrofitment of Existing stock for crashworthiness
Development of appropriate solutions for superior crashworthiness of existing stock, 1000 coaches
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M&P Items PH – 4100, M&P 1. Life Cycle Costing: The concept of Life Cycle Costing for the procurement of High Value /
Sophisticated M&P has been adopted in a limited manner by introducing Mandatory Comprehensive AMC vide Railway Board’s letter no. 98/RS(G)/709/1 Part dtd. 08-09-2011. As discussed in the last meeting, COFMOW to indicate no. of cases / machines where this methodology has been adopted. CMEs of ZRs / PUs to indicate compliance of certification for AMC funds for all such cases in future.
2. Turn-Key Project Execution: All the modernisation projects for setting up a complete line /
shop / shed sanctioned under PH-42 or PH-41 should be executed on Turn-key basis to ensure timely completion and preventing huge cost overrun. ZRs / PUs / COFMOW to work in this direction ensuring that piecemeal tenders are resorted to only in cases of individual machine replacements. Capacity augmentation of production / assembly lines should also be processed as a batch on turn-key basis.
3. Long Term Contracts: The cycle time for procurement / commissioning of piecemeal M&P
must also be reduced substantially. COFMOW is already moving in this direction by way of Price Agreements. Long Term contracts should be explored and progressively adopted by the user Railways as well as COFMOW. In addition COFMOW is finalising a vendor directory for regularly purchased machines which should also help in reducing procurement time.
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Mechanical (Freight) 1.0 Presentation by RDSO
RDSO may make the following presentations:
New designs of wagons New technological developments in wagons
2.0 Equipment Failure 2.1 Hot Axles
The comparative figures for 2008-09, 2009-10, 2010-11 and the current year for Hot axles and Train Partings are as below:
Year (April to March) Hot Axle Train Partings
2008-09 599 793 2009-10 684 778 2010-11 779 717
2011-12 (Up to Dec 2011) 571 453 2010-11 (upto Dec 2010) 548 529
It can be seen that the hot axle cases have been showing a consistently increasing trend. Railways may discuss:
Results of audit of CTRB maintenance facilities in their Railway and action taken thereon
1.2 Train Partings
Train partings continue to occur in substantial numbers. Measures to stem train partings need to be taken.
Railways/RDSO may discuss:
Cases of biased wear of knuckles of imported couplers Pending logged warranty cases of CBCs/components
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Action taken by RDSO in this regard 3.0 Performance of CC rakes
The number of CC, Premium and End-to-end examinations per day Railway-wise during the years 2010-11 and 2009-10 are as follows:
CC Premium End-to-end Railway
2009-10 2010-11 2009-10 2010-11 2009-10 2010-11 CR 0.32 1.5 6.8 6 12 9
ECR 6.48 6.8 9.6 9.6 5.88 7.5 ECoR 3.27 3 3.8 3.5 13.5 11.5
ER 1.16 3.9 8.6 9 13.5 7 NCR 3.19 3.2 1.9 1 3.06 7.1 NER 0 0 2.66 2.1 2.72 0.73 NFR 0.52 0.1 6.67 10.9 4.41 4.2 NR 8.4 8.5 6 4.4 23.5 35.6
NWR 0.35 0.4 0.99 0.8 0.2 0.37 SCR 5.13 5.3 9.52 9.5 6.4 10.1 SER 4.16 4.3 13.45 17.61 16.9 24.9
SECR 4.6 4.8 4.5 6.4 18.5 6.4 SR 2.1 1.8 5.76 6.49 7.79 15.28
SWR 2.35 1.3 2.32 3.29 4.89 5.4 WCR 0.97 1.1 13.2 11.32 8.6 8.42 WR 2.3 2.9 13.5 12.5 2.7 4.9 IR 45.3 48.9 109.27 114.49 144.55 158.4
The above table reveals that over Indian Railways, while the total number of CC and premium examinations have gone up by 7.9% and 4.8% respectively, the end-to-end examinations have also increased by almost 9.6%.
Each time an end-to-end rake is converted into premium rake, 5 examinations per month get reduced to just 2 examinations per month. Assuming an average of 12 hours are lost for each examination from placement to release, this translates into a loss of 1.5 days per rake per month or a loss of 18 days per rake per year. If all end-to-end examinations are replaced with premium, additional 39 rakes can be made available throughout the year through savings in time lost due to detention of rakes for examination.
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Further, it is found during random checks by NCO organization that the incoming CC and premium rakes are sometimes found to have brake power below 85%. This needs to be checked. An average of 771 trains were found running with invalid BPC during 2010-11. This also points towards unsafe running and needs to be controlled.
Railways may discuss:
Strategy to minimise end-to-end examination on the Railways Poor brake power in rakes arriving for PME Trains running on invalid BPC
4.0 World-class Freight Examination Points Railways may discuss:
Status of world-class freight examination points at TKD, MGS and Gooty 5.0 Special drive to eliminate cases of non-working of Hand Brake Wheel
During the drive for checking hand brake working on various Railways, it is being found that around 25% of the wagons are working with jammed/no-working hand-brakes. Railways may discuss:
Reasons for non-working of hand brakes Action being taken by the Railways in this regard
6.0 Maintenance of Private Wagons
The stock of private wagons (wagons owned by other than Indian Railways) is increasing every year. With the introduction of new schemes like PFT, SFTO, AFTO etc., the size of the private wagon fleet is expected to increase at a fast rate. Present policy guidelines lay down that all private wagon maintenance is to be undertaken by the Railways. This situation brings the following aspects into prominence: a. Requirement of developing capacity for maintenance of a larger number of wagons at
locations suitable to the private parties b. Providing a certain acceptable service level to the private players and minimizing
stock detentions c. Maintaining transparency and uniformity while dealing with different private players
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Railways may provide a list of private wagons ownership-wise active on their system and discuss the repercussions of the changing scenario and the preparedness required to deal with the same.
22
Mechanical (PU)
1. Review of Performance of Production Units
Targets of the PUs for the current year vis-à-vis the actual performance of the last year
are as under:-
DLW
Production
2010-11 Target 2011-12
Target Upto Jan. 2012
Production Upto Jan. 2012
ALCO Locos 82 35 31 27
HHP Locos 150 215 176 147
NRC/Export 35 25 20 40
Total 267 275 227 214
CLW
Production
2010-11 Target 2011-12
Target Upto Jan. 2012
Production Upto Jan. 2012
Conventional Locos 160 130 106 140
HHP Locos 70 100 81 59
Total 230 230 187 199
ICF
Production
2010-11 Target 2011-12
Target Upto Jan. 2012
Production Upto Jan. 2012
Conventional 771 743 705
AC EMU 90 360 285
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AC DC EMU 445 120 45
MMTS AP 36 0 0
METRO 16 64 32
DEMU 93 112 61
DEMU / J&K 0 32 24
LHB 0 20 0
SPART 0 9 0
NRC 52 50 34
Total 1503 1510 1210 1186
RCF
Production
2010-11 Target 2011-12
Target Upto Jan. 2012
Production Upto Jan. 2012
LHB 316 426 361 215
Conventional 1063 1046 885 883
Hybrid 140
MEMU 40 112 87 69
NRC 17 16 2
Total 1576 1600 1333 1169
RWF
Production
2010-11 Target 2011-12
Target Upto Jan. 2012
Production Upto Jan. 2012
Wheels 180810 180810 163225 163329
Wheelsets 61281 72000 58615 57501
24
DMW
Production
2010-11 Target 2011-
12 Target Upto
Jan. 2012 Production
Upto Jan. 2012
Loco Rebuilding 109 83 73 79
New Loco 25 18 13
2. Action Plan to achieve the targets and improve production and quality of output.
DLW has manufactured 147 HHP locomotives till Jan. 2012 against the production target of 176 HHP locos for the current year. DLW should plan to make good the shortfalls in HHP loco production.
DLW has turned out the prototype WDP4 locos with twin cabs. More such type locomotives are to be planned.
CLW has manufactured only 59 High Horse Power Locomotives (WAG-9/WAP-5/WAP-7) till Jan. 2012 against the year’s target of 100. CLW should step up production of HHP locomotives.
ICF is marginally behind its target. It should make good its over all short fall and achieve its target of 1510 coaches.
ICF must turn out the LHB chair car rake by March, 2012 as it is to required to run an announced train.
ICF should also increase the rate of production of DMU rakes to meet its target.
Production of RCF has been below target. It has the problem of bunching of LHB coaches in the last quarter. It should plan to ensure physical roll - out of all programmed LHB coaches by the end of March ‘2012.
RCF should plan to meet the target of MEMU production.
While RWF’s recent efforts in supplying wheelsets is commendable, it is marginally short of its target in manufacturing of wheels sets. RWF’s capacity has been augmented to 2,00,000 wheels per annum and hence it should manufacture wheels as per production programme.
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RWF should also expedite its sanctioned work to increase axle production and wheel set assembly.
DMW has commenced ALCO loco production this year. It should achieve its target.
At present, all the six production units are certified under ISO 9001 Quality Assurance System. In view of higher level of dependence on bought out items, it is essential to strengthen the in coming, as well as in-process inspection procedures, so that the overall desired quality levels do not dip.
The capacity enhancement works sanctioned for PUs need to be monitored for timely execution, so that the benefit of the enhanced production capacity can be obtained at the earliest.
There is also need to enhance manpower productivity of all the PUs by continuous review of “ teeth to tail” ratio.
3. Plan for future:
ICF has to rollout DMUs with 3 phase tration and IGBT controls. The production programme of 2012-13 envisages 3 rakes. ICF has to plan a cut off date after which all DMUs will be with 3 phase traction.
ICF also has to develop stainless steel DMUs. These would be of particular help to high rail fall areas of North East where DMUs are being proliferated.
RCF has to plan to fully switch over to production of LHB type of coaches.
DLW should develop its supply chain to manufacture 300 HHP locomotives including substantial number of WDG 5 locomotives.
Early commissioning of RCF / Rae Bareli and RWF / Chhapra and scaling up their production will be of immense significance to IR in next few years.
26
WORKSHOP ITEMS
1. Action taken on the items discussed/decided during earlier meetings:
General Manager’s annual inspection of major workshops on the pattern of open line inspection as advised by CRB- Status?
Annual performance appraisal of officers working in workshop as advised vide Board’s letter 2009/SCC/3/1 dated 2nd February 2009 -Status?
Feedback on 04 items namely curtains, rexines, PVC and laminates to be given to RDSO and RDSO to apprise the action taken on these items –Status?
Progress on assembly of wheel sets by PER(C), JMP, ASR, UBLS, PL and PR and proportionate shortfall in %.
Digitization of corrosion repair diagrams –Status?
Photographic record of refurbished coach both before and after-Status?
Use of manipulators and progressive switch over to CO2 welding for corrosion repair in critical areas-Status?
2. LHB bearing fitment and maintenance of related items: Considering a no. of enroute coach detachments on account of LHB bearing failures,
apart from audit of LHB bearing fitment and maintenance of related items in PL , LLH and JUDW workshops RDSO should circulate a check list on the bearing fitment practices and maintenance of other related items to the Railways immediately. Items pertaining to workshop should be such, that they can be classified as NTXR rejectable items. Similarity for open line the list should be objective enough to enable the line TXR to detain the coach in case of non-compliance of the said items.
3. Maintenance of DEMUs in workshops: Issues have been raised regarding problem of excessive time taken in carrying out POH of DEMU/DPCs as well as the quality of deterioration of POH. Some of the Railways are taking as long as 55 days for POH of DPC which is not acceptable and the time needs to be brought down below 25 days. This has to be carefully planned by adequate planning of material under RSP or otherwise and timely AMCs of engine.
4. Shortfall in manufacture of ICF assembled bogies:
The four Railways ER, NR, SR and SWR have been regularly allotted the RSP work for manufacture of ICF assembled bogies to be supplied to zonal Railways. In some of the
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Railways, there has been a lag of more than one year in completing the allotted work under RSP. ER and NR are lagging in meeting the RSP allotments
Railways to plan for completing all the pending allotments by 2012-13 and distribute as already advised.
5. Quality Issues:
An analysis of the cases of wagons getting sick marked within 90 days of POH in 2011-12 over the IR shows the following major reasons: (i) Door defects (14%) (ii) Roof/Body/Floor defects (6.7%) (iii) Brake Cylinder defects (3.4%) (iv) DV defects (8.2%) and (v) Wheel defects (10.7%). Similarly following major causes have been observed for 100 days sick marking of coaches (i) Water tank/system leakage (15.3%) (ii) Bolster/axle box spring defective (9.4%) (iii) Brake cylinder defective/B.P/F.P (11.1%) (iv) Buffer assembly defective(6.6%) (v) Wheel defects (4.6%) and D.V defects (5.0%).
6. Progress of RSP items:
Refurbishment of Coaches: The overall progress is 72%. CR (64.3%) , NER(8.3%), SER(35%), SR(41%) and WR(42%) are lagging behind their proportionate targets.
Conversion into NMG vans: The progress of CR(32%) and SWR(40%) is less than their proportionate targets and they need to expedite.
Upgraded Rehab of Wagons: The progress of SECR(24%) , NCR (63%) and NWR(60%) is behind their proportionate targets.
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Mechanical (Coaching) Following discussions and presentations pertaining to Coaching items are planned:
Sr. No.
Topic Presentation by
1. Possible scenario for train operations in future - Train sets with diesel locos, running trains at 130 kmph and higher speeds-issues, requirements etc.
Design and development of crashworthy design coaches- existing design and future developments be discussed, international norms of crashworthy design.
Development of CBC with balanced draft gears and other measures for jerk reduction in CBC coaches.
ED/Carr/ RDSO
2. Developments of new coach variants in LHB coaches in recent past and future projects - Salient features.
Future expansion plan for LHB production
Salient features of New Design LHB AC double Decker coaches
CME/RCF
3. Policy review to improve coach housekeeping on IR – Measures to improve effectiveness of existing schemes.
Challenges in managing the outsourcing – Back-up plan in case of contract failure.
Process and resource requirement.
Need for automation and infrastructure improvement.
CME/NFR
4. Infrastructure planning for LHB coach maintenance in workshop and open line- what planning needs to be done in new railways receiving LHB coaches, how the maintenance is different from conventional coaches, major problems in maintenance and operational issues.
CME/NR
5. Mechanized laundry on BOOT scheme – scope and project execution
Pest and Rodent
CME/SR
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Control –Future strategy.
