ICFICF
WELCOMEWELCOMESS
YOUYOU
AN OVERVIEW AN OVERVIEW
OFOF INTEGRAL COACH FACTORYINTEGRAL COACH FACTORY
Factory Area 767100 sq. m (189.5 acres)
Covered Area in Shops
190000 sq. m (47 acres)
Township area
1155440 sq. m(285.5 acres)
Employees 13,000 approx.
Self contained township of 3000 residential quarters with schools and hospital.
Shell Administration
…ICF - Through the years Factory statistics
Furnishing Division
Vital Statistics
Coaches manufactured 43131 as on 31/03/2011
Number of designs evolved more than so far 250
Annual turnover in 2010-11 Rs. 2700 Cr
ICF – Production growthICF – Production growthYearYear TargetTarget OutturnOutturn CapacityCapacity
2005-062005-06 10931093 11751175 10001000
2006-072006-07 12411241 12511251 10001000
2007-082007-08 12901290 12911291 10001000
2008-092008-09 13351335 13371337 12501250
2009-102009-10 14331433 14331433 12501250
2010-112010-11 15001500 15031503 1250#1250#
# Augmentation for 1500 underway# Augmentation for 1500 underway
ICF – Production growthICF – Production growth
0
200
400
600
800
1000
1200
1400
1600
2005-06 2006-07 2007-08 2008-09 2009-10 2010-11
Target
Out-turn
ICF – Production growthICF – Production growth
02004006008001000120014001600
Target
Outturn
PRODUCTION OVER THE YEARS
‘89-’90
‘99-’00
‘05-’06
‘06-’07
‘07-’08
‘08-’09
’09-’10
‘10-’11
CONVENTIONAL 670 662 860 865 875 701 700 518
AIR CONDITONED
83 99 106 105 149 101 125 175
SPECIAL 26 - 19 50 41 5 47 66
SELF PROPELLED – EMU
146 161 155 170 173 492 494 640
SELF PROPELLED –OTHERS
- 84 35 61 49 38 67 101
TOTAL 925 1006 1175 1251 1291 1337 1433 1500
TURN-OVER (Rs.Crores)
816 953 1157 1568 1889 2700 (B.E)
Green EnergyGreen EnergySite Sanganeri,
Tirunelveli
No. of machines 7
Capacity 7 x 1.5MW=10.5 MW
Energy Generated(2009-10)
23.7 million units
ICF’s Electrical energy requirement (2009-10)
25.5 million units
TNEB adjusted units 21.3 million units
Savings in Energy bill (2009-10)
Rs. 7.9 cr.
Likely annual carbon credits
Rs. 1.5 cr. Approx.
Products - Through the years (1950s)
First Coach (1955-56) 100th Coach (1957)
BG 25 KV AC EMU (1960)
Products - Through the years (1960s)
Non-AC First Class (1961)
GM Saloon (1965)
First Rajdhani (1969) Track Recording Car (1969)
Products - Through the years (1970s)
BG 1500 V DC EMU (1970)
Double Decker (1975)
Products - Through the years (1980s)
Rajdhani Express (1980)
Kolkata Metro (1982)
MG Palace on Wheels (1984)
Shatabdi Express (1989)
Self Propelled Vehicles (Introduced in 1990s)
700 HP DEMU (1993) BG 25 KV AC MEMU (1994)
DETC (1995) DHMU (1996)
Special type coaches (1990s)
AC Sleeper with Bio Toilet (1995) BG Palace on Wheels
(1996)
ARMV (1999) Stainless Steel Coach (1999)
Turn of Millennium (2000s)
1400 HP DEMU (2000) AC DC EMU (2001)
Jan Shatabdi (2002) Hyderabad Metro (2003)
Latest Products (2000s)
Deccan Odyssey (2003) Aerodynamic HHP DEMU (2004)
SPURT Car (2005) JDCC (2005)
Latest Products (2000s)
Garib Rath AC Chair Car (2006)
Lifeline Express (2007)MRVC (2007)
DMU for Jammu & Kashmir (2006)
Latest Products (2000s)
Integrated Communication Coach (2009)
SPDHART (2009)
Palace on Wheels for RTDC (2008)
Golden Chariot for KSTDC (2008)
Variants of Luxury Trains manufactured by ICF
DECCAN ODYSSEY (MTDC)
Maharajas Express for IRCTC
GOLDEN CHARIOT (KSTDC)Royal Rajasthan on Wheels
Interiors of the Luxury trains
Taking the pride of place this year - Air conditioned rakes for the Kolkata Metro
Exports - Through the years
Tanzania (1969)Taiwan (1971)
Zambia (1973) Philippines (1976)
Exports - Through the years
Tanzania (1977) Uganda (1978)
Nigeria (1982) Bangladesh (1984)
Exports - Through the years
Muzambique (1985) Vietnam (1996)
Tanzania (1997) Malaysia (2004)
Exports - Through the years
Angola –SDC (2007) Angola –DPC (2007)
Quality Assurance
ISO 9001 certified(2000 version)
ISO 14001 CertifiedBS OHSAS 18001 (2007 Version)
Manufacturing Facilities
Highly systemized manufacturing environment
Entire range of activities – Planning to Despatch
Manufacturing Facilities
Optimized resource utilization Highly skilled work force More than 42000 coaches
manufactured since inception
Manufacturing Facilities
Cut to length lineState of the art facilities:
Plasma punch pressCNC Shearing Centre Pulse MIG weldingCNC profile bendingCNC Press
Manufacturing Facilities
Plasma Cutting Machine
Laser Welding & Cutting Machine
Manufacturing Facilities
Robotic Welding System
Trumpf Laser Cutting Machine
Manufacturing Facilities
LVD Laser Cutting Machine
CNC Turning Centre
Manufacturing Facilities
Resistance Butt Seam Welding
CNC program for draw gear machining in machine shop
Manufacturing Facilities
Special Purpose Jigs and Fixtures
• Roof jig
Manufacturing Facilities
Body shell assembly jig
Manufacturing Facilities
Lifting of Body shell assembly
Grit Blasting
Manufacturing Facilities
Paint Booth Bogie manufacturing
Manufacturing Facilities
Induction heating of Roller Bearings
Electro Discharge Machine
in Tool Room
Manufacturing Facilities
Jig Boring Machine in Tool Room
Planing Machine in Tool Room
Testing Facility
Static Bogie testing
Radiographic testing
Ultrasonic testing
Coordinate measuring system
Load testing
Spectrography
Full fledged LAB facilities exist at ICF
for material testing and NDT
Testing facility
Formation testing electrified track 750 V DC/1500 V DC/25 kV AC
substation
Basic unit testing Commissioning shed
THANK YOU