The main features Industry 4.0  are  Machine Data  collection( Machine status can be accessed through Mobile etc.) , Production optimization( Machine-based job scheduling) , Downtime management (Track reasons for machine downtime, Predictive maintenance ),  Digital Manufacturing (ERP and MES integrations)

Modern Coach Factory (MCF) has rolled out its first LHB DSLR Coach on 11.01.2019.

The coach has following features :

•Under slung  500 KVA Diesel Generator Set releasing space on board accommodating passengers and luggage.

•The coach has also a luggage area with 4-ton capacity.

•The coach has seating arrangement of 6 differently abled with a specially design lavatory keeping in mind the special requirement of these persons.

•Besides this, the coach will accommodate 30 general passengers in a separate area with a dedicated lavatory.

•Further common under-frame has been designed which is compatible with both Crompton & Greaves, Cummins and Kirloskar. Series production has been started

MCF has rolled out  its first AC Hot Buffet Car Coach (LWCBAC) on 29.01.2019 with following features:

1. This coach is having upgraded austenitic stell counter.

2. Deep freezer, Refrigerator , Water cooler, Hot Water boiler,Veg & Non-Veg hot case, Water purifier and smokeless multipoint hot cooking range.

3. It is also having 15  berths for crew/staff of pantry car.

This car is equipped with fire detction and supression system.

First ever Hot Box detector designed to monitor axle and wheel temperature of moving train without manual intervention on IR has been installed and commissioned on 22.03.2017 at MGS-ALD section up line at CAR station (KM no. 705/23-25) of ALD division.

Performance:-

• ​From 01.03.17 to Mar'19, it has detected 28 hot axel cases and 224 brake binding cases at CAR-ALD (Up line). In all these cases train got controlled at appropriate station and section block avoided.                                                  

The Cartridge Taper Roller Bearing Section is the one of the momentous part of the Wagon Overhauling. The section was set up in 2010 for the overhauling of Cartridge Taper Roller Bearings with an initial capacity of 80 CTRB per month. Over the period of time the section has witnessed many technological challenges and has grown up significantly up to 700 CTRB per month by 2018. It was only the beginning of this progressive journey and there were still many challenges to touch the new heights.

CTRB is one of the crucial part of rolling stock that plays a vital role for its smooth, convenient and safe running. Bearing works as an anti frictional element and reduces frictional losses, heat produced and improves service life of Rolling Stock. Proper up – keeping and maintenance of bearings is necessary to ensure reliability and availability of rolling stock. The failure of bearings has a great impact on the reliability of the freight &coaching stock. Considering this importance, North Western Railway has assigned an important responsibility to Bikaner Workshop for developing the CTRB Section as “center for excellence”. 

With the new phase of revamping, the CTRB Section has been constructed centrally and well connected with other sections such that inward and outward flow of material is smooth without any bottlenecks. It is well equipped, air conditioned, checkered iron plate floor, dust proof section thus providing a healthy working environment for staff and material. The section consists of two sub-sections, A dismounting & cleaning Section and inspection & overhauling section. The inspection and overhauling section is designed on product flow basis where all the parts of CTRB are assembled in a uniform pattern. This optimises the overall process & avoids cumbersome nature of work and also helps in better monitoring.

The overhauling activities of CTRB Section are carried out by the well qualified and experienced team of technicians under the supervision of SSE in-charge and overall guidance of AWM and CWM of Bikaner Workshop.

Activities for Center of Excellence:

• layout of roller bearing shop
• dismantling, cleaning, inspection & maintenance of roller bearing assembly
• proper stackingof roller bearing & components.
• Regular calibration of Torque Wrench and display of gauges for training purpose
• Work & Safety instructionsdisplay boards.
• Proper record keeping & traceability.

Fabrication of Trolleys for Roller Bearing and Axle Box:

Jodhpur Workshop has In-house developed trolleys for carrying and safe transportation of Roller Bearings and Axle boxes.

Laying of additional line in Roller bearing shop:- material management - Designated bins for proper housekeeping.

An additional line has been layed in roller bearing section with two turn tables to improve movement of wheels.

Till now, movement of wheels between Roller bearing & Wheel shop were being done through same line and now with this additional line, smooth & faster movement of wheel has been made possible.

Virtual welding machine is used to provide basic training of welding as simulation i.e. without actually welding the parts. By this we can learn how to hold the welding torch, how to maintain the speed of welding and keep the angle of welding torch in a proper way so that the welding joint is proper. After the welding is over, we can also check the faults made by us, so that we can correct our position of welding. In this process actually no welding is preformed i.e. no material is wasted. Moreover this method of Welding is Environment friendly.

LHB Maintenance Activities carried out at Coaching Depot, Agartala

      Besides all maintenance activities that are being carried out routinely at Pitline and Sickline as per maintenance manuals suggested in CAMTECH Manuals, RDSO Manuals and pamphlets etc. there are other maintenance habits that the staffs and supervisors of Coaching Depot, Agartala follows which they consider is of utmost importance for smooth maintenance and running of LHB coaches. Some incidental examples are cited as to why and how these maintenance habits are followed.

“LHB Coaches needs less maintenance”

     This above line as we were told during times of training needs better description as we in Coaching Depot, Agartala have practically experienced that the more the precautionary maintenance routine are performed, the lesser the heavier maintenance routine can be avoided. Some incidental example stated here to support the claims i.e. if we maintain healthy WSP system, the lesser is the case of wheel skidding and wheel shelling. And hence the above statement may be understood as, “In LHB Coaches, Better the precautionary maintenance habits, lesser the heavier maintenance required.” The staffs and supervisors of this depot have a better understanding of why things are done as mentioned in CAMTECH and RDSO Manuals and other maintenance routine performed besides the ones mentioned in those manuals.

The Need for Keeping the WSP System healthy

• The healthier the WSP system in an LHB Coach the lesser is the probability of wheel skidding and wheel shelling.
• The staffs in Coaching Depot, Agartala routinely maintain healthy maintenance practice of WSP system during Pitline maintenance of LHB Rakes and also at Sickline. This practice is done routinely as we have observed that a failure or malfunctioning in WSP system can often lead to wheel skidding and in turn wheel shelling.
• Every failure code is attended to and checked in hardware part as well as the processing system. WSP code “99” and “95” is a motto in itself in this depot, even code 95 is attended to check what the fault was and precautionary maintenance habits are performed.

Hardware performance effects WSP performance

• WSP system healthy when both processor and hardware system perform in tandem.
• Besides keeping the WSP system healthy, hardware parts are kept in check routinely. Hardware parts include Brake Caliper Assembly, Brake Cylinder, and pneumatic systems etc.
• Coaching Depot, Agartala practices lubricating of Brake Caliper Assembly fortnightly, cleaning of breather plugs monthly, keeping pneumatic system healthy etc. so that performance of hardware components does not affect WSP performance.

Need for escorting staffs to be alert

• Escorting staffs of Agartala are advised to be alert for incidents and also to keep monitoring the sound of wheel if any and WSP system enroute and onboard so as to detect early failure of Airbrake and WSP system if any.
• They report to base supervisors when failure detected and are advised for further action enroute so that the failure does not affect the coach further.
• Incidental examples: Cases of detention due to C&W faults on Agartala based LHB rakes are less heard of due to alertness of escorting staffs.
• In one case in the year 2018, escorting staff of AGTL-BNC Humsafar, about one hour after departure from BNC, the guard reported smoke fuming from one of the coaches and train was stopped and C&W escorting staffs were called and due to alertness and activeness of the escorting staffs, the brake binding was resolved in 7 minutes and just a total of 14 minutes was detained.
• In another case in AGTL-ANVT Rajdhani Express on 27/03/2019 at around 0300 hrs, escorting staff reported of damaged axle box in one of the coaches, escorting staff previously reported base supervisors of likely failure of WSP system with failure code 72 & 95 & 72 and hence advice the staffs to closely monitor the said coach. The coach was detached at secondary maintenance depot in ANVT for safety concerns but avoided enroute detachment and hence avoided detention due to alertness of escorting staff. Later it was learnt that the problem arise due to phonic cogwheel not being tightened with required torque at the time of SS-1 of the trolley.

Lessons learned from earlier incidents

• Above incidents taught us to keep escorting staffs alert and also to improve maintenance practice further to always check hardware failures once WSP system indicates a failure code even if system rectifies on its own.
• Routine check of tightening torque of SS-1 coaches during inspection at Sickline

Learning what’s being learnt and new experience from experienced OEM staffs

• Experienced staffs from OEM such as Knorr-Bremse regularly invited by respected CDO, Agartala.
• Staffs share experience to OEM staffs for better understanding and troubleshooting of various parts on regular intervals and for refreshing knowledge of why and how things are done.

Active visual examination of parts of trolley

• Vital parts of trolley such as primary suspension springs, secondary suspension springs, dampers, clearances etc. are vigilantly examined at the time of Pitline and Sickline maintenance.
• Understanding how to detect, for instance regular leakage in damper may be due to reduced tension of spring or broken spring; also the same can be detected by checking safety lug clearance etc.
• Bogie body connections are checked vigilantly and also corrosions are checked vigilantly to avoid mishaps.
• Besides bogie parts other vital parts such as couplers are monitored regularly at the time of pit examination as well as at Sickline.

Brief Description  :   Overhauling of all the Air Brake Components of ICF type coaches are done in-house.   But, for LHB Coaches, Carriage & Wagon Workshops, Perambur was depending on OEM M/s.Knorr Bremse & M/s.Faively.  To overcome the dependence, Shops has developed Test Benches for DV, Dump valve, Air strainer & Cut Out Cock of LHB coaches.  These test benches are extremely useful in ensuring the reliability of Overhauled DV, Dump valve, Air strainer & Cut Out Cock of LHB coaches.