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RB vide No. RB No. 2017/M(W)/814/14 dated 04.01.2017 has advised creation of centre for excellence in Rolling Stock Maintenance in workshops alongwith identified work centres. Bogie shop was nominated to develop centre of excellence for Wagon Repair Workshop. Following actions were identified. After full compliance of the same, the Bogie shop was declared as Centre of Excellence for Wagon Repair Workshop Raipur in Nov’17.

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Items.

1.

Availability of all equipments and gadget.

• Three sets of gauges for Casnub bogie is available with SSE/Bogie.
• All sets are calibrated.
• All the gauges are kept systematically and in ready to use condition.
• Regular use of all gauges ensured.

2.

Material handling equipment.

• At present 4 nos. each of  Red, Green, yellow & blue colours Material Bins kept in the shop floor. 2 more of each colour to be placed.
• Material handling trolley – 6 nos. available. 4 more to be fabricated.

3.

Proper Flooring

• Heavy duty hardonite flooring available in good condition.

4.

Stacking of Material

• Stacking of all new and serviceable material is done on weekly basis.
• Unserviceable and scrap material cleared on day to day basis.
• For small items, plastic crates procured and used for stacking.

5.

Separation of clean and dirty area

• Incoming cleaning of bogie done outside the shop.
• Grit blasting of bogie frame is carried out in isolated location.
• Regular sweeping of the floor is carried out on daily basis.
• Gang way marking done in the floor.
• BVZI – Secondary container to be  kept on shop floor to arrest oil leakage in the floor.

6.

Different Colour Scheme

• Gang way marking done on the entire shop floor.
• Different colour bins used for Serviceable, Unserviceable, rubber item and garbage.
• Pillars are painted in silver colour.

7.

Display of Instructions

• Work instructions, Objectives and targets, important parameters  are displayed prominently and uniformly..
• Three nos flex board to be made containing “ Bogie Shop, Centre of excellence” in Hindi & English for information to all.

8.

Maintenance of side walls

• Cobweb cleaning to be done on regular interval.
• Painting of structures shall be done twice a year

9.

Training of staff.

• No supervisor overdue refresher training.

• Complete digital measurement  in Freight CTRB Overhauling Section
• Inspection using digital gauges & online transfer of data rom work centers to PC
• Display of video tutorial on LED TV Screen

Sections certified 5S in 2017-18::

1. Bogie Mounted Brake Cylinder Section
2. Freight CTRB Overhauling Section
3. Calibration Section of Tool Room

Sections certified 5S in 2018-19:

1. LHB Bogie POH & IOH Section
2. ICF Bogie Overhauling Section
3. CASNUB Bogie Overhauling Section
4. CBC Draft Gear Overhauling Section
5. LHB CTRB Section
6. DV Overhauling Section
7. Spring Shop

Highlights of Centre of Excellence

• 5S certified sections
• Epoxy industrial flooring
• E – Learning Booths at Shop Floor
• Work procedure video on LED display screen
• Display of Must Change and Conditional replacement items
• Streamlined material sub store
• Energy efficient illumination of work area
• Work Instruction display boards
• Ergonomic working environment
• Automation to the extent possible
• Staff Rest Arena inside shop

Equipment A:- Multipurpose portable consisting of both Tapered wheels and tyre fixed on one mobile trolley which enabled to trolley operational both on mono rail as well as on flat surface using tyre. This multi utility trolley is extremely efficient while transporting heavy equipments on to accident site. This trolley consists of two numbers of MS solid tapered wheels and two rubber tyre, which can run on mono rail and road respectively. By providing this functionality trolley can be operated both on rail and road. It is a portable trolley which can be operated by single staff for transship of small items or two hydraulic jacks at a time to work spot quickly. Pushing handles are removable and can be fixed from both ends. Road wheels also removable whenever the ballast height is more by the side of rail. Flexible support brackets are fixed at both end of the trolley. 

Equipment B:-Two telescopic lifting jacks and one displacement jack are connected to one control panel from which Re-railment operations can be carried out. This system is very easy to Re-rail the coach by using 4.4 meters Re-railing bridge even at the points and crossings. Spacer is made of two telescopic tubes is used to connect two Roller Carriages is take over the direct power transmission and routing. For re-railing the coach, single telescopic hydraulic jack is using below the head stock centre in conventional method. At present condition most of the coaches are fitted with Bio-Toilets. Due to this, place is very less in between two bio-toilets to keep the jack under head stock. In order to overcome this difficulty two telescopic lifting jacks are placed under second lifting pads of the coach (inside the trolley) over the Roller carriages which are connected by spacer. Coach will be lifted with two telescopic jacks simultaneously above the rail level, after those two jacks will be moved laterally as a single unit with the help of displacement jack (traverse jack) from one end to re-rail the coach.

The Welding team of Mysore Workshop is continuously focusing on the following areas related to Welding.

i) Welder ii) Equipment iii) Joints iv) Consumable v) Process vi) Inspection

i) Welder

a) Welder Qualification through continuous assessment and competency certification.

b) Imparting practical training to all the welders using ready reference drawings and Welding handbook.

ii) Equipment

a) Usage of advanced MIG/MAG synergic welding plants duly replacing the existing MMAW plants.

b) Preparation of validation certificate for all the welding plants after inspection.

c) Usage of better quality electrode holder, gloves and Auto darkening helmets.

iii) Joints

a) By imaprting continuous training to the welders, good fit ups are being done and poor fit ups are being properly assessed and rectified.

iv) Consumable

a) On proper selection of electrode, preheating according to the manufacturer's recommendation is essential for optimum results. In order to achieve this, a mother oven is being used and electrodes are being kept in quivers for maintaining the required temperature.

b) Ensuring proper storage of comsumable items duly protecting from the environmental factors.

v) Process

a) Preparation and maintenance of test records and process records after the welding process.

b) Welding based on Welding Specification Procedure in order to ensure an optimum result. 

vi) Inspection

a) All the Inspection personnel involved in Welding operations are being sent to various training institutes for continuous improvement.

b) Almost all the Inspection personnel have completed their certification course on Visual Inspection and DPT testing which resulted in drastic improvement during inspection.

 CNC turning lathe (trainer model) is used to provide basic training of programming on various turning operations through simulation.