It is said that behind every successful man, there
is a woman. Similarly, behind every developing nation which has its
vision set on the horizon of achievement, there is a railway system.
The railway system, as it
is popularly seen is mostly a criss cross network of railway lines on
which thunder the rushing railway trains. What lies beneath this
picture perfect is a lot of nut and bolt activity which is not known
to passengers.
Here are the production
units of Indian Railways, where a varied construction activity,
spread out in phases, elaborate and tied to the minutest detail,
makes the railway system what it is. Whether it be the manufacture of
electric or diesel engines, or whether it be coaches, even wheels and
spare parts the emphasis is on quality and constant improvement.
Chittaranjan
Locomotive works (CLW): post-independent India had to provide
attractive effort to haul its trains. The economy of the nation
hinged upon the railway system. One part of the country grew surplus
foodgrains, the other regions wanted it. One part of the nation had
access to ports from where crude oil came, the refineries were
situated far. Who would be the work horse of the nation. CLW provided
the answer. The production of steam locomotives began on January 26,
1950. for a long time, the characteristic chuk-chuk of steam engines
reverberated through villages and cities. But India was growing at a
pace to which steam engine power was not sufficient. Out rolled the
diesel engines in 1968. This factory, located at Chittaranjan, West
Bengal, has produced 2351 steam locomotives upto 1974, and 842 diesel
locomotives upto 1974, and 842 diesel locomotive upto 1994. The
production of electric traction in the country placed new demands for
electric engines. Chittaranjan commenced production of electric
locomotive in 1961. 2354 engines have already been presented into the
natios service-both passenger and freight locomotive. The
latest in the line are WAG7 and WAP5 types.
The WAP4 passenger
locomotive which is already running in major services is of 5000 HP
and designed to haul 26 coaches at a maximum speed of 140 kmph. The
air brake systems are more safety orient and to improve the riding
comfort, the suspension is of primary wheel springs with booasters.
More importantly, the sub-systems of this locomotive-body shell,
bogies, traction motors and control equipment are being produced
in-house.
Diesel Locomotive
Works:
Varanasi, the font of
Hindu spirituality, holds a peculiar charm for a tourist. The sublime
spirituality which is underneath each wave of the holy river Ganges,
the rituals conducted by the popular ghats, the sincere belief
that is a pyre is lit an Manikaran ghat the dead attain heaven, all
make a Varanasi a picture of Indias paradoxical holiness.
Unknown to many, here exist a temple of modern technology, producing
diesel locomotive for Indian Railways. The first engine was launched
in 1964 by Lal Bahadur Shastri.
From a 2% share of
components then, the locomotive is nearly indigenous. The DLW
manufactures about 150 engines per year, i.e. one locomotive every
alternate day. To understand a diesel engine is not difficult it is
actually a powerful engine driving a generator which produces
electricity. The electricity is utilized to drive motors, which in
turn run the loco. The train is so moved. The versatility of the
diesel engines is unquestioned-for freight movement or for passenger
movement, on Broad-gauge or the remaining Metre and Narrow gauge-it
is there everywhere to haul your burdens or you in person.
The magnitude of this
silent operation can be imagined from the fact that the complete
engine, underframe, superstructure, fabricated bogies, and more than
2,000 components are produced under one roof by 7,700 employees.
Probably because of quality in production, the Varanasi locomotive
are running in countries like Bangaledesh, Sri Lanka, Malaysia,
Tanzania and Vietnam. A recent transfer of technology agreement with
M/s. General Motors, USA for 4000 HP microprocessor controlled diesel
locomotives, makes DKW unique. No wonder the unit has achieved the
coveted ISO 9002 certification in February 1997 for the complete
range of manufacturing activities.
Integral Coach
Factory: The first five year plan had provisions for establishing
the Integral Coach Factory, at Perambur, Madras. In 1955, on Gandhi
Jayanti, October 2nd, Jawahar Lal Nehru inaugurated the
production. The whole concept of coaches on the railway underwent a
change with the coming up of this factory. Most of the earlier
coaches were imported and were a wood body could collapse like a
matchbox. The integrated design meant that the steel frame of the
coach would be shock absorbent. Only the end would crumble with an
impact absorbing the force and leaving the rest of the coach intact.
It ensured safer travel for many passengers. The factory has so far
produced more than 29,000 coaches in about 170 designs. The factory
has a tremendous capacity of manufacturing 1000 coaches per annum,
ranging from air-conditioned, self-propelled, special type and
ordinary sleeper coaches.
The air-conditioned
coaches require specialized skills and effort. So do the
self-propelled coaches for suburban services in metropolitan cities,
the diesel multiple units, Metro coaches, and Electrical multiple
units. The double decker special coaches with seats in two levels
and the tourist palace type coaches for luxury trains, also roll out
from this unit. The kitchen or pantry cars, then the Obscillograph
cars used in track maintenance are all given shape here. This unit
was the first to get ISO 9001 certification for the entire factory
upto September 1999. ICF, has been successful in establish an Indian
presence in 11 Afro-Asian countries by export of coaches.
Rail Coach Factory:
The existing infrastructure was not enough for the growing
expectations of public an demands of Indian Railways so another coach
manufacturing factory was set up in 1988 at Karpurthala, Punjab. A
workforce of 7,000 turns out over 1,000 coaches per annum. The core
competence of this unit lies in the manufacture of air-conditioned
and non-AC passenger coaches. About 15 types of coaches have been
manufactured by RCF so far. Evolving a totally new shell and bogie
design was its prime objective. The first ever AC3 tier coach was
built here, which has brought a lot of comfort to traveling
passengers. The most appreciable fact about RCF is that designing is
done in an advanced Computer Aided Design center. With this, the
plant acquires the capability to design coaches with retention
toilets, automatic sliding doors, disc brakes, and other equipment.
The manufacturing
facilities of this ultra-modern plant include sheet Treatment Plant,
CNC Shearing Centre, Cut-to-length line, Cold Roll, Forming Machine,
CNC Laser Profile Cutting Machine, CNC Underwater PLASMA cutting
machine, CNC Press brakes, Synergic Pulse and Programmable Automated
Welding, tunnel type painting etc. the latest feather in the cap of
this ISO 9001 factory is the IRY/IR20 coach. The coach provides
comfortable riding and has been tested upto 180 kmph in an empty
condition. Apart from the look, the axle-mounted disc brakes ensure
safer travel.
Diesel Component
Works: The DCW at Patiala is a unit of the Railways producing
spare parts. One spare part alone may not sound as important, but
spare parts indeed keep the machine rolling. The plant is based on
sophisticated machine tools technology, incorporating CNC, NC &
Logic Control Systems.
The Diesel and Electric
loco requirements are met here and the products include complete
range of components, re-manufacture of Diesel Electric Locomotives,
power packs re-building of engine blocks, cylinder linear,
re-manufacture of traction motors, traction generators, carbon
brushes for traction machines etc. these spare parts produced under
ISO 9002 conditions keep the huge railway system running.
Wheel and Axle Plant:
Do what you will, nothing can move unless wheels are placed to a
frame. So the Wheel & Axle plant, conceived in 1978, was built
with World Bank assistance. Smt. Indira Gandhi inaugurated the plant
at Yelahanka, Bangalore on September, 15th 1984.
The plant follows a
unique process of cast steel wheel manufacture through controlled
pressure pouring. A ladle of molten steel placed in a pouring tank is
sealed with an air tight cover. A ceramic tube is at the centre. Into
this sealed pouring tank air is forced, which pushes the molten steel
up through the tube into a graphite mould positioned above the
pouring tube. Molten steel fills up the mould and lo, the railway
wheel is cast! 2,000 staff work here to produce 4 wheels an 15 axle
types. The factory has a capacity to produce 90,000 wheels and 48,000
axles per year. The turnover of this ISO 9002 plant is approximately
Rs.2,300 million per annum. It uses advanced software to encompass
the complete range of activities. To say that Yelahanka provides the
wheels of progress to a determined nation would not be an
exaggeration.
The railway factories are
indeed silent pillars to an edifice that stands unique in the world
today.
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