Title - CARRIAGE REPAIR WORKSHOP PRESS BRIEF BY CWM

26-06-2013
Bhubaneswar
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CARRIAGE REPAIR WORKSHOP PRESS BRIEF BY CWM
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The Carriage Repair Workshop (CRW) at Mancheswar of East Coast Railway, o­ne of the most modern coach repairing workshop of Indian Railways has achieved new milestone of productivity by overhauling Linke Holfmann Busch (LHB) coaches, which is the first of its kind in the history of Mancheswar Carriage Repair Workshop.
Shri S. K. Pankaj, Chief Workshop Manager in a Press Brief said that, earlier, these coaches were being repaired in West Bengal, Haryana and in Uttar Pradesh etc. Complete overhauling of bogies, air brake system and roof mounted Air-conditioning system including Poly Urethane (PU) paintings, interior and renewal of berths of LHB coaches has been repaired and sent for passenger carrying. In a few months time, the entire Rajdhani/Duronto rakes will now be repaired at Mancheswar and need not be sent to far-off workshops. This will help in better availability of coaches and problems can be better monitored.
PRESS BRIEFS:
CARRIAGE REPAIR WORKSHOP, MANCHESWAR

INTRODUCTION:

Carriage Repair Workshop, Mancheswar (CRW/MCS), a young and dynamic establishment under East Coast Railway, discharges the key responsibility of periodic overhauling of all Mail/Express/Passenger & departmental coaches of East Coast Railway. Establishment of the workshop has helped East Coast Railway to achieve self-sufficiency in maintenance of passenger carrying and other coaching vehicles.

Construction of CRW/MCS was sanctioned by Railway Board in Works Programme 1977-78. Prof. Madhu Dandavate, the then Hon’ble Minister of Railways, laid the foundation stone o­n 26.05.1978. The Workshop was commissioned with the beginning of corrosion repairs o­n 12.11.81, in presence of Shri K. N. Pandey, the then Hon’ble Minister of Railways.
The first off POH coach was turned out from the shop o­n 31.12.1983 in presence of Shri C. K. Jaffer Sharief, the then Hon’ble Minister of State for Railways. Mancheswar workshop will be celebrating 30 years of its operation in December 2013.
       
          Railway Board has sanctioned major work vide Pink Book item No. 328 of 2008-09 at a cost of Rs.25.00 Crores to take the installed capacity of the workshop to 150 coaches per month. Construction work is under progress and is expected to be completed by March 2013.
IMPORTANT MILESTONES:

26.05.1978
Foundation Stone laid by Prof. Madhu Dandavate, the then Hon’ble Minister of Railways.
12.11.1981
The workshop was commissioned with the beginning of Corrosion repair by Shri K. N. Pandey, the then Hon’ble Minister of Railways.
31.12.1983
First Off-POH Coach was turned out by Shri C. K. Jaffer Sharief, the then Hon’ble Minister of State for Railways.
01.09.2003
Group Incentive Scheme was introduced in the workshop.
31.03.2004
MCSW reached the milestone of 100 coach outturn in a month.
31.03.2005
The workshop reaches the milestone of 1000 coach outturn in a year by turning out 1092 coaches in 2004-05.
01.11.2009
Switch over to 18 month periodicity POH & IOH of Bogies.
01.02.2012
POH of BBS Duronto Coaches of Hybrid design
30.04.2013
Highest ever outturn of 134 Coaches (111 POH & 23 IOH)
29.05.2013
First LHB coach turned out from MCSW


INFRASTRUCTURE:

vLand:
§Total area                                  =      314 Acres
§Workshop area                                    =      121 Acres
§Colony/Service Buildings                =      193 Acres
§Covered area in the workshop                =      38,550 Sq. Mts.
vPermanent way inside the workshop:            =      14 Kms.
vPower Supply:
§Receiving voltage                        =      33 KV.
§Connected Load                          =      7500 KW.
§Contract Demand                        =      1059 KVA.
§Standby Diesel Generator Set.                =      500 KVA.
vElectronic gate attendance system: Mancheswar workshop is among first few workshops to have electronic gate attendance system. This has made the task of recording attendance of staff reliable and efficient. Staff employed for manual recording of attendance was released for carrying out productive work.

vWater Supply: The workshop has 3 ground water pumping stations to supply water to workshop and colony.

vCRW/MCS has a self-contained residential colony with 708 quarters. Mancheswar colony also has Kendriya Vidyalaya, Oriya Medium Primary, Upper Primary and High Schools, Railway Institute and Officers’ Club to cater to the educational and entertainment requirement.

vThe Scouts & Guides and the East Coast Railway Sports Association have active units        at Mancheswar.

vECoRWWO/MCS runs nursery school (Shishu Niketan), dance school and      school of fine arts in addition to a number of other activities.

ACTIV ACTIVITIES

§POH of ICF Coaches , Hybrid Coaches & LHB Coaches.
§AC Coaches (Roof Mounted).
§Corrosion Repair & Refurbishment.
§Supply of Bogies for IOH to Divisions.
§IOH of Coaches of Bhubaneswar Depot
§Special Repair to Coaches.
§Supply of Wheel sets to Divisions.
§RSP works.
GROUP INCENTIVE SCHEME:GROUP INCENTIVE SCHEME:

§To improve productivity through staff motivation, The GIS scheme introduced o­n 01.09.2003, was adopted o­n the basis of the GIS scheme in Carriage Repair Shop, Tirupati.

§Mancheswar workshop, which was turning out 60 coaches per month before introduction of GIS, has turned out 111 coaches in April’13.

RECENT ACHIEVEMENTS:

§Highest level of Productionrecorded in April, May 2013. In April’13 workshop outturn was 134(111POH & 23 IOH),In May’13 outturn was 126(106 POH &20 IOH)

§Highest productivity level of 70% incentive recorded in April & May 2013.

§Coach POH increased by 40% in April and 33% in May compared to last year average

§AC coach POH increased by 28% in April & May compared to last year average.

§Corrosion Repair of Coachesincreased by over 60% in April & May compared to last year average.

§IOH of Bogies increased by 60% & 40% in April & May respectively as compared to corresponding period of  last year.

§Monitoring of cycle time(Traffic in to Traffic out) has been started. This has helped the workshop in projecting correct cycle time of POH.Cycle time has been continuously reducing over past few months as a result of intense monitoring.

§Improvement in working environment

§Refurbishing of coaches

§Emergency lighting arrangements: - 34 coaches have been fitted with Emergency Light in 2013-14.

§Implementation of MMIS(Material management information system) module

§E-Procurement: -Mancheswar Depot has the distinction of being the first Depot over Indian Railways to implement e-Procurement.

§Engineering improvements in workshop and colony

§Provision of road signage

§Renovation of Children park

CAPACITY EXPANSIO CAPACITY EXPANSION: CAPACITY EXPANSION:

§At present capacity of Mancheswar workshop is100 POH capacity of workshop has been 100 coaches (90 non-AC + 10 AC coaches) per month.
§Railway Board has sanctioned  major work vide Pink Book item No. 328 of 2008-09 at a cost of Rs.25.00 Crores to augment the installed capacity of the workshop to 150 coaches per month.
§Revised Estimate  ( 38 Crore) has been  sent to Railway Board for sanction to accommodate special facilities  for maintenance of LHB coaches.
§Civil Construction is under Progress 
Expected completion by  MARCH’14.
Conidal shell – Total 17 shell, 11 shell under final
stage of construction.
Expansion of Store Depot – under final stage of construction.
Connecting tracks, pits, flooring etc. would be taken up shortly.
QUALITY / SAFETY 

§All the overhauled coached and bogies turned out from the workshop is checked by independent Neutral Train Examiner. Mancheswar Workshop has ensured Zero NTXR rejection right since August 2001 for POH of coaches.
§Shot/grit blasting of bogie components started in September ’11 to expose the bare metal surface for crack detection.
§Interior panels (decorative thermosetting resin bonded plastic sheet) were earlier replaced as and when they were found in damaged condition. To improve appearance and aesthetics of coaches, panels are being changed o­n age cum condition basis. No patch repairs of panels are allowed o­n passenger coaches being turned out from the workshop.
§Provision of Stainless Steel Panel & Detachable Stainless steel mesh in Pantry Car
§Intensive corrosion repair
§Special Repair to Body Bolster of Coach
§Fire Safety
Workshop has fire tender, water hydrants, Fire extinguishers and open water tanks to fight fire.
FUTURE VISION :

Augmentation of POH capacity to 150 coaches per month:
§Work for augmenting the POH capacity to 150 coaches per month has been sanctioned by the Railway Board vide Pink Book item no: 328 of 2008-09.

§Procurement of machineries and civil construction work is under advance stage.

§The work is expected to be completed by March 2014.

Development of facility to undertake POH of LHB shell and air spring bogies:
§Indian Railways is switching over to LHB design steel shell and ICF bogie with air spring.

§The workshop started POH of hybrid coaches (Duronto) in February 2012.

§The workshop started maintenance of LHB coach (Rajdhani) in May 2013.

ISO certification:
Mancheswar workshop is under implementation of upgraded version of QUALITY MANAGEMENT SYSTEM i.e. ISO 9001:2008 and is expected to be completed by 31/08/2013.
An Environmental Management System (EMS) under ISO 14001 is a structured approach to addressing the environmental bottom line.
Developing the concept further, the workshop proposes to audit, review and modify its maintenance practices so as to be a ISO 14000, OHSAS 18000 certified workshop.
Green energy:
Solar Panels are proposed to be installed above administrative building and staff canteen to harvest solar energy.
We are also planning to use Bio-diesel in our fork lifter & D. G. Set.
Expansion to cater the demand for locomotive & Freight wheels:
The workshop is also developing infrastructure for supply of wagon and locomotive wheel to divisions.
A work has already been sanctioned at the cost of Rs.57.7 lakhs to develop facility for freight wheels.