वष 2017 – 18 की मुख उपल धयां - indian railways...apart from loco...

/ 31

वष� 2017 – 18 की �मुख उपल�� धयां

1. Production Outturn a) Overall Production Vs Target:

321 locomotives (including 25 electric locos) manufactured in FY 2017-18, amounting

to 2% higher over Railway Board’s target. Apart from this, two diesel locos WDG3A

successfully converted in to Electric loco WAGC3.

i. Actual production up to March’2018:

ii) Production of other Major Components:

Apart from loco production, DLW also enhanced manufacturing of major assemblies

largely required as unit exchange spares in Zonal Railways significantly in current

financial year over FY 2016-17 as given below:

Item 2016-17 2017-18 % increase over

2016-17

i. Wheel set assembly 24 69 187%

ii. HHP Power Pack 12 25 108%

iii. HHP Turbo Super Charger (O/H) & Assistance (RSP)

229 324 41%

iv. HHP Turbo Clutch (O/H) & Assistance (RSP)

377 406 8%

315 321

2017-18(RBd Target)

2017-18(Actual)

No

. of

Loco

(A

ll T

yp

e)

2% HIGHER loco production against Rly Bd’s target

/ 31

2. Quality

a) Performance vis-à-vis previous year on failure reported by Zonal Railways:

Diesel Loco failure within 180 days:

Period (Apr to Dec)

No. of failure Average failure per 100 Loco per month

Performance

2016-2017 122 8.53 Failure reduced by 23.74% 2017-2018 87 6.51

b) Settlement of Warranty Claims made by Zonal Railways:

(No. of cases)

Period (Apr – Mar)

Opening Balance

Case lodged

Case Settled

Closing Balance

Remarks

2016-17 280 3042 3027 295

Closing balance reduced by 25.4%

Warranty

complaints reduced by 7.19%

2017-18 295 2823 2898 220

8.53

6.91

2016-17(Apr-Dec)

2017-18(Apr-Dec)

Ave

rage

Fai

lure

s p

er

10

0 lo

co p

er

mo

nth

Comparison of Loco failures per 100 loco per month

23.74% IMPROVEMENT over 2016-17

There is no pending warranty claim more than 3 months old.

/ 31

3. Economy Measures

a) Percentage Reduction in Unit Cost of locomotive:

Unit cost of HHP locomotive produced at DLW has reduced by 3.7% i.e. by

more than ` 0.4 crore (from `12.25 crore in last year to `11.8 crore) during the

current year. Multi-sourcing and indigenization of locomotive components has

lead to reduction in the material cost.

Budget Reduction – Annual Budget (at Final Modification stage) reduced by more than ` 800 crore compared to initial Budget Allotment for FY 2017-18 (` 4190 crore reduced to `3339 crore). Reduction in locomotive cost is the main factor for this reduction of Budget.

b) Electrical Energy Consumption per Equated Unit:

Due to sustained efforts, DLW has been successful in reducing the energy

consumption per loco manufactured. Comparative energy used per loco is given

below:

FY Electrical unit consumption in workshop per loco (KVAH/Loco)

%Reduction in Electrical Energy Consumption over 2016-17

2016-17 31000 11.6%

2017-18 27413

12.25 11.8

2016-17 2017-18

Unit

cost

(` c

rore

)

3.7% REDUCTION in Unit cost

31000

27413

2016-17 2017-18

Avera

ge E

lectr

icit

y

Co

nsu

mp

tio

nK

VA

H/

Lo

co

11.6% REDUCTION in Per loco Electrical Unit consumption in workshop over 2016-17

/ 31

c) Inventory Turnover Ratio:

2016-17 2017-18

Target Achieved Target Achieved

8.45% (-) 2.67% 7.97% *

* Final figure is still awaited. Target figure of 7.97% will be definitely met, expected (achieved) T.D.R. will be approx 5% (including suspense etc.)

d) Funds Booked under PH21, PH41 & PH42 as %age of Budget Grant:

Plan

Head

2016-17 2017-18

BG (` Cr.)

Expenditure (` Cr, up to

31.03.17)

% of BG FMA (` Cr.)

Expenditure (` Cr, up to

31.03.18)

% of BG

PH 21* 3968.57 4062.91 102.38% 3194.18 3258.87 102.03%

PH 41 42.64 37.98 94.17% 25.92 24.09 92.94%

PH 42 174.07 200.98 115.46% 71.11 67.17 94.46%

* WMS-loco manufacturing

4. Occupational Health & Safety

DLW Workshop is certified with ISO 18001:2007 (Occupational Health and Safety Management System)

a) Number of Accidents

b) Average Monthly man hours lost due to IOD cases/100

2016-17

3.7 hrs

c) Supply and use of Personnel Protective Gears and Equipment:

DLW has formulated “Schedule of

and Protective Clothing

(i.e. PPE’s) have been listed with their scale of

for the purpose of safety of workmen

position is reviewed regularly.

All 37 Personnel Protecti

available and being used

Photos of special measures taken are given below:

New Fire Tender : A new Fire Tender

in the Fire Brigade Branch of the DLW Railway

9

2016

No

. o

f A

ccid

en

ts

Minor

Major

Occupational Health & Safety

certified with ISO 18001:2007 (Occupational Health and Safety Management System).

Number of Accidents:

Average Monthly man hours lost due to IOD cases/100 staff

2017-18 Remarks

1.08 hrs 70% improvement over previous year

se of Personnel Protective Gears and Equipment:

Schedule of Safety Equipment

lothing” wherein 37 safety items

(i.e. PPE’s) have been listed with their scale of issue

for the purpose of safety of workmen and the

position is reviewed regularly.

Personnel Protective Equipments are made

available and being used 100% .

Photos of special measures taken are given below:

: A new Fire Tender is included

ranch of the DLW Railway

10 0

2016-17 2017-18

89% REDUCTIONin Accidents over

2016-17

Use of PPEs

/ 31

certified with ISO 18001:2007 (Occupational Health and

staff:

Remarks

70% improvement over previous year

se of Personnel Protective Gears and Equipment:

in Accidents over

Use of PPEs

/ 31

Protection Force. This Fire Tender has many modern features with the capacity of

5000 liters. This will help in tackling the fire incidents of Workshop and Township.

Disaster management: Disaster

Management Plan has been prepared.

NDRF team studied the plan, visited DLW

in Feb’ 18 and guided regarding

preparedness for disaster.

Two motorcycles have been procured and used for round the clock patrolling in

workshop and colony area.

40 sets of walkie-talkie have been provided to RPF officials.

Three baggage scanners are under procurement for installation at workshop and

office entrance.

/ 31

5. Environment Management

a) Development of Alternative Sources of Energy (Solar Power):

i) Roof top Grid connected Solar Power Plant commissioned:

2016-17 2017-18 % improvement over 2016-17

161 kWp 1554 KWp + 1055%

ii) Renewable (Solar) energy generation:

2016-17 2017-18 % improvement over 2016-17

3.6 Lakh units (KWHr) 13.9 Lakh units (KWHr) + 286%

b) GreenCo Rating:

DLW obtained GreenCo Silver Rating under the GreenCo Green Company Rating System and became the first production unit on IR having this certification. Certificate is valid for 3 years.

DLW is ISO 14001:2004 (Environment Management System) certified. c) Scrap Management:

Sale of Scrap:

100% scrap disposal through E-Auction

2016-17 2017-18 Target Achieved Target Achieved

` 7 crore ` 6.20 crore ` 7 crore ` 7.3 crore

Roof Mounted, Grid Connected Solar Power

Plant

d) Rain water harvesting, Water recyclingmanagement:

i) Rain Water Harvesting:

Approx 44000 sqmcovered under RWH. In addition, following actions are also taken:

o Constructed 6 deep

o 8 nos. water bodies connected to storm water drains

o 2 abandoned tube wells converted into recharge wells

ii) Water recycling

o 1774 Million Litermore than corresponding period of

(2016-17 = 1420870

o Recycled water used for irrigation of road side lawns, bungalows lawn/ garden, filling of water bodies at Surya Sarovar, Tagore park and Golf course.

iii) Water conservation & management

o About 17.58% Jan'2018 as compared to corres

(2016-17 = 5289803

o Motorised Gate valve

e) Effluent treatment waste management:

Industrial Effluent Treatment Plant (IETP)for treating contaminated & mixed Petroleum oil and Lubricants (POL) of Around 2,000 litres of oil and grease is separated and sold off

Sewage Treatment Plant (STP)of 12 MLD (Million Litres per day) capacitySTP approx. 5 million litres of water is being recycled every day.

The treated water is released for agricultural and gardening purposes.

The digested bio-manure as sludge dried is used as fertilizer for horticultural purposes.

Online monitoring of STP and IETPPerformance of STP and IETP pertaining to BOD, COD, pH, TSS and oil content is continuously round the year.

None of sewage, whether treated or untreated, is discharged into Holy River Ganga.

Rain water harvesting, Water recycling, Water conservation and

Rain Water Harvesting: sqm roof top area of has been

covered under RWH. In addition, following actions are also taken:

deep recharge wells in colony

8 nos. water bodies connected to storm

abandoned tube wells converted into

Million Liter water is recycled in 2017-18 by STP which is than corresponding period of previous year.

1420870 KL, 2017-18 = 1773696 KL)

Recycled water used for irrigation of road side lawns, bungalows lawn/ garden, filling of water bodies at Surya Sarovar, Tagore park and Golf

ervation & management:

% saving (9.3 lakh KL) in consumption of fresh water till Jan'2018 as compared to corresponding period of previous year.

5289803 KL, 2017-18 = 4359647 KL)

Motorised Gate valve have been provided alongwith automation

Effluent treatment pollution control and

Industrial Effluent Treatment Plant (IETP) for treating contaminated & mixed Petroleum

and Lubricants (POL) of 3 MLD capacity. ,000 litres of oil and grease is

separated and sold off.

Treatment Plant (STP): for treatment of discharged human wasteof 12 MLD (Million Litres per day) capacity. In

million litres of water is being recycled every day.

The treated water is released for agricultural and gardening purposes.

manure as sludge dried is used as fertilizer for horticultural purposes.

Online monitoring of STP and IETP: Performance of STP and IETP for data pertaining to BOD, COD, pH, TSS and oil

continuously monitored online 24x7,

one of sewage, whether treated or untreated, is discharged into Holy River

Recharge well

/ 31

conservation and

by STP which is 24.83%

Recycled water used for irrigation of road side lawns, bungalows lawn/ garden, filling of water bodies at Surya Sarovar, Tagore park and Golf

lakh KL) in consumption of fresh water till ponding period of previous year.

automation of Pumps.

for treatment of discharged human waste

Recharge well

IETP

STP

/ 31

Pollution control:

DLW boasts of a green area of 40% of its total area having more than one

lakh small & big trees.

Release of CO2, CO, SO2, NO2 and particulate matters in flue gas through

different stacks is regularly monitored and kept within the limit prescribed by

Central and State Pollution Control Board

DLW has switched over to use of pictures for worship of Lord Vishwakarma on

“Vishwakarma Pooja” instead of clay idols.

Waste generated from the residential area is segregated as solid waste and

biodegradable waste. Solid waste is dumped at locations nominated by

municipality. Biodegradable waste is dumped in the pits for composting.

Debris are used to fill the low lying area.

100 kg/hour capacity incinerator is functioning to dispose off paint sludge, oil

soaked jute, oil saw dust, paint-overall, lube & fuel oil.

Online Monitoring STP & IETP

100 kg/hour capacity Incinerator

/ 31

6. Certifications

a) IRIS Certification

Action has been initiated to engage consultant for IRIS certification. Tender

has opened on 26.02.2018, consultant will be finalised by April’2018. (PDC for

certificate – March’2019)

b) 5 S Certification

5 S certification has been obtained.

c) IS 3834 Certification

DLW has obtained certification of ISO 3834-2:2005 for Fusion Welding of

Metallic Materials.

d) ISO 50001

DLW has obtained certification of ISO 50001: 2011 for Energy Management

System.

Apart of above, DLW is already an ISO 9001:2008, ISO 14001:2004 and OHSAS

18001:2007 Certified Organization covering integrated Quality, Environment and

Health & Safety Management Systems.

DLW has also recently obtained NABL Accreditation for laboratory.

/ 31

7. Industrial Relations

a) Staff Council Meetings:

Staff Council meetings have been organised as per schedule and problems raised

have been solved amicably.

Description 2016-17 2017-18

DLW Staff Council Meeting 04 04

DLW SC/ST Association Meeting 02 02

DLW OBC Association Meeting 01 01

b) Relationship of Staff with Management:

Relation between staff and management is very healthy and cordial.

Suggestions for improvement in work environment are considered for discussion

and implementation.

No industrial unrest took place during the financial year and not a single hour

of work was lost.

Transparency is given utmost importance in communication between management

and employees.

Special efforts were made to improve the illumination in shops and make all

drinking water purifiers and water coolers functional.

Spot award to staff/team for motivation.

c) Staff Grievance Redressed :

Every shop/section has been provided a grievance/ feedback register for employees’

problem. Grievances are studied, monitored and tackled systematically to prevent

recurrence:

FY No. of Grievances

Received Disposal of Grievances

Remarks

2016-17 103 103 (100%) 19.4 % reduction in grievances over

2016-17 2017-18 83 83 (100%)

8. Welfare

a) Staff Canteen, Toilet and Rest Rooms in factory premises including separate toilet facilities for ladies

i) Staff Canteen:

There are two modern i.e. Staff Canteen & Workshop Canteen. Both the canteens are running successfully as per needs of our employees. Following facilities are available in workshop canteen:

Pleasant ambience

Stainless steel dining

Washrooms with modern fittings

Provision of 70” LED TV

Vitrified tiles flooring

Transparent kitchen areacooking equipment

Modular kitchen with fresh air cooling and fume exhaust system

Stainless steel working table

Stainless steel sink for cleaning of utensils with hot and cold water facilities

Air tight containers and stainless steel containers for storage of groceries etc.

Auto coffee and tea dispensers in shops

Provision of water coolers with attached purifiers

ii) Toilets and Rest Rooms in factory premises including separate facilities for ladies:

All shops are attached with toilets

Renovated 10 lavatory blocks for hygienic and clean environment current year.

7 separate toilet facilities for ladies

Water cooler with attached purifier

, Toilet and Rest Rooms in factory premises including separate toilet facilities for ladies:

modern canteens in DLW premises i.e. Staff Canteen & Workshop Canteen. Both the canteens are running successfully as per needs of

Following facilities are available in

ambience

tainless steel dining furniture

Washrooms with modern fittings

Provision of 70” LED TV

Vitrified tiles flooring

Transparent kitchen area with modern cooking equipment

Modular kitchen with fresh air cooling and fume exhaust system

steel working table

Stainless steel sink for cleaning of utensils with hot and cold water facilities and Automatic Dish Washer

ir tight containers and stainless steel containers for storage of groceries etc.

Auto coffee and tea dispensers in shops

Provision of water coolers with attached purifiers

Toilets and Rest Rooms in factory including separate facilities for

All shops are attached with toilets

lavatory blocks for hygienic and clean environment in

eparate toilet facilities for ladies have been constructed

Workshop Canteen

Inside view of Workshop Canteen

Water cooler with attached purifier

Toilet

/ 31

, Toilet and Rest Rooms in factory premises including

Workshop Canteen

Inside view of Workshop Canteen

Toilet facility

Coffee Dispenser

/ 31

Three change rooms/ rest rooms for female staff in different shops have been provided.

6 new water booths were provided.

iii) Staff Lockers – Procurement of more than 750 new lockers for workshop staff has been done.

b) Recreational Amenities for Staff in Colony :

Community Hall, Institute, Barat Ghars-03

nos, Kalyan Kendra, Rangshala, Employee

Club and Officers’ Club are functioning in DLW

Township for various social needs of the staff.

Cinema Club:

An air-conditioned Cinema Hall (seating

capacity of 650) with multi-channel audio

system and digital projection is functioning

in DLW.

Parks and gardens:

Two parks and one big pond named

"Surya Sarovar" is also situated in DLW premises where festival like Chatt Puja,

Jivitputrika Puja, Dev Depawali etc. are

organised.

c) Medical facilities:

105 bedded well-equipped Railway Hospital, a Health Unit and a First-Aid post in

workshop are functioning, taking comprehensive health care of more than 50,000

beneficiaries (around 6100 employees plus 5200 retired employees & their family

members).

Facilities available:

i. Medicine, Cardiology, Paediatrics, Obstetrics & Gynaecology, Surgery, Urology,

Orthopaedics, ENT, Ophthalmology, Dentistry, Endoscopic surgery &

Physiotherapy. Diagnostics services, Pathology – Haematology &

Bio-Chemistry, X-ray- Routine & Special X-Ray, Dental X-Ray, digital X-Ray &

ECG.

Cinema Club

Surya Sarovar

ii. Mobile based medical registration

doctors’ appointment including the status of running no. of token for individual

doctor and reporting of lab investigation have bee

on mobiles through an Android app for staff of DLW.

d) Educational facilities

i. One school up to Secondary Education, run by DLW administration more than 1000 students are being taughtwith “Smart Class” for

ii. One Girl's degree College in DLW premises.

iii. Two Central Schools Varanasi region. Result of class 10th was 100%.

iv. One Sr. Secondary School (Private).

v. One Bal-Niketan (run by DLW Women's Welfare Organization).

e) Colony upkeep

Maintenance, Roads, S

Drainage etc.

• DLW has a total of 36

about 6100 employees and officers in a lush

green, pollution free township with more

than one lakh trees.

keep the colony “Clean and Green

• Major roads have been resurfaced

8.4 kms road repaired

One km reinforced cement concrete road newly made

near the east gate for heavy material movement.

• SMS based complaint management systems

working for redressal of general electrical complaints

colony area. On an average 75 complaints per day are

attended.

• Illumination in colony area is excellent

• More than 7600 nos LED tubelights,

employees and 136 Solar lights have been fitted

conservation.

• 48 CCTV Cameras have been provided in DLW campus for

and monitoring of unscrupulous activities.

Screenshot of DLW HMIS webpage

medical registration: Facility to do medical registration,


doctor and reporting of lab investigation have been made available online and

on mobiles through an Android app for staff of DLW.

facilities:

One school up to Secondary Education, run by DLW administration more than 1000 students are being taught – 14 classes have been provided with “Smart Class” for imparting education in a modern way.

One Girl's degree College in DLW premises.

Two Central Schools - KV No.-4, DLW got 4th position out of 32 KVs in Varanasi region. Result of class 10th was 100%.

One Sr. Secondary School (Private).

Niketan (run by DLW Women's Welfare Organization).

including Garden

Maintenance, Roads, Streetlights,

3684 staff quarters for

00 employees and officers in a lush

green, pollution free township with more

Efforts are made to

Clean and Green”.

Major roads have been resurfaced. About

8.4 kms road repaired and resurfaced in current year.

One km reinforced cement concrete road newly made

near the east gate for heavy material movement.

SMS based complaint management systems is

for redressal of general electrical complaints of

colony area. On an average 75 complaints per day are

Illumination in colony area is excellent.

nos LED tubelights, 50000 nos. LED bulbs distributed among

and 136 Solar lights have been fitted to promote energy

have been provided in DLW campus for improved safety

of unscrupulous activities.

Screenshot of DLW HMIS webpage Screenshot of DLW HMIS Mobile App

Glimpse of Lush Green

/ 31

: Facility to do medical registration,


n made available online and

One school up to Secondary Education, run by DLW administration where 14 classes have been provided

4, DLW got 4th position out of 32 KVs in

Niketan (run by DLW Women's Welfare Organization).

distributed among

promote energy

improved safety

Screenshot of DLW HMIS Mobile App

Glimpse of Lush Green Township

Solar Light

/ 31

f) Other Notable Features:

Activities managed by Railway Women Welfare Organization:

Staff welfare function of DLW is also supplemented by Railway Women’s

Welfare Organization who run the most popular primary school of DLW

township called ‘Bal Niketan’ )बालिनकेतन( , a vocational training centre for

differently-abled children called ‘Chetna’(चेतना) and a number of other

centres aimed at adult literacy, computer literacy, painting, stitching, crèche,

etc.

For obtaining pay roll information of DLW employee, a

new pay roll mobile App “DLW EMP Payroll Info” has

been launched

Two nationalised Banks with 6 ATMs and one Co-Operative bank are

functioning within DLW campus.

Bal Niketan School

Screenshot of DLW EMP Payroll Info Mobile App

SBI ATM BOB ATM

/ 31

9. Sports

a) Sports Facilities:

Golf course with 18 hole (11

fairways, 56 Acres)

International size standard

Swimming pool.

One synthetic Basketball court & one

cement Basketball both with flood

lights.

One Volleyball court with Flood light

facility.

One Handball ground.

One Cricket ground with pavilion.

One Football ground.

One Hockey ground.

One Gym with multi-equipments.

Two indoor Badminton Courts with

wooden flooring.

One wrestling hall with two wrestling

mats.

Two synthetic tennis courts with

flood lights.

b) Achievements at Various Levels:

Awarded ICF Cup for the year 2016-17 for

best overall performance minor units

(Runners-up).

i. Medals won in All India Railway

Championship during 2017-18:

• The Wrestling team won 7

individual medals (Gold – 1, Silver-3, Bronze - 3)

• DLW Golf team secured Silver Medal

• DLW Handball team secured Silver Medal

• One athlete won Silver Medal in Athletics 20 Km walk

ii. Gopal Yadav represented Indian Railways Wrestling team in 62nd Senior National

Wrestling Championships held at Indore in Nov. 2017 and won Gold Medal in 86

Kg FS .

iii. Arjun Yadav & Virendra Kumar Patel represented Indian Railways Wrestling team

in 62nd Senior National Wrestling Championships held at Indore in Nov.2017.

International Size Standard Swimming Pool

Tennis Court

18 Hole Golf Course

/ 31

iv. Akash Bhashin represented Indian Railways Basketball team in 68th Senior

National Basketball Championships held at Chennai in Jan’2018 and team

secured Bronze Medal.

v. Ashish Singh, Faiz Ahmad, Ashish

Yadav Avinash Yadav & Deepak Banshal

represented Indian Railways Cricket

team for Ranji Trophy Matches, T-20

Matches and Syed Mushtaq Ali All India

inter-zonal tournament.

vi. Inter-departmental Athletics (Men &

Women), Basketball, Chess, Cricket,

Handball and Volleyball tournaments

successfully organized by DLWSA for

the financial year 2017-18.

Badminton Court

/ 31

10. Public Image & Brand Value

a) Initiatives taken:

i) WDG3A Conversion to Twin Co-Co Electric loco (WAGC3)

In view of large scale electrification, it was decided to convert surplus WDG3A

Locomotives into Electric Locomotives. Converted loco will work as a twin loco consist

(2 X 5000 HP) and comprises of one cab per loco. Each converted loco will have 01

Panto and will be equipped with dynamic braking. DLW has been given responsibility

to redesign for conversion loco and carry out all modifications/assembly work. Heavy

reengineering work involved in redesigning the underframe.

Following major activities were undertaken in this project:

Finalisation of Equipment layout.

3D modeling and weight balancing of the conversion loco via CAD.

Remodeling of complete pneumatic piping with IRAB-1 Brake panel, suitable

for electric traction.

Major modifications/ strengthening in the underframe of WDG3A to make it

monocoque design and to accommodate major/heavy electrical equipments

viz. Transformer unit, smoothing reactor, BA-1, 2 panels, rectifiers etc. More

than 120 plates of different sizes and shapes were used for modification.

Modification in Cab of WDG3A to provide additional side door (1 no), machine

room doors (2 nos.) and to accommodate AC-2 panel.

Cable harness in AC-2 panel and laying of power cables for all electrical

equipments viz transformer, TM, SL etc done afresh. More than 8 kms. Of

cabling was done.

Modification in the roofs of the old WAM4 with respect to the location of

transformer, for use on the conversion loco.

DLW has succsessfully converted two diesel loco WDG3A in to Electric loco WAGC3

loco.

Conceptual Design of WAGC3

/ 31

ii) Electric Loco:

DLW has successfully ramped up the electric loco

production from 2 locos manufactured in last year to 25

locos in current year till Mar’2018 as per target given by

Railway Board. After provision of OHE in DLW, electric

loco testing has also been started at DLW, resulting in

reduction of loco testing time by 10 days per locomotive.

iii) Locomotive with Loco Cab Video & Voice Recording (LCVR) System:

DLW manufactured first ever HHP diesel locomotive equipped with LCVR system was

turned out on 15th Jan’2018. Loco Cab Video and Voice Recording System (LCVR)

has been installed which will provide effective and tamper proof video and voice

recording of events within loco cab and in front of the Cab(track) for post event

analysis akin to black box used in aircrafts. So far two locos have been turned out.

iv) Reduction in Cab Noise Level:

DLW has initiated action for achieving substantial reduction in noise levels in loco

cabs . The acoustic insulation scheme designed and provided on walls & floor of

cabs and side walls & roof of long hood of locomotive. This scheme consists

layers of fire resistance anti vibration pad, noise barrier, PU foam, fire resistance

non woven fabric and dimpled aluminum sheet. As a result DLW has reduced the

noise level in front cab from 91.6 to 85.6 dB(A) and in rear cab from 98.8 to 87.8

dB(A). So far 6 locomotives with reduced noise level have been rolled out. Zonal

Railways have given positive feedback of significant reduction in the noise levels

in loco cabs of these locomotives.

Electric Loco with OHE

WAGC3

Loco with LCVR System

Camera

/ 31

v) Sri Lanka Loco Project:

DLW signed agreement on 5th Jun’2017 with RITES for supply of 10 Nos 3000 HP

12 cylinder 710 G3C EMD engine, dual cab, AC-AC locomotive on HHP platform.

Since it is new loco, design including 3D modeling of the loco has been

completed. Procurement of uncommon items is in process. First prototype is

likely to be rolled out by July' 2018.

CAB 1

DB ARRGT

ECC1

ENGINE 12 CYL

EQUIPMENT RACK

HVAC

BOGIE ARRGT

BATTERY BOX FUEL

TANK

SIDE BUFFERSWIVEL TYPE COUPLER

UNDEFRAME AIR COMP

CAB2

GEN BLOWER

RADIATORS

TCC 1&2TA12 CA9 ECC2 +HL

Uncommon items Common items (HHP Loco)

RADIATOR FAN

vi) DUAL MODE LOCOMOTIVE

To cater the requirements of routes with both electrified and non-electrified sections,

dual mode locomotive is being development by DLW. Dual mode locomotive will be of

4500 HP, capable of running in both Diesel and Electric modes with a speed potential

of 135 kmph. It will give following advantages to the fleet of locomotives in IR:

i. Reduction in detention at traction change points.

ii. Increased availability of locomotives.

iii. Reduced man days for shunting.

iv. Improved flexibility in last mile operation.

v. Increase throughput.

vi. Electrified territory –

a. Excellent operational flexibility in case of natural calamities.

b. Higher reliability due to redundancy of traction power.

Extensive design efforts were involved in relocating/removing existing loco

equipments and mounting additional electrical items as shown below:

Conceptual Design - Sri Lanka Loco

CONCEPTUAL DESIGN

1st prototype Dual mode loco is likely to be turned out by Aug’ 18.

CONCEPTUAL DESIGN - DUAL MODE LOCOMOTIVE

prototype Dual mode loco is likely to be turned out by Aug’ 18.

/ 31

MOTIVE

b) Recognition received:

i) Public Image

Press releases, write-ups, GM’s articles and display advertisements were published in

the National and Local Dailies as well as in magazines & house journal “Samvad” also.

Description and Photographs of Prominent events were posted/uploaded on DLW

Website as well as on social media Twitter and Facebook.

Besides, Video Clipping of "Hon’ble MOSR and Minister of State for Communication

(I/C) flagged-off Electric Locomotive" is uploaded on YouTube.

During April’ 2017 to March’

highlighted and covered by media the

clippings attached as annexure)

a) New Production Record:

manufacturing 334 locomotives during the financial year

2016-17. The most notable factor is that out of 334

locomotives first time 2 electric locomotives were

manufactured. It is a matter of great pride that the

above production indicates more than one locomotive

per day.

b) Best Production Unit Shield :

Production Unit Shield of Indian Railways for the year

2016-17, the second consecutive year

c) Visit of National Press Party :

member National Press Party including 04

officials of Public Relations Directorate,

Railway Board visited DLW on 28

2017. They went round the workshop

along with senior officers. In the workshop

the Press Party witnessed ongoing

manufacturing processes and discussed

DLW's future plans for enhancing the

production of High Horse Power and

Electric locomotives with concerned officers. They took keen interest in witnessing

existing manufacturing facilities and the

later covered their visit in appreciable

press releases.

d) Inter Railway Dance Competition

'Nrityanjali' : Inter Railway Dance

Competition 'Nrityanjali' was organized on

01st May at Auditorium (Cinema Hall). As

many as 366 participants of 19 teams

from different Zonal Railways and

Production Units participated in this

competition. On this occasion Genera

Recognition received:

ups, GM’s articles and display advertisements were published in



as well as on social media Twitter and Facebook.


off Electric Locomotive" is uploaded on YouTube.

March’2018, following events of DLW were prominently

highlighted and covered by media thereby creating a positive public image (news

clippings attached as annexure):

Record: DLW set a new record of

manufacturing 334 locomotives during the financial year

otable factor is that out of 334

irst time 2 electric locomotives were also

manufactured. It is a matter of great pride that the

above production indicates more than one locomotive

Best Production Unit Shield : DLW bagged Best

ction Unit Shield of Indian Railways for the year

second consecutive year DLW has won this shield.

Visit of National Press Party : A 14

member National Press Party including 04

officials of Public Relations Directorate,

ted DLW on 28th May,

They went round the workshop

along with senior officers. In the workshop

the Press Party witnessed ongoing

manufacturing processes and discussed

DLW's future plans for enhancing the

production of High Horse Power and

locomotives with concerned officers. They took keen interest in witnessing

anufacturing facilities and the expansion project in the Workshop.

later covered their visit in appreciable

Inter Railway Dance Competition

: Inter Railway Dance

Competition 'Nrityanjali' was organized on

May at Auditorium (Cinema Hall). As

many as 366 participants of 19 teams

from different Zonal Railways and

Production Units participated in this

competition. On this occasion General

/ 31

ups, GM’s articles and display advertisements were published in




were prominently

reating a positive public image (news

locomotives with concerned officers. They took keen interest in witnessing

in the Workshop. They

/ 31

Manager and President, DLW Women's Welfare Organisation gave away awards to

the winners and participants of the contest.

e) Locomotives exported to Myanmar Railways : In the financial year 2017-

2018, Diesel Locomotive Works had

received export order of 18 state-of-

the-art meter gauge 1350 HP

locomotives from Myanmar Railways.

The first consignment of six

locomotives of this export order was

supplied to Myanmar Railways on

June, 17. Second and third

consignments of six locomotives each

were exported on October, 17 and

January, 18 respectively. This also

earned the Railways `139 crore.

f) Visit of High-Level Delegation of

Mozambique : A High Level

delegation headed by Mr. Miguel Jose

Matabel, Chairman, Mozambique

Railway visited DLW on 15th June,

2017. The visit instilled great

confidence in visitors when they saw

the modern production facilities at

DLW and is expected to pave the way

for getting more orders for exporting

diesel locos to African Countries.

g) Visit of CRB : Shri A.K.Mital,

Chairman, Railway Board visited DLW

on 29th July, 2017. He flagged off the

2200th HHP locomotive. On this

occasion, Shri Mital also inaugurated

newly built ultra-model Loco Paint

Shop.

h) Swachchhata Pakhwada & Swachchhata Diwas : “Swachchh Rail Swachchh

Bharat – Swachchhata Pakhwada”

organised from 16th to 31st August,

2017. Swachchhata Diwas was also

organised on 02nd October.

i) Akhil Rail Hindi Natyotsava :

Akhil Rail Hindi Natyotsava – 2017

organised from 22nd to 24th August,

2017. 15 teams of Zonal Railways &

Production Units of whole Indian

Railways were participated in this

competition. DLW won the first prize in this competition. The Natyotsav concluded

with various colourful cultural programme and prize distribution on 24th August.

Myanmar Loco

/ 31

General Manager was the chief guest and President, DLW Women's Welfare

Organisation was the guest of honour who gave away to the winner teams and

individual performers.

j) Visit of Iran Delegation : 02 officials including Vice President/Fleet Affairs of the

Railways of the Islamic Republic of Iran, along with ED/RITES & GGM/RITES

visited DLW on 28th August, 2017 for technical discussion on supply of 4000+ HP

AC-AC standard gauge locomotive and 4000 HP Power-pack. A second team of

senior officers from Iran Railways visited DLW on 12th Feb’2018 to discus

modalities and technical aspects for supply of 200 HHP locomotives.

k) Visit of Hon’ble Prime Minister :

Hon’ble Prime Minister Shri Narendra Modi

was in Varanasi on 22nd & 23rd

September, 2017. During his visit,

Hon’ble Prime Minister stayed in DLW

Officers Guest House. In connection of

PM’s visit, the Hon'ble Governor Shri Ram

Naik and Hon'ble Chief Minister Shri Yogi

Adityanath of UP also came to DLW

township. On this occasion, Hon'ble PM

inaugurated various projects in Varanasi.

l) Visit of Member/Traction and Bulk

Indent Meeting : Shri Ghanshyam

Singh, Member/Traction visited DLW on

15th September, 2017. He flagged off

425th HHP Dual Cab Loco. Bulk Indent

Meeting for spares of HHP locomotives for

2019-20 also held on 15th September,

2017. Shri Singh addressed the meeting.

m) Dashahra, Durga Pooja and Surya-

Sasthi : Dashahra, Durga Pooja and

Surya-Sasthi of DLW are very famous

festivals in Varanasi, in which Dashahra

include enacting of the excerpts from epic

Ramayan as well as attractive fireworks

and burning of effigies of Ravan,

Kumbhakaran and Meghnad at DLW

stadium. Durga Pooja is celebrated at Community Hall with installation and poojan

of beautiful idols of Durga. Besides, two day long Surya-Sasthi Mahotsav is

celebrated on Surya-Sarovar.

n) Vishwakarma Pooja Celebrations :

Historic decision of DLW of using

/ 31

portraits of Lord Vishwakarma in place of clay idols for pooja purposes was taken

into practice this year also at Vishwakarma Poojnotsav held on 17 September,

2017 at DLW. Earlier clay idols used in Pooja were immersed in River Ganges,

causing water pollution.

o) Participation in Exhibitions: With a

view to promote “Brand DLW”,

participation in various exhibitions was

undertaken. DLW stalls which displayed

various products and related sub-

assemblies attracted a large number of

people including various vendors and

suppliers. Various exhibitions in which

DLW participated during 2017-18 were:

International Railway Equipment

Exhibition (IREE) – 2017 from 11th to

13th October, 2017 in New Delhi.

India International Trade Fair (IITF)-

2017 from 14th to 27th November,

2017 in New Delhi

National Vendor Development

Programme cum Industrial Exhibition

on 02nd and 03rd February, 2018 in

Varanasi

Taj Mahotsav on 18th to 27th February, 2018 in Agra.

p) Skill Development Programme : Under the Prime Minister Skill Development

Programme, 471 local youths trained.

q) Visit of Hon’ble Minister of State of Railways and Minister of

Communication (I/C) : Shri Manoj Sinha, Hon’ble Minister of State of Railways

and Minister of Communication (I/C)

visited DLW on 12th January, 2018. He

flagged-off DLW manufactured Electric

Locomotive ‘WAP7’ in a grand ceremony.

On this occasion Shri Sinha also held

DLW’s performance review meeting.

r) 4 new mobile apps : According the

target of the Hon'ble Railway Minister,

DLW has made 4 Mobile Application

(Material Related, Bill Payment, Outsider Electricity Bills and Employee Payroll) in

the month of January’2018, which will facilitate the obtaining related information

and the public transparency will come in the work. The above apps can be

downloaded from the Google Play Store.

s) Green & Clean DLW : DLW township area is green & clean, having more than

one lakh small & big trees. It’s around 40% area is green. One can perceptibly feel

a temperature drop of 3°-4° Celsius, on

entering DLW campus, as compared to

outside area. People from the city and

adjacent areas come to DLW for morning

walk, due to its healthy and pollution free

/ 31

environment. Besides, a lush green Golf Course of 18 Holes and two wings at DLW

also attract the Golfers. Not only Railway officers and employees, but Golfers from

outside of DLW also come to play here.

t) Other Events : International Day of Yoga on 21st June, 2017, World

Environment Day on 05 June, 2017 and National Unity Day on 31st October

were prominently covered.

To ensure that the DLW’s image attains the highest degree in excellence a

strategy on PR front was implemented by Public Relations Organisation of Diesel

Locomotive Works. Each and every endeavour was made to highlight the above

achievements and activities of DLW by exploiting the rich potentials of mass media

viz national press, AIR, Doordarshan as well as other TV Channels and projected a

good image of DLW in public.

Brand Value:

Over the last 50 years, DLW has established unbeatable “Brand Equity” in respect

of locomotive sales to Non-Railway Customers (NRCs). This is backed and

supported by impressive after-sales service and spares-support to all customers.

This is manifesting in repeat orders from the clients. Moreover, DLW also gets

tough competition from open markets viz BHEL, SAN/Bangaluru etc. for getting

WDS6ADT supply orders.

Our pro-active initiatives for “Make in India” campaign have brought forth

rewarding dividends in terms of

proliferating our foot-prints not only

inland but also on foreign shores.

Despite adversities, DLW recently

bagged orders for 04 WDG3A from

NALCO/Angul, NALCO/ Damanjodi &

L&T for NTPC/ Khargaon, 03

WDS6ADT from RES/ RITES and 10

nos. 3000 HP HHP based for Srilanka

during FY 2017-18 (worth ₹149.94 Cr.)

Further, DLW is expecting orders for 3 WDS6 ADT loco from RITES/RES, 08

WDG3A loco from LANCO/ Anpara, NTPC/ Telangana, NTPC/ Korba, NSPCL/ Bhilai

and approx 200 nos. 4000 HP standard gauge (SG) HHP locos from Iran.

DLW has delivered 36 locomotives to NRCs including 18 YDM4 locomotives

exported to Myanmar and 01 WDG4D to OPGC/Bhubneshwar worth ₹ 333 Cr

during 2017-18. This includes locomotive spares supplied to NRC worth ₹ 10.73 Cr

against annual target of ₹ 8.00 Cr.

The above have achieved by continuous interaction with prospective customers and

endeavouring to meet their expectations within overarching government framework.

A rigorous follow-up with NRCs by Marketing Division ensures re-dressel of

requirements of our valued customers.

Business of locomotives & spares to NRC/Export for last three years is given below:

HHP Loco for OPGC

/ 31

c) No. of pending Audit cases > 1 year:

There are no pending Audit Cases to be replied, more the one year with this organization.

2

141

91

179 192

92

179

333

2015-16 2016-17 2017-18

Export Domestic TotalRs. Crore

/ 31

11. Training and Skill Development of Employees

a. Training Facilities

Technical Training Centre (TTC) of Diesel

Locomotive Works, Varanasi is functional since

1959 to impart training for new recruits, working

staff and supervisor, Act Apprentices and

Vocational training to Under Graduate Engineering/

Management students. There is also one more

training centre - Indian Railway Welding Research

Institute (IRWRI) which functions as ‘Apex Body’ of

Indian Railways for improving welding quality and

research.

Facilities in Technical Training Centre:

Basic Training Workshop: Fitting and Machine

shop equipped with conventional and CNC

machines.

Electrical & Electronics lab equipped with cut

models and wiring diagrams.

Computer Lab for computer training viz.

Computer awareness, advanced computer

training, ORACLE, Hindi Kunjiyan / Unicode and

AutoCAD training.

Library: TTC is having library of more than 1000 technical and management books

for the knowledge upgradation of trainees and faculty members in various

branches i.e. Mechanical, Electrical,

Management and Computer Applications.

Classroom facilities: There are ten classrooms

(including six AC rooms) with 25 seats

equipped with LCD projectors, computerised

interactive boards are available for in-house

training.

Auditorium / Conference Hall: One Air-

conditioned Conference hall & one other Auditorium is available at TTC for

seminars & workshop with audio-visual facilities with 180 and 100 seating

capacity respectively.

i. Main Activities of Technical Training Centre (TTC):

In-house training for DLW supervisors & staff, Probationers and Zonal

Railway’s supervisors and staff

Initial training for newly recruited supervisors, artisans (RRB/promotions / New

appointees)

Training of Act. Apprentices (Non-ITI and ITI) as per Apprentices Act.

Degree & Diploma Apprentices training as allotted by Board Of Apprenticeship

Training (BOAT), Kanpur

Technical Training Centre

/ 31

Vocational training for Under Graduate Engineering Students

‘Kaushal Vikas’ (PMKVY) training for local youth

TTC regularly organizes Seminar/Talk/Meeting in Auditorium / Seminar hall.

ii. Indian Railway Welding Research Institute (IRWRI)

IRWRI is well equipped with all the required

welding facilities i.e. MIG, TIG, SMAW,

Stainless Steel welding etc. Plasma cutting

facility and Weld Research Lab. Main

activities are -

Training of DLW, NER, ECR, ER, CR &

NFR welding professionals &

co-ordinate between Regional

Welding Institutes and function as

Apex Body of Indian Railways for

Welding training

Conducts different modules of Welding Courses for welders, supervisors & trainers

Conducts Welder Qualification Test as per ISO:9606-1 for DLW & other Rly

Workshop welders

Research & Quality Improvement Activities

Welding related problems of DLW

Quality audit of Regional Welding Institutes

Indian Railway Welding Research Institute

Weld Lab of IRWRI

/ 31

iii. Training data:

Special efforts were made to impart increased training to staff and also increase skill

development of local youth. Training performance of TTC and IRWRI as compared to

2016-17 is as under, indicates increase in man-days by 19%.

Training

Imparted

2016-17 2017-18

No. of Trainees Man Days No. of Trainees Man Days

TTC

IRW

RI

Tota

l

TTC

IRW

RI

Tota

l

TTC

IRW

RI

Tota

l

TTC

IRW

RI

Tota

l

Refresher 541 364 905 6002 4895 10897 734 445 1179 8555 6604 15159

Skill development programme for local

youth (कौशल

िवकास योजना)

230 87 317 2070 783 2853 85 18 103 1020 216 1236

Grand Total 771 451 1222 8072 5678 13750 819 463 1282 9575 6820 16395

b. System for ensuring proper training to employees:

For ensuring proper training to the employees/trainees following system is in place at TTC and IRWRI:

Well qualified Teachers are posted in TTC. Incharge of IRWRI is having P.hd in

Welding.

TTC arranges training to the trainers to upgrade their teaching skill by training in

Out-side Institutions.

Standardisation of lesson plan for all courses to ensure uniformity in content and

coverage of various topics in training module.

13750

16395

2016-17 2017-18

Tra

inin

g M

an

days

19% INCREASE in Training Man days over last year

/ 31

Different cut models and circuit diagrams of Locomotive equipment/parts in

finished/manufactured form are available in TTC/IRWRI. Practical demonstration is

also being done for better understanding of trainees.

Interactive digital boards with LCD projector and visual presenter is provided in

the classrooms for better understanding and display of teaching materials.

Grading system for all faculty members is in place for continuous evaluation of

teaching faculty through trainees’ feedback.

Digital database is being maintained for continuous monitoring of mandatory training courses. Any shortfall is promptly reported to concerned Unit In-charge to ensure compliance.

Kaushal Vikas Yojna: In keeping with the PM’s vision of skill development of local youth, programme of “Kaushal Vikas Yojna” has been started and so far 521 local youths have been trained free of cost in different trades vis Electrician, Welder, Carpenter, Fitter etc.

वष 2017 – 18 की मुख उपल धयां - indian railways...apart from loco...

Documents