वष 2018-19 की मुख उपल धयां 1. production outturn · emergency fire exit...

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वष� 2018-19 की �मुख उपल�� धयां

1. Production Outturn Overall Production Vs Target:

276 locomotives (including 145 electric locos and 2 conversion loco) manufactured in

FY 2018-19

Production 2018-19:

The electric loco manufacturing plan for DLW for 2018-19 has sudden been enhanced

from 173 to 400 electric locos by Railway Board (vide letter no. 2015/Elect

(TRS)/440/4 dated 26.10.2018). Considering the lead time of supply of material and

even after optimum utilisation of available capacity, the enhanced plan of 400 electric

locos at DLW for the current FY 2018-19 is not achievable.

538

276

2018-19(Rly Bd Target)

2018-19(Production)

No

. of

Loco

(A

ll T

yp

e)

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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 failures Remarks

2017-18 87 Failure reduced by 12.6%

2018-19 76

B) Settlement of Warranty Claims made by Zonal Railways:

(No. of cases)

Period (Apr – Mar)

Opening Balance

Case lodged

Closing Balance

Remarks

2017-18 295 2823 220 Closing balance reduced

by 28.2%

2018-19 220 2028 268

87

76

2017-18… 2018-19…

No

. of

failu

res

12.6% REDUCTION in failures

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

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3. Economy Measures

A) Percentage Reduction in Unit Cost of locomotive:

Average unit cost of HHP locomotive is as under:

FY Average unit cost of HHP locos (WDG4D & WDP4D)

2017-18 ` 11.86 crore

2018-19 * ` 12.17 crore

* Cost for FY 2018-19 is provisional (for 15 closed Loco batches).

B) Electrical Energy Consumption per Equated Unit:

Comparative energy used is given below:

FY Electrical unit consumption (KVAH) Remarks

2017-18 8799495 (workshop) 12% saving over

previous year 2018-19 7737208 (workshop)

C) Inventory Turnover Ratio:

2017-18 2018-19

Target Achieved Target Achieved

7.97% (-) 4.02% 8.25% (-) 2.03%

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

Plan

Head

2017-18 2018-19

BG (` Cr.)

Expenditure (` Cr)

% of BG BG (` Cr.)

Expenditure (` Cr)

% of BG

PH 21 3194.18 3258.87 102.02% 3205.95 3113.98 97.13%

PH 41 37.08 26.89 72.5% 14.77 7.64 51.7%

PH 42 79.26 67.21 84.8% 5.37 3.36 62.5%

Plan head 21 is not operated in DLW, it is operated in Zonal Railways. Expenditure of RSP locos are being shown in PH 7200 in DLW.

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4. Occupational Health & Safety

DLW has made integrated Quality, Health, Environment and Safety Policy. In

conformance to provision/ requirements of OHSAS Management, DLW is having

certificate of OHSAS-18001 (Occupational Health and Safety Management

System) since 2005.

A) Number of Accidents:

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

2017-18 2018-19

1.08 hrs 3.6 hrs

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

DLW has formulated “Schedule of Safety Equipment

and Protective Clothing” 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.

All 37 Personnel Protective Equipments as per latest

EN/IS specs, are made available and being used

100%.

D) Safety seminars:

Year Safety Seminars

2017-18 04

2018-19 05

1 1

0

1

2017-18 2018-19

No

. o

f A

ccid

en

tsMinor

Major

Use of PPEs

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E) Safety inspections:

Year Safety Inspections

2017-18 144

2018-19 163

F) Other important work executed:

Disaster management Plan of DLW has been approved by NDRF

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

workshop and colony area.

Three baggage scanners are installed at entrance point of administrative building.

JPO for working under OHE issued and implemented

Instructions for Safe working on heights issued & compliance monitored by Safety

Cell

Safety awareness training is imparted to all new entrants / workman / supervisors

at shop floor and at Technical Training Centre to enhance safety awareness.

Massive training programs had been organized by safety officers, result 100%

workshop staffs are trained in fire fighting.

Safety belts & fall arresters have been provided to all the staffs working at height

for protection against fallen hazard. Training are also imparted by safety cell

amongst staff those working at height.

Automatic Fire Alarm System has been provided in Administrative Building for

quick response in controlling the fire hazard.

Emergency fire EXIT boards have been placed at suitable places in Administrative

Building for helping in evacuation during fire emergency.

Fire instruction boards have been placed at many places for better awareness to

staff regarding control of fire and safety of workman.

Fire balls have been provided as automated fire extinguishing system in store

areas where inflammable materials are stocked. Fire extinguishing ball i.e. “Fire

ball”, is such an automated fire fighting system. Fire ball is a ball shaped fire

extinguisher. When a fire occurs and no one is present, it automatically gets

triggered within 3-5 seconds of coming in contact with fire. Besides this, it gives a

loud noise as a fire alarm. It shall then effectively disperse-extinguishing Dry

Chemical Powder (1.3 kg quantity) without any need of a manual intervention.

For better communication to enhancing emergency preparedness the new higher

capacity Hooter placed in DLW.

New emergency exit provided in Design building for easy evacuation of staff

during emergency.

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5. Environment Management

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

i) Roof top Grid connected Solar Power Plant commissioned:

2017-18 2018-19

1.86 MWp Installation of 2.0 MWp under PPP model is under progress

ii) Renewable (Solar) energy generation:

2017-18 2018-19 % improvement over 2017-18

13.9 Lakh units (KWHr) 17.7 Lakh units (KWHr) + 27%

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

2017-18 2018-19

Target Achieved Target Achieved

` 7 crore ` 7.30 crore ` 7 crore ` 10.5 crore

Roof Mounted, Grid Connected

Solar Power Plant

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D) Rain water harvesting, Water recycling, Water conservation and management:

i) Rain Water Harvesting: Approx 44000 sqm roof top area of has been covered under RWH. In addition, following actions are also taken:

o 47 deep recharge wells in colony

o 8 nos. water bodies connected to storm water drains

o 4 abandoned tube wells converted into recharge wells

ii) Water recycling

o 1314 Million Liter water is recycled in 2018-19 by STP.

o Recycled water is 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 Consumption of fresh water:

(2017-18 = 4359647 KL, 2018-19= 4425613 KL)

o Motorised Gate valve have been provided alongwith automation of Pumps.

E) Effluent treatment pollution control and waste management: Industrial Effluent Treatment Plant (IETP)

for treating contaminated & mixed Petroleum oil and Lubricants (POL) of 3 MLD capacity. Around 2,000 litres of oil and grease is separated and sold off.

Sewage Treatment Plant (STP): for treatment of discharged human waste of 12 MLD (Million Litres per day) capacity. In STP approx. 3.6 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 purpose.

Recharge well

IETP

STP

Online monitoring of STP and IETPPerformance of STP and IETP pertaining to BOD, COD, pH, TSS and oil content is continuously 24x7, round the year.

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

Pollution control:

DLW boasts of a green area of 40% of its total area

lakh small & big trees

Release of CO2, CO, SO2,

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

Central and State Pollution Control Board

DLW has switched over to

“Vishwakarma Pooja”

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 compo

Debris are used to fill the low lying area.

100 kg/hour capacity incinerator

soaked jute, oil saw dust, paint

F) Tree plantation:

2017-18

5130 nos.

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

continuously monitored online , round the year.

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

boasts of a green area of 40% of its total area having

lakh small & big trees.

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


Central and State Pollution Control Board

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

“Vishwakarma Pooja” instead of clay idols.



municipality. Biodegradable waste is dumped in the pits for compo

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.

2018-19

5235 nos.

Online Monitoring STP & IETP

100 kg/hour capacity Incinerator

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having more than one

NO2 and particulate matters in flue gas through


for worship of Lord Vishwakarma on



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

to dispose off paint sludge, oil

19

nos.

Online Monitoring STP & IETP

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6. Certifications

DLW is an ISO 9001, ISO 14001 and OHSAS 18001 certified Organization covering

integrated Quality, Environment, and Health & Safety Management Systems. Our

efforts for a clean and green DLW ensure that the pollution levels of water, air,

exhaust-emissions and hazardous wastes are well within the limits.

Apart from above following certificates have also been obtained:

A) IRIS Certification

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

has opened on 28.01.2019 for certification (PDC for certificate – Sept.’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.

E) GreenCo Rating:

DLW certified with GreenCo Silver Rating under the GreenCo Green Company

Rating System. Certificate is valid for 3 years.

F) NABL Accreditation

DLW has also obtained NABL Accreditation for laboratory.

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7. Industrial Relations

A) Staff Council Meetings:

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

have been solved amicably.

Description 2017-18 2018-19

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 awards 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

2017-18 83 83 (100%) 6% less grievances received over previous year 2018-19 78 78 (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 furniture

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 facilitiesand Automatic Dish Washer

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

Auto coffee and tea dispensers in

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 lavatory blocks for hygienic and clean environment

Separate toilet facilities for ladies

, Toilet and Rest Rooms in factory premises including 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

Stainless steel working table

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

eparate toilet facilities for ladies have been constructed

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, Toilet and Rest Rooms in factory premises including

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

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

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 5780 retired employees & their family

members).

Cinema Club

Surya Sarovar

Facilities available:

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

Orthopaedics, ENT, Ophthalmology, Dentistry, Endoscopic surgery &

Physiotherapy. Diagnostics services, Pathology

Bio-Chemistry, X-ray

ECG from three private hospitals (namely Batra Hospital New Delhi, Medanta

Hsopital Gurgaon and Heritage Hsopital Varanasi) or so empanelled to provide

medical services.

ii. Mobile based medical registration

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

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

on mobiles through an Android app for staff of DLW.

D) Educational facilities

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

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

iii. Two Central Schools

iv. One Sr. Secondary School (Private).

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

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. Efforts are made

colony “Clean and Green

• Major roads have been resurfaced

13.45 km road repaired and resurfaced in current year as compare

year of 8.4 kms.

• SMS based complaint management systems

general electrical complaints of colony area. On an average 75 complaints per

day are attended.

• Illumination in colony area is excellent

Screenshot of DLW HMIS webpage

Glimpse of Lush Green Township

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


Physiotherapy. Diagnostics services, Pathology – Haematology &

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

from three private hospitals (namely Batra Hospital New Delhi, Medanta


medical registration: Facility to do medical registration,



on mobiles through an Android app for staff of DLW.

facilities:

One school up to Secondary Education, run by DLW administration where 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 & KV, Kanchanpur.

One Sr. Secondary School (Private).

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

including Garden

Maintenance, Roads, Streetlights,

3684 staff quarters for

employees and officers in a lush

green, pollution free township with more than

Efforts are made to keep the

Clean and Green”.

Major roads have been resurfaced. About

13.45 km road repaired and resurfaced in current year as compare

SMS based complaint management systems is working for redressal of


Illumination in colony area is excellent.

Screenshot of DLW HMIS webpage Screenshot of DLW HMIS Mobile App

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Glimpse of Lush Green Township

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


Haematology &

Ray, digital X-Ray &

from three private hospitals (namely Batra Hospital New Delhi, Medanta


: Facility to do medical registration,



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

Welfare Organization).

13.45 km road repaired and resurfaced in current year as compared to previous

for redressal of


Screenshot of DLW HMIS Mobile App

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Screenshot of DLW EMP Payroll Info

• More than 7600 nos LED tubelights, 50000 nos. LED bulbs distributed among

employees and 136 Solar lights have been fitted to promote energy

conservation.

• 90 CCTV Cameras have been provided in DLW campus for improved safety

and monitoring of unscrupulous activities.

• 34 nos. CCTV cameras have been installed in Central Hospital and Associated

Health Units.

• 3 baggage scanners have been installed at

Administrative Building.

• 08 nos. Automatic Number Plate Recording

(ANPR) cameras have been installed at

entrance/exit gate of DLW Premises.

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

Bal Niketan School

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Civil Complaint Management

System Mobile App

Another mobile App “Civil Complaint Management

System” for various civil related works for employees

has been launched

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

functioning within DLW campus.

SBI ATM BOB ATM

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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 mud court with Flood

light facility

One Handball mud ground

One Cricket ground with pavilion and 4 practice wicket

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:

Medals won in All India Railway

Championship during 2018-19:

(i) In Athletics, our two athletes won one

Silver & one Bronze Medal

(ii) The Wrestling team won 4 individual

medals (Gold – 1, Silver–1, Bronze –

2)

(iii) DLW Golf team secured Silver Medal

(iv) DLW Handball team secured Silver Medal

(v) DLW Basketball team secured IV position

(vi) DLW Volleyball team qualified for Quarter-final

International Size Standard Swimming Pool

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Medals/Participation in Sr. National Championship during 2018-19:

(i) Jyoti represented Indian Railways in 58th Sr. National Athletics Championship

held at Bhubneshwar in Sep’2018 and won Silver Medal in Hammer Throw

(ii) Gopal Yadav & Arjun Yadav represented Indian Railways Wrestling team in 63rd

Senior National Wrestling Championships held at Gonda, U.P. in Nov/ Dec’2018

(iii) Gopal Yadav & Arjun Yadav represented Indian Railways Wrestling team in 1st

Edition of the Traditional Senior Men Free Style National Wrestling

Championship at Pune in Dec’2018

(iv) Akash Bhashin represented Indian Railways Basketball team in 69th Senior

National Basketball Championships held at Bhavnagar, Gujarat in Jan’2019

(v) Ashish Yadav & Avinash Yadav represented Indian Railway Cricket team in Vijay

Hazare Trophy held at Banglore in the month of Sept./Oct. 2018

(vi) Ashish Yadav, Faiz Ahmad & Avinash Yadav represented Indian Railway Cricket

team in Ranji Trophy Matches held at various places in the month of Nov. 2018

to Jan.2019

(vii) Amit Kumar, Shushant Kumar Mishra & Sonu have been selected in Indian

Railways Handball team for participation in 47th Senior National Handball

Championship to be held held at Thiruvnnamalai from 23rd to 28th Feb’2019.

(viii) Inter-departmental Badminton, Basketball, Chess, Cricket, Handball and

Volleyball tournaments Successfully organized by DLWSA for the financial year

2018-19.

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10. Public Image & Brand Value

A) Initiatives taken:

i) Conversion of WDG3A Diesel Loco to WAGC3 Electric Loco:

DLW created HISTORY by converting 02 Diesel Locos to Electric Loco of 10,000 HP.

DLW achieved the milestone of manufacturing of 1st unit of prototype of WAGC3 loco

on 28th Feb’18 within 69 days from Design to roll out of 1st prototype unit. The second

unit of the conversion loco was ready on 30th March’19. The twin permanently

coulpled Co-Co loco WAGC3 was dispatched on 30th March’19. DLW has achieved

challenging target with the help from CLW and RDSO, under the guidance of Railway

Board. There is huge increase of 92% in traction HP (From 2x2612 HP to 2x5000

HP).

Oscillation and performance trials by RDSO completed on 28.08.18. CCRS inspection

done on 14.11.18. Railway Board sanction for running of the loco over Northern

Railway received on 27.11.18. Hon’ble PM flagged off 1st WAGC3 loco on

19.02.19 at DLW.

ii) Conversion of WDG4 Diesel Loco to WAG11 Electric Loco (3 Ø):

/ 32

After historical and world record conversion of 2 WDG3A locos to Twin Co-Co Electric

WAGC3 locomotive, DLW was given the responsibility of conversion of 2 WDG4 HHP

Diesel locomotives to Twin Co-Co WAG11 Three-phase Electric locomotive with the

target of turning out first prototype by 31st Aug’18. DLW achieved this challenging

target with the help from CLW and RDSO, under the guidance of Railway Board.

This was the first time in world history, that such a high capacity conversion was

successfully done. This conversion is also special because, traction power after

conversion has been up graded by 64%.

1stunit of Prototype WAG11 has been rolled out on 30.08.2018 and 2nd unit on

28.12.2018.

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Salient Features:

1 Type of Service Freight

2 Formation Twin Loco (Vestibuled)

3 Weight (Ton) 252T

4 Axle Load 21.0 T

5 Gear Ratio 17:90

6 Traction Horse Power (HP) 6000 x 2 = 12000 HP

(79% increase)

7 Max. Speed 105Kmph (Test speed 115 KMPH)

8 Diesel Alternator Set / Transformer 6531 KVA x 2

9 Traction Motor 12 No. (Type 3 phase I.M )

10 Maximum Tractive Effort 108 T

iii) Electric Loco:

DLW has successfully ramped up the electric loco

production. 02 locos manufactured in 2017. 25

locos manufactured in 2018. Further, DLW has

manufactured 145 locos in 2018-19.

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.

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

DLW has manufactured 25 locomotives equipped with LCVR system (24 HHP

locos + 01 WAP-7 loco) in 2018-19. 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.

Camera

Loco with LCVR System

Electric Loco with OHE

/ 32

v) 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 7

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.

RDSO awarded a consultancy contract to IIT/KGP for Noise source identification and

control in HHP Locomotives. IIT/KGP has prepared Acoustic Insulation scheme and

fitted in cabs of WDG4DLoco no. 70800 at DLW. IIT/KGP has carried out remaining

acoustic Insulation work at Kazipet shed on the loco. Sound Pressure Level

measurement has been done by IIT/KGP in consultation with RDSO on 26th-28th

Dec’2018. Final report is awaited from IIT/KGP.

vi) 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. is under

process. Total 3 locos has been dispatched in Fy 2018-19..

Sri Lanka Loco

vii) DUAL MODE LOCOMOTIVE

To cater the requirements of routes with both electrified and non

dual mode locomotive is being development by DLW. Dual

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 tr

Eleven uncommon items alongwith Underframe Asm & Main Integration kit have been

received at DLW. Manufacturing of the 1

turned out by Nov’19.

CONCEPTUAL DESIGN

viii) Fog Vision system

(FVS):

DLW manufactured first ever 02

HHP diesel locomotives equipped

with Fog Vision system (FVS) were

turned out on 13th Dec’2018 and

26th Dec’18 to Diesel loco shed/

TKD. Fog Vision System (FVS) is capable of assisting the loco pilot by enhancing

visibility under extreme/dense/mild fog conditions for operation of passenger and

freight trains at a higher speed. FVS fitted Loco is under trial

section from date 06.02.19.

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



Reduction in detention at traction change points.

ailability of locomotives.

Reduced man days for shunting.

Improved flexibility in last mile operation.

Increase throughput.

Electrified territory –

Excellent operational flexibility in case of natural calamities.

Higher reliability due to redundancy of traction power.


received at DLW. Manufacturing of the 1st Dual mode loco has started and likely to be

CONCEPTUAL DESIGN-DUAL MODE LOCOMOTIVE

system

DLW manufactured first ever 02

HHP diesel locomotives equipped

with Fog Vision system (FVS) were

Dec’2018 and

Dec’18 to Diesel loco shed/



freight trains at a higher speed. FVS fitted Loco is under trial between NDLS and JAT

section from date 06.02.19.

/ 32

electrified sections,

mode locomotive will be of



Excellent operational flexibility in case of natural calamities.


Dual mode loco has started and likely to be

DUAL MODE LOCOMOTIVE



between NDLS and JAT

/ 32

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 "DD Documentary of DLW" & “DLW Varanasi manufactures

energy efficient locomotives” are uploaded on YouTube.

During April’ 2018 to March’2019, following events of DLW were prominently

highlighted and covered by media thereby creating a positive public image:

a) New Production Record of Electric Locomotive: DLW set a new record of

manufacturing 323 locomotives during the financial year 2017-18. The most

notable factor is that out of 323 locomotives record 25 Electric Locomotives were

also manufactured & two locomotives converted from Diesel to Electric. From the

year 2018-19 to 2021-22, DLW has been given the production target of 998

Electric Locomotives set by Railway Board by influencing the work style of DLW.

It’s a breakthrough matter that DLW has also speedy manufactured 145 Electric

Locomotives this FY.

b) Best Production Unit Shield: DLW bagged

Best Production Unit Shield of Indian Railways

for the year 2017-18, the third consecutive year

DLW has won this shield.

c) Visit of Member/Traction: Shri Ghanshyam

Singh, Member/Traction, Railway Board held a

review meeting on 09th June, 2018. In the

review meeting, he obtained detailed

information about the manufacturing of electric

locomotives and conversion of diesel

locomotive to electric locomotive.

d) Visit of Hon’ble Prime Minister: Hon’ble

Prime Minister Shri Narendra Modi was visit in

Varanasi on 14th & 15th July, 2018 and 17th &

18th September, 2018. 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, Azamgarh and Mirzapur

district on 14th & 15th July, 2018 and Varanasi district on 17th & 18th September,

2018.

/ 32

e) Visit of DG/RS: Shri V.P.Pathak, Director General/RS, Railway Board held a

review meeting on 17th July, 2018.

f) Jagran Film Festival: Jagran Group organised

“Jagran Film Festival” at DLW Cinema Hall from

19th to 21st July, 2018. The renowned artists of

film industries were came on this occasion.

g) All India RPF Badminton Championship:

Under the auspices of DLW RPF All India RPF

(Gazetted and Non-Gazetted) Badminton

Championship was organised from 24th to 28th

July at Badminton Hall of DLW Officer's Club. 57

Officials & Jawans of Host NER (DLW, RPF

Affiliated) including SWR, NWR, WR, EcoR, SCR,

NR, NCR, CR and RPSF participated in this

championship. In this Championship, on the basis of maximum points South

Western Railway was declared Champion and Central Railway got runner-up.

h) Visit of Member/Traction: Shri Ghanshyam Singh, Member/Traction, Railway

Board held review/coordination meeting with Diesel Locomotive Works (DLW),

Varanasi, Chittaranjan Locomotive Works (CLW), Chittaranjan and Diesel Loco

Modernisation Works (DMW), Patiala at DLW on 16th August, 2018. In the

review/coordination meeting, he discussed in detail about the steps to be taken

for increasing in the production of Electric Locomotives.

i) Vishwakarma Pooja Celebrations: Historic

decision of DLW of using portraits of Lord

Vishwakarma in place of clay idols for pooja

purposes was taken into practice this year also at

Vishwakarma Poojnotsav held on 17th September,

2018 at DLW. Earlier clay idols used in Pooja were

immersed in River Ganges, causing water

pollution.

j) 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.

/ 32

k) Visit of Hon’ble Minister of Railways & Coal:

Shri Piyush Goyal, Hon’ble Minister of Railways

& Coal visited DLW on 23rd November, 2018.

Hon’ble MR expressed his happiness and

satisfaction at the ambition of team-DLW to give

world class locomotives to India and global

market. He was delighted to see the progress of

aggressive plans of DLW to ramp up production

of Electric locomotives.

l) Rail Mantri Rajbhasha Running Shield: DLW bagged Rail Mantri Rajbhasha

Running Shield for maximum work done in Rajbhasha Hindi on 11th December,

2018.

m) Visit of High-Level Delegation of Etihad

Rail, UAE: A high-level delegation of Etihad Rail,

United Arab Emirate comprising of Mr. Munsoor

Alam, Asset Manager Director along with Mr.

Mohammed Abdulla Al Shehni, Senior Engineer

Power System, Mr. Andries Petrus Laubscher,

Senior Manager Rolling Stock visited Diesel

Locomotive Works on 14th December. On this

occasion delegation members witness facilities in various shops they acquainted

themselves with the manufacturing process. They also discussed various technical

and commercial aspects with the concerned officers.

n) Visit of Member/Traction: Shri Ghan Shyam

Singh, Member/Traction, Railway Board flagged-

off DLW manufactured 100th Electric Locomotive

WAP7 “SHATAK” in a ceremony held at Diesel

Locomotive Works, Varanasi on 07th January,

2019 along with Smt. Rashmi Goel, General

Manager and seven DLW employees, who are

going to retire in January.

o) Visit of CRB: Shri Vinod Kumar Yadav,

Chairman, Railway Board visited DLW on 08th

February, 2019. In the presence of CRB, six

DLW employees, who are going to retire in

February, flagged-off DLW manufactured a 6000

HP Electric Locomotive ‘WAP7’ and a 3100 HP

Diesel Locomotive ‘WDG3A’ for dispatch to Non-

Railway Customer at DLW Loco Test Shop.

Earlier, CRB went round the New Block Shop, where he inspected the proposed

augmentation work for Electric Locomotive manufacture.

/ 32

p) Visit of Hon’ble Prime Minister: Shri

Narendra Modi, Hon’ble Prime Minister of India

flagged-off DLW manufactured first 10000 HP

Twin Co-Co Locomotive converted from Diesel

to Electric at Diesel Locomotive Works,

Varanasi on 19th February, 2019. Before

flagging-off, Hon’ble Prime Minister reviewed

the attractive exhibition & video film and

inspected the driver cab of above locomotive. On this occasion, Shri Ram Naik,

Hon’ble Governer of UP, Shri Yogi Adityanath, Chief Minister of UP, Shri Manoj

Sinha, Hon’ble Minister of State for Railways & Minister of State Communication

(I/C) and Dr. Mahendra Nath Pandey, Parliament Member, Chandauli were

present.

q) 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 2018-19 were:

Railway Week Exhibition from 15th to 17th April, 2018 in Bhopal.

MET+HTS-2018 from 27th to 29th September, 2018 in Mumbai.

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

Programme, till now total 521 local unemployed youths were trained.

/ 32

s) 6 new mobile apps:

According the target of the

Hon'ble Railway Minister,

DLW has made 5 Mobile

Application (Material Related,

Bill Payment, Outsider

Electricity Bills and Employee

Payroll) in the month of

April’2018 and also a Mobile

Application (DLWCMS- DLW Complaints Management System) for Quarter Holder

in the month of January’2019, 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.

t) 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 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.

u) Other Events : International Day of Yoga on 21st June, 2018, World

Environment Day on 05 June, 2018 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

/ 32

also on foreign shores. Despite adversities, DLW recently bagged orders for 14

WDG3A from NALCO Damanjodi, NTPC Ramagundam, Korbam Singrauli, Lara

Gadarwara & Kahalgaon, 09 WDS6ADT from RES/ RITES during FY 2018-19 and

10 nos. 3000 HP HHP based for Srilanka during FY 2017-18 (worth ₹149.94 Cr.)

Further, DLW is expecting orders for 7 WDS6ADT loco from SAIL/RSP, Bokaro &

RCF Mumbai, 07 WDG3A loco from HTPS/ Harduaganj, NTPC/ Talcher, NSPCL/

Bhilai and 05 nos. 3000 HP Cape Gauge (CG) AC-AC locos from Mozambique.

DLW has delivered 27 locomotives to NRCs including three 3000 HP locomotives

exported to Srilanka worth ₹ 151.15 Cr. in 2018-19. Apart from this, DLW has also

supplied locomotive spares to NRC worth ₹ 14.24 Cr.

The above have achieved by continuous interaction with prospective customers and

endeavouring to meet their expectations within overarching government

framework with backend support of production division. A rigorous follow-up with

NRCs by Marketing Division ensures redressel of requirements of our valued

customers.

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

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

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

179 192241

141 51

179

333

292

2016-17 2017-18 2018-19

Export

Domestic

₹ Crore

/ 32

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 and outside Institutional 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

/ 32

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

/ 32

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 (up to Mar’ 2019)

as compared to 2017-18 is as under, indicates increase in man-days by 6%.

Training

Imparted

2017-18 2018-19

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 & other courses

2163 514 2677 11535 7227 18762 2576 685 3261 13630 6258 19888

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.

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.

1610319888

2017-18 2018-19

Tra

inin

g M

an

Days

6% improvement in training man days

/ 32

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 “कौशल �वकास योजना” has been started and so far 521 local

youths have been trained free of cost in different trades viz Electrician, Welder, Carpenter, Fitter etc.

C. Other highlights and achievements:

97.68% (cumulative) capacity utilised till date

4026 DLW staff has been trained under ‘ स�म ’ scheme as directed by CRB

193 supervisors and technicians have been trained in 17 Special Conversion

courses of “Diesel to Electric” loco production

38 employees have been imparted through outside Institutional Training

3195 undergraduates engineering students have been given vocational/internship

training

TTC officers and staff along with trainees participate in cleanliness drive at their

own premises as a part of ‘�व�छ भारत अ�भयान’ on every Saturday

वष 2018-19 की मुख उपल धयां 1. production outturn · emergency fire exit...

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