Magazine for the Partners Transmashholding Subway Carsofthe1930s Has Recreated Metrowagonmash Colossus Universal Industrial PLANT: KOLMNA

№ 4 09/2010 Magazine for the partners Transmashholding subway carsofthe1930s has recreated Metrowagonmash colossus Universal industrial PLANT: KOLMNA

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Moscow, Butyrsky Val st.,26,bld.1 [email protected]. Editorialofficeadress:127055, Editor K.Dorokhin,phone:(495)660-89-50, Magazine forpartnersofCJSC Transmashholding 14 Contents 12 Edition 999copies N. Belova,M.Fedorova E. Kozachenko, A. Severov, A. Omelchenko, Authors: К.Dorokhin,E.Bychkova, Universal undustrialcolossus Kolomna plant: Cover story Corporate news Moscow-area shipwrights T of NEVZelectriclocomotivesafter-salesservice Concept oftheinformationsupport T NEVZ youthprojects–goal-orientedwork Cooperation management:newapproaches Quality Innovations TVZ: implementationoftheIT-technologies Operation have beeninserviceofFinlandforalmost40years Novocherkassk Sr1electriclocomotives Holding abroad has recreatedsubwaycarsofthe1930s Metrowagonmash Exclusive echnologies raditions

Phone: (495)234-57-46 www.imars.ru M. Fedorova, V. Grebennikova Layout: JSCImarsGroup 14–15 20–21 18–19 16–17 12–13 22–23 4–11 2–3 24 22 transmashholding6 NEWS

One more subway cars producer established in Russia Oktyabrsky Electric Railway Novosibirsk subway. “Conclu- Director Anatoly Meshcherya- possess the whole range of Car Repair Plant (OEVRZ, is sion of the contract with the kov. According to his words special features. Under the a part of CJSC Transmash- Novosibirsk subway means “start of manufacture of the customer`s requirements they holding) has won the tender for that one more subway car new product opens brand new will be equipped with BARS the supply of the train set of 4 manufacturer has appeared in market perspectives for the automatic operation system; subway cars — 2 head cars Russia”, said the First Deputy plant”. traction equipment in the origi- and 2 intermediate cars for the of Transmashholding General Under the contract terms nal design. The saloon interior the train set should arrive to finishing will be executed of Novosibirsk till October 15. metal with powder painting not The customer will get the cars of plastic. model 81-714/717, which have Mastering of subway cars for many years made the basis production is a brand new ac- for production of the largest tivity for Oktyabrsky Plant. Russian subway cars produc- The main activity of the enter- er- Metrowagonmash plant. prise is heavy overhaul of pas- OEVRZ has mastered produc- senger locomotive-hauled tion, guided by the technical cars and electric train cars. documentation obtained from Since 2008 OEVRZ has also this enterprise. been carrying out operations The cars, which Oktyabr- on the repair of the rolling sky Plant will manufacture for equipment for the Moscow the citizens of Novosibirsk, will subway.

15 kV gas engine has been created at Kolomna Plant for the first time in Russia

CJSC Transmashholding to- currently purchased abroad. Different types of gas: natural, basis of vibration spectrum gether with the partners is mas- New gas motor 6GMG was associated, generator and ma- measuring and in case of tering production of the concep- created together with OJSC nure, can be used as fuel. Fol- knocking occurrence elimina tually new type of product — gas Kolomna Plant (a part of Trans- lowing the results of the com- ting it, up to the cylinder switch engines designated for genera- mashholding), Conver LLC, plex tests carried out at CJSC off. Inclusive of cogeneration tion of electric and heat energy CJSC Radugaenergo on the ba- Radugaenergo (Vladimir region), (generation of electric and heat at the base load, standby and sis of diesel D49 basic design. It the acceptance committee re energy) coefficient of efficiency emergency power plants. can be produced with 8, 12 and commended construction of the of the gas engine can reach Creation of the gas motor 16 cylinders depending on the pilot series of gas engines. 90”, the Chief Designer said. has a significant importance power required by the customer “The advantage of the new In the course of tests, eco- gas engine is high efficiency logical and vibroacoustic char- coefficient which is ensured by acteristics meeting the Rus- the original way of gas supply sian and European standards through quick-response sole- were achieved and that allows noid gas charging valves, indi- operating gas engines in the vidual for every cylinder”, said dwellings zones with minor ex- the Chief Designer for Ma- penses on noise insulation. chine Building of OJSC Kolom- The application of gas en- na Plant Valery Ryzhov. gines is economically effec- According to his words tive — estimated production such design significantly im- cost of electric power, generat- proves dynamic characteristics ed at the application of the gas of the engine, increases safety engine, makes less than 1 ruble of operation by means of elimi- per kilowatt that is four times nation of gas penetration into less than the existing rates. for meeting the market de- in the range of 800–2000 kV. the exhaust line. “Control sys- Gas engines can be applied mand for 800-2000 kV power Gas engine is a reciprocat- tem allows monitoring the op- both in the remote regions of local energy sources which are ing motor with electric ignition. eration of every cylinder on the the country and as local power

2 № 4 09/2010 NEWS sources in the industrially ad- increasing reliability and stabil- Potential customers of great social implication. It will vanced regions. Particularly ef- ity of power supply, reducing gas engines are the enter- allow keeping down the rates ficient is the application of gas emissions of harmful and pol- prises of gas, coal, energy growth and ensuring failure- engines in the areas where gas lution agents into the atmos- industries, fuel and power free operation of heating sys- is the main type of fuel. phere, raising the economical sector, military institutions, tems within winter season. According to the experts` efficiency of power supply. municipalities and other con- The pilot project with the ap- opinion, the implementation of Application of gas engines will sumers. plication of gas engines is gas engines into the country`s allow decreasing circuits` volt- Application of gas motors planned to be implemented in power grid will contribute to age during peak loads. in municipal engineering has a Kolomna.

Transmashholding is establishing locomotive corporate service system at the RZD network

CJSC Roslocomotive (Trans- fact that OJSC RZD, as a cus- morskaya station (Far East keep track of the performance mashholding affiliate company) tomer, pays for the actual op- railway), Kaliningrad station of its products in the real oper- and OJSC Russian Railways erating time of the locomo- (Kaliningrad railway), Kur- ating conditions, stated Viktor have signed a contract for the tives. This encourages the bakinskaya section (Moscow Ivanov, Deputy of Transmash- after-warranty service of loco- service center to continually railway), on the basis of the holding General Director for motives. The service will be maintain higher level of the Tuapse depot (Nothern Cau- Service Maintenance. Such carried out by the affiliate structure specially created by the holding — TMH-service LLC. Corporate service, established on the basis of the Bratsk locomotive repair depot will serve mainline electric freight AC locomotives, operating at the Eastern range of OJSC RZD (attached to the Vikhorevka depot). Moreover, TMH-service, as a contractor, was handed over the servicing of locomotives attached to the Nizhneudinsk depot. Transmashholding under- takes obligations of servicing not only the new locomotives which have been supplied to the Russian railways recently (E5K, 2ES5K, 3ES5K) but also electric locomotives produced at the Novocherkassk Electric Locomotive Plant (being a part stock mechanical availability casian railway) and also in the a monitoring within the whole of the company) in Soviet and also enables the holding new locomotive repair depot products` life cycle will allow years — series VL80 and specialists to define the sche Maksim Gorkiy (Volga main- introducing modifications to VL85. dule and volume of mainte- line). the future developments and The personnel which will nance service and repair of the In future there are plans to upgrading the existing machin- be involved into the corporate locomotives on their own. expand after-warranty service ery samples. The company an- service system completed The Bratsk locomotive re- on the whole spectrum of the ticipates that the new policy in special training (also at the lo- pair depot is not the only cen- manufactured products. the sphere of the after-warran- comotive producing plant); the tre for locomotive servicing. “With the introduction of ty product service will lead to employees obtained the rele- Currently an alternative is be- the corporate service network the cost-cutting of the rolling vant accreditation. ing considered of opening the holding will get an oppor- stock life cycle and increase of The special feature of the service centers on the basis of tunity of carrying out engineer- the economic return at its ope concluded agreement is in the locomotive depotes of Pri- ing developments monitoring, ration”.

№ 4 09/2010 3 COVER STORY KOLOMNA PLANT: Universal industrial colossus

Amand Egorovich Struve — the founder of the Kolomna Plant: «For the creation of such a plant unweary- ing and plodding efforts, patience and long-term experience are required... The most energetical as- pirations, work up a sweat, many concerns and efforts are put into it. The time the plant existed is the pledge of its future prosperity and development…»

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On the way of technical progress T he creation of the Kolomna Plant was caused by the intensive railroads construction in Russia in the second half of the XIX century. A military engineer Amand Struve, who won a contract for the construction of the bridge across the Oka river in Colomna, rented from the peas- ants of Bobrovo village 10 tithes and 315 fathoms of “unsettled land” and on Sep- tember 2(14), 1863 obtained a right to “carry out construction both industrial and manufacturing” on the rented land. Originally, the enterprise comprised of several ma- Kolomna Plant chining workshops and specialized in the production of bridges (railroad, pedestrian, In 1869 Kolomna Plant was one of the first in Russia for town transport) the metal work for which had been earlier purchased abroad. The to start manufacture of locomotives, mastered perfect examples are Palace and Liteyny their mass-production. Own design locomotives bridges in Saint-Petersburg, Borodinsky, were created. In 1871 the Emperor Alexander the II Krasnokholmsky, Moskvoretsky, Krymsky bridges in Moscow, the longest at that time approved the KMZ charter, in 1892 the enterprise was bridge across the Dnepr in Kiev. The plant transformed into “The Joint Stock Company of Kolomna developed at a quick pace. The need for the Machine-Building Plant”. Since 1878 river paddled railroad engineering grew with every introduced mainline. And already in 1865 pro- steamers, towing and passenger, steam schooners duction of various types of cars (total of 75 were built. thousand cars of different types were manufactured), field engines was launched, preparation for the construction of locomo- to Armand Struve and Kolomna Plant. Here Russia diesel and electric locomotives, was tives started. Amand Struve invited his also the first electric street cars for Kiev the first domestic enterprise to organize se- brother Gustav Struve as a companion, who were manufactured. ries manufacture of diesel locomotives (1933), headed the enterprise. In 1869 Kolomna In 1902 Kolomna Plant acquired a license produced within its history over 3 thousand Plant was one of the first in Russia to start for the production of diesel engines from diesel locomotives. In 1932 together with “Di- manufacture of locomotives, mastered their “The Russian Society of Diesel Engines” and namo” plant Kolomna Plant introduced the mass-production (mainline, industrial, nar- after a while became the largest Russian de- first Russian electric freight locomotive. row-gauge) and created locomotives of its own design. For 88 years of locomotive building at the Kolomna Plant over 10 300 Electric street car was firstly applied in Russia due locomotives of 200 types were produced. to Armand Struve. It was firstly manufactured by KMZ On November 5, 1871 the Emperor Ale for Kiev. xander the II approved the KMZ charter, in 1892 the enterprise was transformed into “The Joint Stock Company of Kolomna Ma- veloper and manufacturer of various purpose Practically from the first years of its op- chine-Building Plant”. Among the cofound- diesels (transport, industry, power engineer- eration Kolomna Plant was the supplier of ers was the merchant of the 1st guild Anton ing, military-industrial complex etc.). In 1907 products for the Military Department — nar- Ivanovich Lessing. the first world river motorship was construct- row-gauge steam engines, machine-gun Together with the locomotive building ed in Kolomna, in 1908 — four-stroke marine carts, pontoons for boat bridge across the shipbuilding was developed at the plant: since diesel and the first world marine double- Danube, airship hangar, armament trolleys, 1878 river paddled steamers, towing and screw motorship tanker for the transporta- ambulance cars, motorships “Kuban” and passenger, steam schooners were built. Total tion of petrol. Total of 85 motorships were “Terek”, even submarines. of 128 steam vessels were constructed. produced by the plant. With the beginning of the Great Patriotic Electric street car as a type of public Kolomna Plant was the first in the USSR War of 1941–1945 the major part of the transport was firstly applied in Russia due to master production of the revolutionary for plant was evacuated to Kirov where on

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Kolomna steam locomotives of the beginning of the XX century

a tight schedule production of military equipment was set up: tanks, “katusha” In the middle of 1950s Kolomna Plant mastered mine throwers, self-propelled mountings. production of diesel locomotives. TEZ diesel freight The employees, remained in Kolomna, car- locomotives under the drawings of the Kharkov Plant ried out repair of military equipment. Manu- facture of various types of armaments and named after Malyshev were massively manufactured munitions was established, construction of (812 units constructed), production of the new diesel traveling platforms for air defence guns was locomotives of own design was mastered. At the mastered, 2 armored trains were built. Moreover, during the war the plant execut- same period the first in the country gas turbine ed large orders of metallurgical complexes: locomotives G1 and GP1 were fabricated at the plant, manufactured coke pushers, equipment for works on the creation of the mobile power plants blast furnaces, hot-metal ladle cars, mine hoists, convertors. For the reconstruction were carried out. operations on the liberated territories diesel engines, spare parts for power plants were sively manufactured (812 units construct- In 1959 Kolomna Plant was appointed produced. ed), production of the new diesel locomo- the head enterprise for the development In the middle of 1950s with the cease tives of own design was mastered. At the and production of diesel passenger loco- of the steam locomotive building, Kolom- same period the first in the country gas motives. In 1960 manufacture of the TEP60 na Plant mastered production of diesel turbine locomotives G1 and GP1 were diesel passenger locomotives which were locomotives. TEZ diesel freight locomo- fabricated at the plant, works on the crea- in serial production till 1987 was launched. tives under the drawings of the Kharkov tion of the mobile power plants were car- Total of 1472 units of TEP60 were con- Plant named after Malyshev were mas- ried out. structed and some of them are still in oper-

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TRADITIONS OF QUALITY The products of the Kolomna Plant many times picked up the highest Rus- sian and international awards. In the pre-revolutionary period the enterprise had a status of “the Emperor`s plant”: at the All-Russian exhibitions in St- Petersburg in 1870, in Moscow in 1882, in Nizhny Novgorod in 1896 the plant products were awarded Coat of arms — the highest state award. At the World exhibition in Paris in 1900, at the international exhibitions in Milan in 1906, Bordeaux in 1907, Turin in 1911 the enterprise took the Gran Prix, at the international exhibition in Buenos Aires in 1910 — the DE GRAM PREMIO diploma. Moreover, at various international and Russian industrial exhibitions it won several gold and silver medals. In Soviet times Kolomna Plant was awarded three orders: the Order of Lenin (1939), the Red Banner of La- bour (1945), the Order of the October Revolution (1971). Currently Kolomna Machine-Building Plant also traditionally preserves the high-quality of production. Great attention is paid to both personnel development and equipment ca- pability of the facility.

TEP70BS diesel locomotive in operation ation. Within 1960–1968 new family of ma- unit were manufactured. One of the two ganizing of welding of huge and solid struc- rine diesels for the Navy (types D42 and diesel locomotives TEP80 constructed at tures, acquiring all types of metal-cutting D43) was introduced, moreover, engines the end of 1980s during trial runs for the equipment, providing assembly and com- type D42 acquired wide application not only first time in the world showed the speed of prehensive tests of produced goods. Ad- in military but also in civil shipbuilding. In 271 km/h. vanced methods of heat, chemical heat and the mid of the 60s a line of medium-speed During the economic crisis at the end of galvanic treatment found application at the four-stroke diesels D49 of modular design 1990s the work on the new equipment did facility. A system of strict control over the for diesel locomotive building, shipbuilding, not cease. The first domestic high-speed treatment and assembly procedures was power plants, large dump trucks etc. was AC locomotives EP200 of 8 000 kV were set up together with the comprehensive created. Total of about 40 thousand diesels designed and manufactured. Since 2000 testing of products. of various modifications were produced at production of modular portable power Developments of the designers, scien- the Kolomna Plant. plants has been mastered at the enterprise tific-research, manufacture of the first pilot Development and mastering of produc- and they are applied as the sources of self- products stipulate close cooperation of the tion of perspective diesel series D49 be- contained power supply for the enterprises designers, industrial engineers, production came the basis for the creation of the new of oil and gas extracting industries in the re- facility. generation of diesel locomotives. Series- mote Russian regions. This allows introducing new products at produced from 1987 to 2006 2 942 kV die- the high technical level and prepare their sel passenger mainline locomotives TEP 70 Manufacturing complex series production under tight schedule. carry out considerable part of passenger Traditionally all the products are manu- In the total volume of the plant`s pro- transportation on non-electrified sections of factured directly at the plant. Production of duction machining of parts, product assem- Russian railroads and the CIS countries. In such a diversity of goods required master- bly and testing makes 60–65. Only at the 1975–1977 two prototype models of diesel ing of all technological conversions: iron, main production facility about 2 thousand passenger locomotive TEP 75 of 6 hp in one steel and non-ferrous metals smelting, or- cutting machines are installed. Taking

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into account mass serial manufacture of the process requirements including the ap- gether with the product cost value and its diesel products, automatic and in-line sys- plication of non-destructive examination consumer appeal. tems with the application of special ma- method (gamma and X-ray flaw detection, Reconstruction of engineering and de- chines, CNC machines are operated in the ultrasonic testing, dye penetrant inspection signer basis is carried out at the plant, workshops, including “machining centre etc.). Production procedures imply suffi- “combined” technologies of design and module” type mainly of foreign producers. cient amount of various types of tests of production are being implemented which Product quality control system is intro- both single parts and units and products on allow avoiding extra costs and moving to a duced and applicated at the plant. It in- the whole. All bench testers and test instru- new level. Complex computerization is ex- cludes all the stages of the products life- ments pass recertification with the partici- ecuted and new information technologies cycle: development, manufacture, pance of the GosStandart representatives. covering the whole facility are introduced. operation. The specialists follow through fit- All series-produced goods have certificates In the list of new production methods is ting out of the production, including pre- of compliance. the implementation of the production tech- project scientific-research work, designing, nology of main and connecting-rod inserts production, testing, experimental develop- Not resting on laurels of diesel engines of CHN 26/26 dimension ment of the prototype models, technologi- In the modern conditions competition of of bimetallic Gliko band. Brand new pro- cal and organizational and material produc- any goods in the market comes to the com- duction methods of turbochargers, cylinder tion support work. petition of the technologies applied. Pre- caps and liners final machining on the mul- Methodic work on improving series cisely on the technological level are the tipurpose machining centers Hermle and products aimed at quality upgrading is car- possibilities of the implementation of the Traub have been introduced. ried out. Quality control is executed under designers` technical solutions defined to- Technologies of plasma-powder welding deposition of diesel engine valves are launched in the welding facility, metal-poly- All technological conversions are mastered for mer compounds for the formation of fixed diversified operation: iron, steel and non-ferrous metals joints and elimination of defects of ferrous smelting, welding of solid structures is arranged, and nonferrous castings are introduced in welding. all types of metal-cutting equipment are purchased, In forging shop the technology of crank- assembly and comprehensive tests of produced shaft hot forming with the unique method of goods are provided. A system of strict control over upset bending is applied. Production of bogie suspension springs with hot coiling the treatment and assembly procedures as well as method is set up. comprehensive testing of products was set up. In thermal shop processes of the work- piece normalization and improvement are mastered together with carburizing and ni- triding of various types of workpieces, thermal treatment of locomotive drive gear teeth surface with high-frequency currents. In order to increase lacquer coating operating life a new Helios company technology of locomotive painting was introduced. At the current stage of scientific development it is difficult to imagine designing of products and structures without CAD (computer-aided design) system. At the moment OJSC Kolomna Plant carries out designing of the new objects with the wide application of PCs, peripheral equipment and modern software. Currently the fleet of modern computers and servers numbers over 1700 items, the majority of them are united into local networks on functional basis. In the course of development of the new products, finishing of the manufactured ones and preparation of production, design-engineering divisions are actively applicating CAD of all levels and packages of engineering analysis. Equipment for metal laser cutting Within the framework of the implementation

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of the integrated production control system operations on the installation of the single information network which unites all the existing local networks and all the plant`s divisions are being completed at the enterprise. “Today there are no doubts that the progress is achieved only where they man- age to implement to the maximum modern information technologies. Symbiosis of technologies — information and manufacturing — allows attaining ultra-high quality, production level and processability”, be- lieves Vladimir Karpov, OJSC Kolomna Plant General Director.

Mastering in development The main areas of the Kolomna Plant activity are engineering design, industrial production and after-sales service of the mainline locomotives (passenger and diesel freight locomotives, electric passenger locomotives), diesel units (medium-speed engines and diesel electric-power generators for diesel locomotives, power plants and vessels). OJSC Kolomna Plant is a monop- olist in the Russian market of diesel passenger mainline locomotives. Its share in the market of diesels and diesel-generators makes 78, spare parts for diesels — 62. OJSC Kolomna Plant is the only Rus- sian producer of the diesel mainline passenger locomotives, creator of the first domestic prototypes of the mainline high-speed passenger AC locomotives EP 200, passenger DC locomotives EP2K, diesel freight locomotives 2ТE70. In 2002 modern 4000 hp diesel passenger locomotive ТEP70BS with the train cars power supply was developed and produced. The diesel locomotive is completed with the economy diesel engine type D49, In the diesel engine assembly shop modern microprocessor control and diagnostic system, air purification units of the original design and a range of other modifi- Product quality control system is introduced at cations is introduced. ТEP70BS has a mod- the plant. Fitting out of the production, designing, ular structure which is accepted as the ba- manufacture, testing, experimental development of sic one for the creation of the standard range of locomotives: 4000 hp diesel pas- the prototype models and material production support senger locomotive ТEP70U (without power work are carried out. supply), 8 160 hp diesel twin-unit freight locomotive 2ТE70 and 4 800 kV passenger DC locomotive EP2К. out passenger operations on the mainline 6 000 kV diesel twin-unit mainline freight lo- In 2006 series production of diesel pas- railways in Russia, Lithuania, Belorussia comotive 2ТE70. It is equipped with high- senger locomotives TEP70U and TEP70BS and Uzbekistan. efficiency diesel — generator, microproces- with 160 km/h (120 km/h) design speed was In 2004 the enterprise for the first time in sor control and diagnostics system of the set up. TEP70BS diesel locomotives carry Russia developed and manufactured a new diesel locomotive systems, conditions

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in the driver`s cabin are improved. The tion commutator motors of 4 800 kV hourly The Kolomna Plant engines are operat- new diesel freight locomotive 2ТE70 is des- capacity was manufactured. The machine ed in Germany, France, Bulgaria, China, ignated for the replacement of the diesel is designated for handling of passenger Egypt, Syria, Mongolia, India, Pakistan, in locomotives 2ТE116 and 2ТE10, the opera- trains on the electrified (3 kV DC current) Cuba, in the states of the former Soviet Un- tional life of which has ended, and com- sections of the Russian railroads, gauge ion and some others. pared to them, it has higher traction effort 1520. EP2K electric locomotive can also be In 2006 D49 locomotive diesels were that allows increasing the consist weight on operated in all the CIS countries. The new certified for the compliance with EURO IIIA lines with diesel traction, raising travel electric locomotive is destined for the re- environmental standards, which came into speed of the freight trains by 10–20 km/h, placement of the Czech locomotives ChS2 force in 2009. cutting down operating costs by decrea and ChS2T on the Russian railroads. 81 In 2004 the enterprise was the first in sing fuel and oil consumption and applica- electric locomotives EP2K are already oper- Russia to produce the cutting-edge fully au- tion of the microprocessor control and di- ated at the Western Siberian, Southern Ural tomatic electric power plant designated for agnostics system, improving working and Oktyabrskaya railroads. the emergency power supply of the Busher conditions of the locomotive crews. Setting Medium-speed diesel engines and die- nuclear power plant in Iran. in operation 2ТE70, able to run 6 000 ton sel-generators of the two power ranges OJSC Kolomna Plant is the supplier of trains, allows increasing railroads carrying ChN26/26(D49) and ChN30/38(D42), which diesel products for the Russian Navy. In capacity by hauling trains with diesel and are applied in diesel locomotive building, 2005–2006 a unique diesel-diesel unit electric traction without their rebuilding. The fixed and marine drilling rigs, mobile and DDA12000 for the main power plant of results of the 2ТE70 diesel locomotives op- modular portable power plants, as part of 24 000 hp total power for the corvette eration in difficult weather conditions in the marine diesel-generators are in production. project 20 380, the modern multipurpose Ulan-Ude depot confirm the compliance of Series-production engines type D49 are ship of the Russian Navy, was created. The 2ТE70 technical and operational character- manufactured in V-shaped design (8, 12 main electric power plants for the XXI cen- istics with modern requirements to diesel and 16 cylinders) and cover the power tury diesel electric submarines “Lada” and mainline freight locomotives. range from 588 to 4 412 kV. D42 engines “Amur” were produced. At the end of 2005 passenger electric are produced in lines (4, 6, 8 cylinders) of Together with the series products locomotive of DC current EP2K with trac- 450-1850 kV. manufacture works on the creation of the

Electric passenger locomotive of DC current EP2K

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Corvette of 20380 project with the Kolomna Plant power unit

Golden professionals possibility of the alternative fuel types ap- ods: trainings, business games, computer- Today OJSC Kolomna Plant staff plication. based education. The enterprise specialists makes over 6,5 thousand people. carry out teaching and consulting of the Among the plant`s specialists are: doc- The secret of leadership employees from other organizations in ac- tors and candidates of science, talented The enterprise cooperates with the edu- cordance with the license for the right of engineers, designers and technologists. cational institutions on the issues of the conducting educational activities. The plant`s employees were many times training of specialists of the professions the The system of social partnership is awarded state prizes and bonuses for plant requires, externships in the divisions actively developing, based on the collec- the creation of the new equipment and of the OJSC Kolomna Plant, distribution of tive contract between OJSC Kolomna mastering of series manufacture of the graduate students. Plant and the employees represented by new products. For the adaptation and integration of the Mechanical Engineers Trade Union the new employees in the team, a system of Committee. the entry traineeships for the young special- Guarantees in the sphere of the work new and upgrading of the perspective ists is functioning together with the system safety and social safety of the employees modifications of the diesel engines are be- of the young employees mentoring and a are being realized under the contract and ing carried out. Works on the construction School of the young supervisors and spe- the working and living conditions are being of the new D500К diesel which should be- cialists. The contests of professional skills improved. Medical and preventive treat- come the basis for the new series of multi- “Best in profession”, “Young supervisor” ment of the staff is arranged, rest and sani- purpose engines are executed. and also scientific and technical confer- tation of the employees and their children Priority tasks in the sphere of the new ences of the young specialists have be- are ensured. equipment creation are: the future increase come a good tradition. Solidarity of goals, values and interests, of the operating economy, decrease of The goal of preserving and increasing transfer of the accumulated knowledge and metal consumption, increase of reliability intellectual potential is successfully real- experience contribute to the intergenera- and motor capacity, improvement of envi- ized. In-plant training is arranged with the tional continuity of the Kolomna Plant em- ronmental characteristics, ensuring the application of the new active learning meth- ployees.

№ 4 09/2010 11 EXCLUSIVE Metrowagonmash has recreated subway cars of the 1930s

Since May 2010 a seven-car retro-train has been operating on the Sokolnicheskaya line of the Moscow subway. Produced by OJSC Metrowagonmash to commemorate the 75th subway anniversary, the train is the exact copy of the first train-set of the Moscow subway of 1934.

Recreated subway car of the 1930s. «Retro» project

etrowagonmash design office series-produced cars model 81-717.5М, car was in the fact that the applied materials started the preparation of the 81-714.5М was taken as a basis. Running of the interior on the one hand had to be in М technical documentation for gear, electric, pneumatic and brake equip- maximum conformity with the formerly used the future train-set of the “Ret- ment of retro-cars are the same as in the in the type “A” cars and on the other hand ro” project subway cars only in the begin- series rolling stock. Exterior design and in- comply with the effective requirements of ning of this year. Since the retro-train should terior finishing are maximum close to the the fire and public health codes. be operated with passengers in the stand- old cars designs. The difficulty in the elabo- Firstly, the design of the cushioned by mode of traffic schedule, design of the ration of the documentation for the “Retro” seats of the spring type had to be restored.

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Such seats existed in many types of sub- saloons with the wall lamps located in four The external design of the head cars is way cars for a long time up to the current rows on the side walls and on the ceiling. In maximum close to the design of the first series cars model 81-717.5М, 81-714.5М. type “A” cars domes of these lamps were of subway cars. The headlights are the same Design of the cushioned seats was re- glass which is not acceptable under the as on the old cars but completed with more stored but the materials applied – covering of modern safety requirements. The engineer- efficient xenon lamps. leatherette and fillings are of fire-resistant de- ing office developed the design of such At the body ends of the cars original sign. The color of seats of the retro-car com- lamps with the application of domes of fire- wooden hand-rails made of beech are plies with the materials of the interior finishing resistant polycarbonate with energy-saving mounted. of the “A” type cars. Cheek trimmings of the lamps fed by 80 V / 220 V 50Hz converter. Seven-car subway “Retro” train was sofas which separate the distance near the Details of the interior saloon finishing - win- constructed at Metrowagonmash at the end doors and seats are made of steel frame with dow casings and guard beads – were made of of April this year and delivered to the Mos- lining of the fiberglass panels. The most com- beech, as in the old cars. Fixings of the interior cow subway. In the beginning of May OJSC plex was the restoration of the finishing mate- finishing details – door sections, window friez- Metrowagonmash specialists conducted its rial- flexible paper-based laminate used in the es, air gratings, moulding fillets were made of tuning-up, inspection and running tests on

«Retro» car interior original cars. For the new cars to comply with aluminum alloys, as in the modern cars, but the line of the Moscow subway and then the modern fire safety regulations it was de- decorated with film coating imitating the wood passed it to the Moscow subway for opera- cided to apply fire-resistant glass-fiber plastic in the old cars. Hand-rails of the passenger sa- tion. with the embossing identical to the texture of loon are of the same design as in the “A” type On the day of the 75th anniversary of the embossing on the flexible paper-based cars of steel tubes with bichromated coating. the Moscow subway the “Retro” train took laminate in the cars of the 30s. Bodies of “Retro” cars are painted with mo on the first passengers and since then it is To make the new cars like the original dern polyurethane coloring agents of the same regularly operating on the Sokolnicheskaya ones it was necessary to equip passenger color as type “A” cars. line.

№ 4 09/2010 13 HOLDING ABROAD Novocherkassk Sr1 electric locomotives have been in service of Finland for almost 40 years

In Finland they know well about the Novocherkassk Electric Locomotive Plant which is a part of CJSC Transmashholding. The history of this cooperation reaches back to the 70s of the last century, when a serious task was set for the Soviet partner - to create an electric locomotive for the Finnish railroads.

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those years the Finnish Railroad Department In imposed severe requirements to the engineering level and quality of the locomotive. By the joint-efforts of the employees of the All-Union (now All-Russian) Scientific-Re- search and Design Institute of Electric Lo- comotive Building (VElNII) and NEVZ designers in 1971 a single-unit eight-wheel electric AC locomotive Sr1 was manufactured. The machine, which the Finns used to call “the Siberian wolf” (sipe rian susi), was designated for hauling of the freight and passenger trains. Its equipment has a high level of reliability during the operation at the height of up to 1200 m above sea level, sur- rounding air temperature variations from -40 to +40 degrees and humidity up to 90 . In 1973 the first four electric locomotives were delivered to Finland. Deliveries of Sr1 to the Finnish railroads were carried out Sr1 electric locomotive. Finland

prolongation of the Sr1 electric locomo- In was of interest due to the fact of application tives life cycle. of angled tie-rods for the transfer of longitudinal The cooperation with the Finns contin- forces between the bogy and bogies as well as frame- ues today. Currently 10 rotors of the Sr traction engines are being repaired at NEVZ, supported suspension of traction motors (of ChS2 the contract for 20 collector-shoe gears has type) — both were used on the domestic series been concluded, an order for 120 brackets locomotive for the first time. of traction engines brush holders has been received. In the second half of the year an order for repair of 8 stators and 8 traction till 1995. Within the whole supply history electric locomotives, heartily speak of the engine rotors will be received. Finland received 110 machines. cooperation with the Novocherkassk Elec- The service life of the electric locomo- Sr1 was the first electric locomotive on tric Locomotive Plant, are grateful for tive is almost 50 years! Not every machinery the Finnish railroads. The name for this series of locomotives can be decoded as Sаhkоveturi raskas — heavy electric loco- The world crisis had an impact on the Finnish motive. Its weight makes 84 tons. Length economy also. The Finnish railroads are over coupler pulling faces - 18,96 m. One- planning to extend the service life of the Sr1 hour rating -3 280 kV, continuous rating 3 100 kV. Design speed 140 km/h. The elec- electric locomotives till 2016-2018. And the NEVZ tric fixtures were supplied by the Finnish –produced electric locomotives are running company Strоmberg. from Vainikkala, a settlement, located almost All the 110 machines are in operation today and are not going to rest. One third at the Russian-Finnish border, to Helsinki. They of them have already passed the 6-million certainly make stops in the small cosy town Lahti mileage and continue to work. It is the evi- in the south of Finland which is considered to be dence of the design reliability and high- grade execution of the locomotive. Despite the heart of the country. They carry passengers the anecdotes of the Finns temperament, and cargo. they became the great fans of our machinery which they highly estimate. Specialists of the Finnish Locomotive Plant (Hyvinkaa), showing true attention to their orders of manufacturer can boast with such a quality where they carry out repairs of the Sr1 spare parts delivery for the repairs and characteristic of the products.

№ 4 09/2010 15 OPERATION TVZ: implementation of the IT-technologies

Severov Aleksandr Vasilievich, Head of the OJSC TVZ IT Department

ith the beginning of the Climatic Lavatories and filling XXI century the Tver Carriage equipment Power supply of storage-tank Doors Works started production of W Water supply the first cars fitted with the IT systems. Surely the ideas, studies and at- tempts had been 4–5 years earlier. But it was in 2001 that the first passenger cars with the speed of 200 km/h for the “Nevsky Express” train were produced. What was their difference from the usual parlor and compartment cars? For the first time a centralized system of diagnostics control and monitoring was in- Braking equipment troduced in the cars, which monitored the equipment condition, power supply data, climatic variables of the car. It controlled Fire alarm Warning system the lighting, the end users and the climatic Access control unit, maintaining the automatically set temperature in the car rooms. The system allowed to get the information from the converter and door controller. The data on the operation of all systems, of the events and faults was reflected on the display in the service facility. The system displayed on the screen the information on the next stop, speed, current time and date. The first experience showed that the centralized system of control and diagnos- Control of the axle-box tics has no future. It is not able to expand and reducing gear heating without the increase of the overall dimen- sions, complication of the software and re- Unified cars control system. Equipment components spectively constant increase of the hardware capacity. Then TVZ decided to unification of the communications protocol doors, climatic variables of the cars, power abandon the idea of the centralized system between the devices on the transport level supply data, condition of the cars fire alarm, of control and diagnostics and switch to the were solved. Various diagnostics and con- condition of the cars lavatory system and distributive system. The goal was to cover trol systems were implemented: for the car system of the axle-box heating. TCMS gave all the car systems with the monitoring, ex- and for the consist. the train master an opportunity to control pand the system diagnostic functions within In 2004 the “Burevestnik” train was doors (close, block), set the temperature the consist, minimize the control elements manufactured and it had a self-contained limit of the cars, report the detected param- of the car equipment, widen the control system of car/consist control and monitor- eters and information about the contingen- functions of the car/consist systems. The ing (TCMS) for that time, a passenger infor- cy cases to the marshalling points via GSM- problems of division of information net- mation system. TCMS allowed reflecting modem. In 2006 “Krasnaya Strela” train works on the local car and consist network, information on the condition of the cars was produced. The amount of monitored

16 № 4 09/2010 OPERATION

parameters in the cars, compared to “Bu- passenger train enables passengers to travel The train system apart from the train revestnik” train, increased almost twice and safely in the compartments with their lug- TCMS includes car information system, sat- the number of devices joined up into the gage. This system checks the passenger in ellite communication, satellite TV and GLO- single information space grew by 30. and gives an access to the compartment, al- NASS/GPS position control system. Since 2006 operations on the implemen- lows to engage its alarm. Information dis- What comes next? The Chief-Designer tation of the IT systems not only on the se- plays in the cars are divided into 3 types: Department and the IT Department are col- lected trains but on the series cars started. displays in compartments or in the common lectively developing and mastering IT tech- First, they were car models 61-4179, 61- premises of the sitting cars, displays in the nologies, applied in the cars. 4194. In 2008 IT systems were introduced in compartments for the disabled people, route One of the directions of development is the series cars of the new model lineup. boards. The information to the display is the switch from the Uniform car systems Practically, 2008 became the year of the se- passed on from the car TCMS. protocol to the General-purpose car sys- ries implementation of the IT systems. How can the modern appearance of the passenger car be described? Let`s start TVZ has produced cars equipped with the IT systems. with the doors. The cars are completed with Ideas and elaborations were first introduced in reclining side doors with both automatic 2001 for the «Nevsky Express» train. In future close and manual drive. The end doors are automatic. The door control is carried out by connection between the consist and the locomotive push-buttons outside and inside the car via is seen. It will allow exchanging data on the systems door control modules. Information on the operation and carry out visual communication. doors is reported from the doors monitoring box to the car TCMS. Then let`s look at the brake equipment. The cars are completed Almost all the car systems are united into tems protocol. Its distinguishing feature is with bolster and bolsterless bogies. Bol- the network via network adapter. All the in- that on the physical layer it is based on the sterless bogies are equipped with disc formation on the operation of the car equip- Ethernet and on the transport layer on TCP/ brakes with antiskid device. The informa- ment is reported to the car TCMS, processed IP — on the whole it all gives infinite possi- tion from this device it transmitted to the car there and is passed on to the train TCMS. All bilities of connecting new devices to the car TCMS. The car power supply is carried out the cars are united into the train network via TCMS, substantial increasing of the amount via the high-voltage power-line, from the network adapters. The train network is de- and speed of data transmission. Currently generator or from the peripheral device dur- signed on the basis of the Ethernet technol- part of the suppliers, including foreign ones, ing the stop in the depot. The cars are com- ogy on the physical layer and on the TCP/IP is switched on to this protocol. pleted with the following equipment: car on the program layer. The train TCMS gath- Another direction is the integration of electrical equipment control panel, conver ers all the information from the TCMS of all the car systems, the consist and in per- ter, equipment box, generator, battery. The cars and reflects it on the display in the HQ spective the train into the single OJSC TVZ information on the car power supply is re- car. The train TCMS allows controlling cli- and OJSC RZD information space. Current- ported to the car TCMS. mate, doors, starting up car equipment test- ly a system of data accumulation and trans- The climatic equipment is represented ing, sending running lines to the displays, fer is introduced, which is connected with by the three main systems: ventilation, con- information on the next stops. the OJSC TVZ information centre. This sys- ditioning and heating. Climate control in the In 2008 the work on the implementation tem allows transmitting any data on the op- car is possible both in manual and automatic of the wireless RF information communica- eration of the car systems, events and con- modes. Information on the operation of the tion system (BRISS) between cars was tingency cases. In 2011 connection of the climatic equipment, control modes, temper- completed. This work was started after an- OJSC RZD service centers to this system is atures is passed on to the car TCMS. The fire alyzing the operation of the train networks. planned. alarm is represented by the fire alarm system Due to the fact that the notion of the “con- In future we see the close connection with room sensors. The sensors determine stant formation trains” does not exist in between the consist and the locomotive. the level of smoke, dust, measure the tem- OJSC RZD, the cars are sorted in the con- Currently they are like two different worlds peratures. On the basis of this data a conclu- sist and this leads to the constant connec- connected at best with a 3 000 V power sion of the fire existence in this or that room tion and disconnection of the railway cou- line. These two worlds have something to is made as well as of the sensors` condition plings. Steady-state contact should be talk about, in particular, data on the opera- and terms of their maintenance inspection provided for the information channels, that tion of the brake equipment, condition of and service. Information on the operation of is not possible to ensure at constant con- the system of axle-box heating, operation the fire alarm, sensors` condition and fire is nection and disconnection and also at the of the power supply system, contingency reported to the car TCMS. Car compart- low qualification of the employees in the cases can be transferred. Information on ments are completed with LCD TVs, marshalling yards. Radio channel eliminates the start of braking action can be transmit- conductor`s compartment is equipped with this problem because it doesn’t depend on ted to the cars, in future — a picture from the car information system broadcasting the maintenance personnel. The cars are the head cam for the passengers etc. Visual video and audio data. The system of moni- automatically connected into the train net- communication can be arranged between toring, access control and security of the work by their coupling. the consist and locomotive teams.

№ 4 09/2010 17 инновации Quality management: new approaches

Evgeny Kozachenko, Head of the Technical Regulation, Tests and Quality Control Department, CJSC Transmashholding Since March 2010 CJSC Transmashholding has started procedures on the implementation of the new quality management tools at the Holding enterprises.

accordance with the provi- sions of the Concept “Flaw- In less quality. Strategy and road map”, developed by Alstom specialists, since March 2010 an implementation of procedures on the introduction of modern quality management tools such as 8D — Problem Solving; FMEA — Failure Mode and Effects Analysis; Statistical Proc- ess Control (SPC) and Poka Yoke (Mistake proofing) has begun. At the first stage a training on the application of the 8D tool — Problem Solving is carried out. This is the most simple and clear to the vast audience of the consumers quality management tool which does not require any extra specific knowledge, com- prehensible to everyone who intends to apply it, on the intuitive level. As additional tools during the 8D: brain storm, Pareto and Ishikawa Diagrams, Five Whys and PDCA cycle are used.

8 stages of solving 8D represents an effective tool of solving problems connected with quality of product manufacture. The basis of the tool are eight steps (stages) of problem solving: This quality tool has been successfully of the Quality Directorate of CJSC Trans- D1. Description of the problem/failure implemented for many years at the enter- mashholding Valogi Sukhinin. 30–40 of D2. Building of the team prises all around the world, in particular, it the training course consists of the theory D3. Problem evaluation is widely spread at the machine building insight and the rest of the time is devoted to D4. Defining of actions of the problem facilities. Efficiency of the 8D is associat- case studies solution. For this purpose the localization. Corrective actions to ed with the fact that is contains all the es- whole group (40–50 people) is divided into protect the customer sential steps of problem solving, starting sub-groups of 4–5 people who themselves D5. Identification of the root cause from the root cause analysis, eliminating set up a problem connected with the quality D6. Permanent corrective actions of the problem causes up to their preven- assurance, then with the help of the brain D7. Preventive actions tion. storm method and Pareto and Ishikawa dia- D8. Conclusions, closure The training course on the 8D tool is grams gradually implement all the 8 steps elaborated and carried out by the Director of the problem solving.

18 № 4 09/2010 инновации

ENTERPRIZE OF THE FIRST WAVE

NEVZ Production company LLC—is in accordance with ISO and certifica- project, of which the company ad- the enterprise of the so-called “first wave” tion audits are regularly carried out, ministration will await an effect and of certification on the compliance with the situation of the systems duplica- return of investments. At that, ex- IRIS. The enterprise`s choice is caused both tion and impossibility of using devel- penses on certification will most like- by the economic and organizational factors. oped documents on the processes and ly be recorded on the profit and loss Currently alongside with the absolute ad- procedures not stipulated in ISO account. vantages of the IRIS implementation we 9001 will occur at the preparation for 4. Suppliers of components do not have anticipate the following problem points: certification. a desire to implement IRIS Standard 1. Implementation of IRIS Standard re- 3. High cost of operations on the imple- and also carry out operations on the quires elaboration of the substantial mentation of IRIS Standard associ- improving of the existing quality amount of documents, including new ated firstly with the large amount of management system. Without this it enterprise standards and reconsidera- enterprises, remoteness of certifica- is impossible to implement IRIS at tion of the existing ones because: tion bodies and consulting companies TMH enterprises. • 14 procedures should be documented (for example, the average number of 5. Implementation of IRIS Standard will under IRIS (in ISO 9001 only 6) employees at the IRIS-certified Euro- require parallel implementation of • 19 required processes under IRIS — pean enterprise makes about 500 peo- quality management tools and inter- (in SO 9001 only 3). ple, NEVZ personnel capacity makes national standards: ISO 14001:2004, 2. As far as the enterprises have the sys- 8 500 people). IRIS implementation EN50126 RAMS, which will lead to tem of quality management certified will be a serious, costly investment rising project cost.

Up to now the 8D training has been car- pervising the issues of designing of the IRIS at the “pilot” enterprise (NEVZ Prod- ried out at 6 enterprises — NEVZ, BMZ, new rolling stock, then the training was uct company LLC). The requirements of MWM, TVZ, DMZ and Kolomna Plant. On carried out at NEVZ Product Company the introduction of IRIS at the railway engi- the whole over 200 people have passed the LLC and OJSC VElNII and then under the neering enterprises are specified in the Or- training course. At the end of August it is set schedule. der of the OJSC RZD President V.I. Yakun- planned to carry out training at OJSC DMZ in as of 17.09.2009 № 1943r “Of the and OJSC Kolomna Plant HC. Quality management: approval of the main guidelines of OJSC Since September 2010 a cycle of New approaches RZD policy in the field of strategic man- training seminars on the FMEA — Failure It also should be noted that CJSC agement of product, consumed by OJSC Mode and Effects Analysis has started. Transmashholding is executing preliminary RZD”. In the framework of this project im- Firstly, the training was completed by procedures on the implementation of the plementation, the following stages of op- CJSC Transmashholding specialists, su- International Railway Industry Standard — erations are stipulated (see the diagram).

2008–2009 2010 2011 2013–2014

Execution of the preliminary audit by Alstom for the further evaluation of volume of work. Drawing Choice of the consult- of business-plan of IRIS Getting acquainted with ing company. Submit- Certification of compli- implementation. TMH the main principles of ting an application for ance with IRIS Stand- administration is taking IRIS Standard certification. Actual ard a decision on the start of start of work. IRIS implementation. Carrying out training and implementation: 8D, FMEA, SPC

№ 4 09/2010 19 COOPERATION NEVZ youth projects – goal-oriented work

he V Youth Scientific and Technical Conference took place at Novocherkassk Elec- T tric Locomotive Plant. The projects presented on it are designated to improve production process and increase quality of manufactured products. The works were ranked basing on 6 criteria — priority of the presented issue, system application of analysis methods and problem identification, level of measures implementation, effectiveness in measurable units, freshness of ideas, personnel involvement, systematic data submittal and talent of presentation. The plant General Director and Presi- dent of the jury Sergey Podust noticed that every year the projects become more and more creative. Proactive life approach of the participants, their enthusiastic attitude to work, desire not only to introduce pro- posals but also to maintain their ideas — it all allows young professionals and workers putting their knowledge into use and finding innovative solutions. Projects-winners of the previous conferences are successfully The analysis of operational motions se- tions by 8,27 hours per month (99,24 hours implemented in the workshops and have quence in the nameplate area was executed per annum). real economic effect. All materials present- with identification of losses, resulting from ed at this conference fully comply with damage of special coating due to slipping these terms. of finished nameplates out of hands. II PRIZE The employees designed and manufac- Project of the welding and body tured a new tank for photosensitive emulsion builder workshop “Application of I PRIZE coating, implemented application of fixtures tools of the “Lean manufacturing” in Project of the plating workshop (clips) for dipping of plates into emulsion the hot bending area”, authors: “Elimination of harmful effect of which allows to eliminate nameplates` slip- А. Marchenko— deputy workshop hazardous chemical substances on ping and cut down the risk of chemical in- chief; Y. Zelenkov — job foreman; the employees and optimization of jures by contact with poisonous aggressive Е. Rossol — senior industrial engineer; motion in the nameplate production environment. Rearrangement of the area and О. Ukraintzev— manager of the lean area”, authers: А. Platonova — relocation of equipment, decreasing em- manufacturing department. industrial engineer, E. Tumanova — ployees motions, were executed. industrial engineer; О. Fedor Economic effect is represented in natu- chenko — workshop mechanic; ral value and amounts to motions reduction After the execution of the analysis of areas А. Batishev —maintenance foreman. by 49,6 km per month (595,9 km per an- in the blank production facility, a section of num), cutting down of time spend on mo- hot bending, having the largest amount of the

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intrashop motions, was chosen. Current state The rest five projects also were highly It is proposed to change the technology of traffic during the intrashop transfer of parts estimated. by implementation of the new tooling (speci in this section was analyzed. fication is handed out) which will allow cutting obvious losses and allotting time for TASS 10 TOOL SHOP configuration (or other nomenclature) machin- III PRIZE “Allocation of the chemical oxi- ing by one month on 65,7 hours (basing on Project of the fixing shop “Sys- dation section in the hardening area the plan of 45 current collectors monthly). tem approach to the optimization of of the tool shop”, author: Е. Sorok- production processes in the fixing in— deputy workshop chief. shop with the application of modern CHIEF WELDER DEPARTMENT industrial engineering methods”, au- “Optimization of bogie side frame thors: Н. Klochko — industrial engi- For cutting down costs on the tooling re- welding technology in the weld as- neer; V. Malenko— job foreman; М. pair, increase of its service life by 30, im- sembly shop”, authors: S. Poveren- Belokon — industrial engineer; Е. Fo- provement of quality of produced parts, it is niy — deputy chief welder; V. Muli- menko— senior industrial engineer; proposed to apply modern method of metal ka — industrial engineer; М. Kovalev — senior engineer of cer- chemical oxidation with changing of technol- Е. Melnikova —production manager. tification and quality management de- ogy and allocating production facility for partment; С. Gorbunov — manager of constructing optimal technological chain. the lean manufacturing department. Experimental work on the definition of economic effect of the welding rod ∅ 1,6 mm DEPARTMENT OF THE CHIEF instead of ∅ 2 mm application in the section It is planned to organize a new welding PROCESS ENGINEER of bogie frames production in the weld as- station for parts welding with gun welders “Project of the computerized re- sembly shop. The results showed that switch which will allow cutting down traffic under cording system of introducing tooling to ∅ 1,6 mm welding rod will cut total time of the plan of 2010 by 878,7 km per annum, limit for CNC machines”, author: welding and fettling operations at the manu- fully eliminating parts excess production and V.Samoylov — senior industrial engi- facture of bogie frames by 350,67 hours or organizing operation of the section based on neer. 43,83 shifts and reduce costs by 164,5 thou- the “Pull” principle, avoiding welding seam sand rubles (11,49). Annual economic ef- defect, associated with the equipment being fect for the whole enterprise will make not adapted to manufacture. Analysis of the current condition of the 1 369 573 rubles. In the area of six-spindle automatic ma- limit introducing process is carried out. The chines elements of “SMED” which allowed analysis showed, that in the stowage of sec- cutting down changeover time by 40 min- tion 7 of the electric machinery shop №2 “in- HARDWARE WORKSHOP utes (by 20) were implemented. Total active tooling” of various producers to total “Optimization of production proc- amount of the saved working time made amount of 2,685 mln rubles was accumulat- ess at the machine section”, authors: 996 hours per annum. ed. Implementation of this project will allow V. Kovtun — industrial engineer; In the area of big drilling and tread-cut- defining actual tool consumption, keeping А. Ozersky — deputy workshop chief; ting after relocation and final disposal of in- precise record of tool distribution, avoiding А. Shchurov — head of workshop tech- active equipment, segmentation of produc- excessive storage of tools and eliminating of nical office; Е. Kaygorodov — manager tion and optimization of material flow, 37 m2 possible equipment downtime, reducing ex- of the lean manufacturing department. of production space was cleared, handling penditure on purchase of costly tooling, ar- distance was cut down by 74 and han- ranging its distribution procedure. Moreover dling time reduced by 82. The cleared time spent by industrial engineers on inquir- Analysis of estimated time spent on the space was used for location of the end ies and updates of limit approval will be cut. changeover of lathe tools is carried out. products storage area which allowed dis- Self-centering chucks which allow cutting charging passages of the second aisle and changeover time are tested and proposed the area of big drilling, enabling segmenta- EXPERIMANTAL SHOP for application. Instead of tooling, produced tion of the A-product production process. “Optimization of machining of as- by the tool shop, more innovative Sandvik The third part of the project gives a re- sembly units for TASS 10 current col- cutting tool was offered. view of the implementation of statistic lector”, author: М. Tkachenko — chief Number of changeover operations is methods in section 1. Noticed, that within 2 on the electric machinery shop № 2. cut from 12 to 5 and changeover time of years about 30 parts were analyzed in the lathe tools is reduced by 33–50 at ma- workshop. 15 technological processes are chining of shafts, anchors, piston. Lathe brought to controlled condition. Due to car- Analysis of problems at the formation of productivity increased by 37–40 at ma- rying out statistic analysis, workshop loss- sets of assembly units for current collector chining of shafts, anchors, piston due to the es, resulting from defects in production, in the electronics workshop with the defini- application of the Sandvik equipment. Eco- within 1,5 years were cut, on the average, tion of customer demand for current collec- nomic effect of executed procedures made by 89,6 thousand rubles. tor components was executed. 163 thousand rubles.

№ 4 09/2010 21 TECHNOLOGIES Concept of the information support of NEVZ electric locomotives after-sales service

A.V. Omelchenko, Head of the Marketing Department

Novocherkassk Electric Locomotive Plant

ffective work of the Russian scheduled repairs. NEVZ traditionally car- and repair, together with the electric loco- railroad transportation is ries out after-sales service of manufactured motives operation manuals, set of photo- based, as in the whole world, products and recently it has been actively graphic sketches and depot set of drawings E on the reliability and safety of arranging servicing of its electric locomo- are supplied. the rolling stock operation. Timely and high- tives. In accordance with GOST 2.601-2006 grade servicing, in the established amount, Currently the plant produces electric lo- “Unified design documentation system. Op- ensures high operating availability of the comotives of new series – 2ES5К, E5К, erational documents” development of the electric locomotive, reduces need for un- 2ES4К, EP1М и EP1P. For their servicing whole range of operational documents is

22 № 4 09/2010 TECHNOLOGIES

PRELIMINARY CONTENT AND STAGES OF the SYSTEM CREATION 1. Systematization of the design documentation for all types of electric locomotives 2. Development of spare parts and assembly units list 3. Update of operation manual 4. Development of annex to operation manual – album with the description of main locomotive units and circuits 5. Manual on units assembly-disas- sembly 6. Manual on defects elimination 7. Manual on repairs 8. Service book

plementation should become an interactive electric locomotive inquiry and communications system. Training manuals This set of service documentation is firstly created in hard copy and then con- stipulated: spare parts and assembly units Since 2006 the enterprise has been exe- verted into electronic form. Also interactive list, spare parts and materials consumption cuting work on the establishment of the new circuit diagrams and pneumatic circuits, rates, wall technical charts etc. However on and improvement of the existing operational scanned depot electric locomotive dra the stage of the electric locomotive design- documentation. Electric locomotives of all wings set, pictures of units can come with ing, developer of the design documentation types are completed with produced laminat- the inquiry and communications system. doesn`t execute them in full. ed color circuit diagrams and pneumatic cir- Eventually the whole set of service docu- Plant`s specialists studied problems cuits (color charts), electric locomotive opera- mentation is integrated into electronic shell arising in operation, servicing and repair of tion manuals in soft form: CD-disks. with search functions which can be placed the new series electric locomotives. It was A training film “EP1М (P) electric loco- on Web-platform of Transmashholding In- revealed that the reasons of their occur- motive cabin arrangement” was produced. tranet-network. rence directly depend on the quality of de- Documentation is distributed to all RZD Implementation of the electric locomo- pot personnel training, availability of train- structures on commercial basis: railroad tive inquiry and communications system ing manuals and high-grade operational technical schools, training centers, techni- will allow the user having quick access to all documentation. cal schools, higher education institutions, necessary information on the design and centers of scientific-research information, operation of the electric locomotive and Directorates for the railroad material and carrying prompt and high-grade repair of NEW DOCUMENTATION technical supply, Roszheldorsnab, Zheldor- the rolling stock, cutting costs. The following training and opera- remmash enterprises. For training purposes creation of train- tional documentation is developed and But the future lies in the integrated and ing programs, guideline films, programs on issued typographically: multitask, block, electronic, interactive doc- test passing, electronic trainers, sets of wall • Operation manual for electric loco- umentation system on locomotives opera- technical charts and other training tools is motives EP1, EP1М(P), tion and repair. In search of such a system possible on the basis of inquiry and com- 2ES5К(3ES5К); the experience of domestic industrial enter- munications system. • Spare parts and assembly units list prises (aircraft, automotive, agricultural en- For the purpose of the implementation of for electric locomotives EP1, gineering), as well as foreign locomotive electric locomotive service information sup- EP1М(P), 2ES5К(3ES5К); building companies, was studied. In Russia ply concept and also in solving the financing • Wall technical charts on the de- they did not find functionally complete and issue, NEVZ Production company LLC needs sign of the electric locomotive finished electronic system which would the support of CJSC Transmashholding. In EP1М (P). cover all required issues of equipment op- case of positive decision, implementation of These are high-quality polygraphic eration, service and repair. the electric locomotive interactive inquiry publications made with the application A concept of information support of and communications system will contribute of 3D graphics. electric locomotives servicing has been de- to the arrangement of high-quality servicing veloped at the plant and the result of its im- of the new electric locomotives.

№ 4 09/2010 23 TRADITIONS Moscow-area shipwrights Kolomna Plant, located far from the sea, made a great impact into the development of the Russian shipbuilding. Currently over 700 engines of 25 modifications, produced at the Kolomna Plant, are in operation on the ships and vessels.

olomna shipbuilding started in 1878. Then the first river steam-boat “Kulebaki” was К manufactured at the plant, designated for the transportation of materials from Kulebakinsky Plant of Novgorod province. Because of the absence of the dock, the steam-boat was constructed in the plant facility and then carried on the roll- ers to the Moscow–river. In 1880 a steam- boat workshop, consisting of small shel- «Delo» motor vessel, produced at Kolomna Plant in the beginning of the XX century tered dock, was established. Firstly the plant build stem-boats for its own cargo was awarded the Guard title and the SCH- cialists called them “the black holes in the transportation but soon it started to receive 423 submarine conducted a complicated ocean”. orders for the ships of the same type from transfer along the Northern way to the Pa- The unique scientific — reseach ships outside. Kolomna steam-boats appeared cific ocean. The majority of the Soviet type “Yuri Gagarin”, antisubmarine cruisers on the Oka, Moscow, Volga, Nothern Dvina submarines, produced during the Great type “Moscow”, push boats “Marshal rivers and the Kaspian sea. Patriotic War 1941–1945, were equipped Blukher” and “Marshal Tukhachevsky” are Mastering of diesel engines produc- with the Kolomna engines. equipped with the Kolomna engines. tion in 1903 became a significant step for In the post-war years the Navy develop- Kolomna diesel engines as main ship the plant. Trials of the application of die- ment program made the Kolomna Plant engines were delivered to the USSR for the sel engines as main ones for the river and a creator and supplier of the combustion motor boats of different purposes, tank sea vessels started. In 1907 “Kolomna engines. In 1948 the plant started produc- ships, marine rescue tugs, tuna boats, fire diesel” paddle-tag was built under the ing diesel engines for the Volga navigation boats and were also exported to be applied project of the engineer Raymond A. Ko- company: for the towing motor vessels of on the war speed vessels. reyvo. Motor vessel — that started to be the “Krasnoye Sormovo” type and “Bolshaya OJSC Kolomna Plant has a license for the name for river and sea vessels with Volga” cargo motorships. development and production of marine die- diesel engines. By 1910 series production For many years the Kolomna Plant en- sel engines and diesel-generators for the of diesel engines was set up at the plant, gines were installed at submarines of 611, NAVY ships and also the Certificate of Rec- 57 of them were marine ones. Marine 613, 615, 633, 641, 629, 641B projects and ognition of the Russian River Register. diesel engine building at the Kolomna also at the tank ships and ship bases. The Recently the activities of the Kolomna Plant before the First World War was suc- border ship “Purga”, completed with the ar- Plant in the field of marine diesel engine cessfully developing both due to the sup- tillery, was also equipped with the Kolomna building, interrupted in 1990s, have been ply of diesel engines to the shipbuilding engines. This ship could navigate in the ice resumed. The plant is actively participating plants and construction of the motor ves- and was designated for fighting with jack- in the process of the marine fleet revival. sels at its own dock. Due to the necessity lighters near the Kamchatka shores. In Currently Kolomna Plant is taking part in of submarine fleet development during 1950-1960 the border ships were complet- several projects of the Russian Navy on the the First World War, designing of subma- ed with the Kolomna engines. construction of surface ships class “Cor- rine diesel engines was launched. In the In the beginning of the 70s the govern- vette”, “Frigate”, submarines of 636, 1650, 1930s 3 submarines of “Shchuka” type ment motor vessel “Russia” of the “river- 01570 projects were founded at the plant. In 1937 they sea” class was manufactured. During its whole history Kolomna Plant, were transported by the Oka river to Nizh- In the 1980s construction of engines for as the engine supplier closely connected ny Novgorod and completed at the Kras- the installation on submarines of 877 and with the Russian shipbuilding enterprises, noye Sormovo Plant. The SCH-421 sub- 636 projects — the most low-noise subma- has been honorably pursuing traditions of marine was decorated with the Order of rines in the world, was set up. Because of design and production of the high-grade the Red Banner in 1942, SCH-422 in 1943 the difficulty in detection, the western spe- and reliable marine engines.

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