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Standard Note for Production Unit Clw As on 31.03.20 STANDARD NOTE FOR PRODUCTION UNIT CLW AS ON 31.03.20 1 Contents SN CHAPTER PAGE NO. 1. INTRODUCTION 3 2. SALIENT FEATURES 10 3. ORGANISATIONAL CHART 12 4. PRODUCTION PERFORMANCE 14 4A. ELAAU/Dankuni 23 5. DESIGN&DEVELOPMENT INCLUDING TOT 25 6. QUALITY ASSURANCE 31 7. MARKETING INCLUDING EXPORT 36 8. STATUS OF M&P 39 8A. STEEL FOUNDRY 44 9. STAFF POSITION 49 10. UNIT COST OF THE PRODUCT 51 11. INDUSTRIAL SAFETY 57 12. FUTURE PLANS 56 13. OTHER ISSUES 58 2 1 INTRODUCTION 3 1. INTRODUCTION : 1.1 The Works and Administrative office of Chittaranjan Locomotive Works (CLW) are located at Chittaranjan, Distt. Paschim Barddhaman in West Bengal. In addition, it has a Stores Purchase office in Kolkata and inspection cells in New Delhi, Mumbai, Kolkata and Bangalore. 1.2 CLW is the first industrial gift to free India by the planners of the nation. The issue of setting up a locomotive manufacturing unit had been under active consideration of the Central legislature and, in the late thirties, a committee consisting of M/s Humphries and Srinivasan, was appointed to investigate into the possibility of establishing a locomotive manufacturing unit along its economic viability. The initial project at Chandmari, a place near Kanchrapara in the state of West Bengal, could not mature due to partition, which inevitably necessitated a change of site. The present site of Chittaranjan was selected after a fresh survey. Railway Board’s approval was obtained in the year 1947. The locoworks was initially established for production of 120 average sized Steam Locomotives along with the capacity to manufacture 50 spare boilers. Production of steam loco commenced on 26th January, 1950. The first President of India, Dr. Rajendra Prasad dedicated the first steam locomotive to the nation on 1st November, 1950; and on the same day the factory which was called Locomotive Manufacturing Works, was named after the great Patriot, Deshbandhu Chittaranjan Das. Production of Diesel Locomotive was taken up during 1968. After manufacturing 2351 Steam Locomotives of 5 types and 842 Diesel Locomotives of 7 types, production of Steam and Diesel Locos were discontinued from 1971-72 and 1993-94 respectively. Production of Electric Locomotives commenced in 1961. However after producing 4635 nos of Conventional Electric Locomotives ( DC, AC/DC and AC) of 14 variants, its production was discontinued from 2016-17. At present CLW is manufacturing only 3-phase Electric Locomotives. Upto 31.03.20, 7185 nos. of Electric Locomotives of different variants including 2550 nos of 3-phase Electric Locomotives have been produced by CLW. 1.3 CLW has augmented its production capacity for Electric Locos in phases besides absorbing 3-phase technology. It has also set up additional manufacturing facility at (ELAAU) Dankuni which started its production during March 2016. 1.4 Production of Traction Motors and control equipment commenced in April 1967. During the year 2019-20, upto 31.03.20, 2330 TMs were produced. 1.5 Steel Foundry was set up in F.Y. 1962-63 for production of steel castings for Steam Locomotives. It took up production of castings with the State of the Art technology provided M/S Rockwell International Corporation, USA in the year 1990-91. Steel Foundry/CLW has been accredited with CLASS- ‘A’ FOUNDRY certificate by RDSO on 9th August 2012. 1.6 CLW has in house facilities for machining and assembly of wheel sets, fabrication and machining bogies. The facilities include modern CNG machines, Plasma Cutting machines, Inert Gas Welding etc. 1.7 CLW has an exclusive Centre for Design and Development with CAD/CAM facilities. 1.8 There is a well-established quality assurance/inspection for incoming material and stage inspection and final inspection of the CLW manufactured items. 1.9 CLW has been sanctioned “Creation of additional facilities for enhancement of production capacity” . The major works are: 1.Additional Bay of Loco Fabrication &Loco Assembly Shops. 2.Extension of Traction Motor Shops. 3.Additional Machinery &plant, Tools, jigs &fixture. 4.control Information Management System. 5.Augmentation to various Ancillary Shops. 1.10 CLW has acquired ISO-14001 certificate both for its works and township for a neat and clean environment, ISO 9001:2008 certificate for Quality Management System and OHSAS 18001:2007 for occupational health and safety management system, 5S certification for Workplace Management System, ISO-3834-2:2005 (Manufacturing of Shell body of Electric Locomotive) certificate, ISO-50001 (Energy Management System) certificate for commitment for 4 reducing operating cost, significant financial savings through increased energy conservation & improved energy efficiency. ELAAU/Dankuni of CLW has acquired IMS certificate and 5S Certification. 1.11 Chittaranjan is a true example of Environment preservation and consciousness. Its lush green ambience talks of the efforts of the Administration as well as the residents of the township in the conservation of Environment, as well as using of all the existing natural resources in an eco-friendly manner. The concerted and unending efforts have been rewarded immensely by the World Environment Foundation; and the Golden Peacock award for Environment Management 2006 had been conferred to CLW on 9th June 2006. 1.12 CLW has complied fully with the provisions of the Industrial Safety Act, 1948. CLW in its safety policy aims to ensure 100% safety for all workers working in Chittaranjan Locomotive Works. CLW is the proud recipient of the Safety innovation award 2006. The award was conferred to CLW on 6th September, 2006 by the Safety and Quality forum of the Institute of Engineers (India). 1.13 During the F.Y. 2015-16, CLW has moved towards complete switchover to 3-phase and started producing only 3- phase locomotives from December 2015. 1.14 During the F.Y. 2015-16, CLW has completely switched over from GTO to IGBT technology. The 1st WAG-9 class freight loco No.31215 fitted with IGBT based Power Converter was commissioned on 18th December,2009. 1.15 The first electric locomotive WAP-7 type (no. 30277) with Head on Generation (HOG) scheme was flagged off on 30th June,2010. Up to Feb 2017, 46 such locomotives have been commissioned. TFP 7775 with double hotel load winding has been provided with Hotel Load Converter. The modified arrangement eliminates need of Autotransformer (used earlier to boost 750V to 960 V) and also reduces line to earth voltage from 2.4 kV to 750V, improving the overall reliability of HOG system. 1.16 High Reach Pantograph: Action has also been taken for provision of one High Reach Pantograph in locomotives required for Dedicated Freight Corridor. 1.17 Complete VCU redundancy: 5 locomotives have been turned out with feature of complete VCU redundancy for avoiding necessity of cab changing. 1.18 Indigenous Wheel Discs for WAP-5 locomotives have been developed by SAIL and complete requirement of material is sourced on SAIL Durgapur. 1.19 An automated new paint booth has been commissioned under AP-50 Project. In the paint booth, PU painting is being carried out in a controlled atmosphere. 1.20 CLW PRODUCES RECORD 431 ELECTRIC LOCOMOTIVES OF 2019-20: CLW has produced 431 locomotives in FY 2019-20. With this CLW has become largest manufacturer of locomotives in the world. In last FY 2018-19, CLW turned out 402 locomotives. CLW has been inducted in LIMCA BOOK OF RECORDS for producing 402 Locomotives during FY 2018-19. 1.21 PRODUCTION OF FIRST EVER 9000 HP LOCO: Under "Make in India" initiative, CLW has successfully produced IR's first 9000HP locomotive and turned out on 31.03.2019. With this IR joins the elite club of manufacturer capable of producing 9000HP locomotives. The locomotive will facilitate in improving through-put by delivering better acceleration reserve at higher balancing speed. 1.22 CLW WON FIRST PLACE IN SOLO DANCE FORM IN ALL INDIA RAILWAY CULTURAL COMPETITION 2019: In the All India Railway Cultural Competition held on 08-10 April, 2019 in DLW auditorium, Varanasi organised by North Eastern Railway , Varanasi Division , Km. Mousami Saha of Chittaranjan Locomotive Works (CLW) got First position in the Classical Solo Dance Recital. It is a matter of great pride for the CLW. 1.23 VENDORS MEET BY CLW: a. VENDORS MEET BY CLW AT KOLKATA ON 2ND MAY 2019; As per directives of Railway Board, a Vendors Meet was organized by Chittaranjan Locomotive Works (CLW) in association with ER, SER & METRO Rly in the Belvedere Club at Kolkata on 2nd May 2019. The objective was development of new vendors as well as 5 enhancing product range of existing vendors. High purchase value items as well as items for which very few approved sources are available were showcased. Emphasis was given on indigenization of imported items. b. QUARTERLY VENDORS MEET BY CLW: Quarterly Vendors Meet was organized by Chittaranjan Locomotive Works (CLW) in Administrative office meeting room at Chittaranjan on 5th Dec 2019 . The objective of this quarterly vendors meet was discussions on supplies of mechanical items to be made during December 2019 to March 2020 for steady production of locomotives. c. VENDOR MEET BY CLW: A vendor meet was organized by Chittaranjan locomotive Works (CLW) in Chittaranjan Club on 05.02.2020 for educating domestic vendors on facility of payment through “Letter of Credit” LOC mode. This vendor meet was organized jointly by the Stores deptt of Chittaranjan locomotive Works and State Bank of India. 1.24 SCOUTS & GUIDES PROVIDES DRINKING WATER AT CHITTARANJAN RAILWAY STATION: In this peak summer, the volunteers of Scouts & Guides team of CLW carried out a philanthropic services by providing drinking water to the passengers to all the trains stopping at Chittaranjan Railway station from 11.30 hrs to 16.00 hrs daily.
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