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South Central Railway Carriage Workshop Lallaguda Brochure

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South Central Railway Carriage Workshop Lallaguda Brochure South Central Railway Carriage Workshop Lallaguda Brochure - 2020 1.0 General 1.1 संक्षिप्तइक्षिहास Brief History: The Carriage Workshop / Lallaguda was established in 1893 as the Locomotive, Carriage and Wagon Workshop of the Nizam State Railway (NSR). The Government of Hyderabad took over direct control of the Railways in 1930 and renamed it as the Nizam Guaranteed State Railways (NGSR). It is one of the oldest surviving examples of modern Industrial Architecture in the Twin Cities. It signaled the beginning of major industry in the state. A few structures in use today date from the time of the workshop’s initial commissioning. The precinct provides us with a glimpse of not only the industrial advances made over more than a century but is also a repository of heritages from a bygone era. Restored wagons, coaches and a variety of artifacts relating to railway history have been preserved and quite a few are displayed at the site. Notable among these one finds a meticulously restored coach of 1886 vintage. South Central Railway was carved out on 2nd October 1966, and Lallaguda Workshop went on to become a major workshop of the zone. It continued to be a composite workshop for MG/BG rolling stock till 1973. As a result of phasing out of steam locos, the Workshop took up POH of all types of BG coaches and hence rechristened as “Carriage Workshop” during 1997. Page 1 of 60 1.2 प्रमुखउपलक्षधियां Major milestones: 1893 Established as Loco, Carriage and Wagon workshops under “NIZAM’S GUARANTEED STATE RAILWAY”. 1951 Brought under Central Railway. 1966 Carved out as South Central Railway. 1975 POH of BG steam cranes. 1981 POH of AC coach. 1997 Rechristened as CARRIAGE WORKSHOP. 2000 Awarded ISO-9002: 1994 Certification. 2003 Commenced POH of DHMUs trailer cars. 2006 Commenced POH of EMU TCs and Tower wagons. 2007 Awarded ISO-9001: 2000 Certification. 2007 Commenced 18 months POH. 2008 Commenced IOH of bogies (9 months). 2009 Commenced Refurbishment of coaches. 2009 Commenced modernization of workshop (from Nov’09). 2011 Commenced POH of power cars of DHMU and DEMU. 2012 Awarded ISO 9001:2008 Certification. 2012 Commenced LHB Coach SS1 Schedule. 2013 Commenced LHB Coach SS2 Schedule. 2015 Commenced POH of EMU & MEMU Motor coach. 2015 Commenced SS1 of Double Decker coaches. 2015 Implemented WISE-II. 2016 Commencement of LHB Coach SS3 Schedule. 2016 Implemented IPAS. 2016 Accredited with 5S Workplace Management System (WMS). 2016 Accredited with IMS, Containing QMS (ISO 9001:2015); EMS (ISO 14001:2015); OSHAS (180001:2007) & EnMS (ISO 50001:2011). 2017 Awarded Green-Co Silver Rating by CII/Hyderabad. 2017 Accreditation of NABL certificate to CMT Laboratory. 2017 Received best innovation award for “Automated single car test rig”. 2018 Received Railway Minister Shield (sharing) for “Best Workshop over IR”. 2019 Received “Best Establishment Award” for imparting training to 550 Trade Apprentices for the year 2018-19. 2019 Received “Gold Prize” for Energy conservation in 2018-19 from “Her Excellency Tamilisai Soundararjan , Honorable Governor of Telangana on 20-12-19. 2020 Received Certificate of “Best Energy Efficient unit” from Confederation of Indian Industry in August 2020. Page 2 of 60 1.3 मु奍यक्षिशेषिाएं Salient features: 2. Total area of Workshop 13.97 hectares 3. Covered area 4.25 hectares Rail track length 8.25 kms 4. M&P 549 nos. 5. Railway quarters 584 nos. 6. WMS budget Grant 2020-21 Credits –322 Crores (Mech- 256.14 ; Elec – 65.86crores) Debits – 301.72crores (Mech – 240.67 ; Elec – 61.05) 7. Avg Monthly Target 2020-21 a) POH –133.64 VUs (RB) b) IOH of bogies – 230 nos c) IOH of Fiat Bogies (SS1)- 58 nos 8. Average power consumption/month 1.60 lakh units.(including Solar) 2020-21. 9. Manpower as on 01.01.2021. Sanctioned Actual Vacancies (Mech + Elec) 3256 2660 596 1.4 काययशालाकीिियमानगक्षिक्षिक्षियां Present activities of the Workshop: • POH of AC & Non AC BG ICF/RCF/BEML coaches. • POH of LHB Coaches i.e. SS-II and SS-III schedules • POH of Duronto (Hybrid) coaches • POH of DEMU Power &Trailer cars & SPART coaches • POH of EMU/MEMU coaches • POH of Tower cars • IOH of ICF conventional bogies for divisions. • IOH of FIAT bogies for SS-I schedule of LHB coaches • POH of Defence owned coaches. • Supply of wheel sets to divisions. • Fitment of Bio-toilet tanks on coaches. • Over hauling of DVs, BMBCs & other air brake components for division. • Nodal workshop for implementation of WISE-II • Chemical and Metallurgical testing/analysis of components. • Manufacturing of all types of locomotive filters at LOFP/SC. • Rail Bogie Karkhana/Yadgir : Manufacturing of FIAT bogie frames • Basic Training Centre offers a) Refresher courses to Artisan Staff b) Imparting training to Apprentices engaged against Apprentice Act, 1961 c) Skill development programmes. Page 3 of 60 1.5 संगठनचार्यOrganization chart: Sk. Salauddin AWM-I Sandeep Kumar WM/LGDS G. Seshadri AWM-II Prashant Kumar Dy.CME/LGDS [Vacant] K. Krishna PE/LGDS Chaitanya AWM-III N. Ganga Raju K. Srinivasa Rao Dy. CEE/LGDS ADEE Ch. Eswaraiah K. Thavare Naik Prasun Chakraborty Dy. CMM SMM/M&E CWM Y. V. S. Prakash Rao K.K. Subramani WAO AWAO R. Papa Rao ACMT S. Laxman Rao WPO S. Rabindranath Sabar Sr.DEN S. Dakshna Murthy AEME/LOFP S. V. S. Raju AWM/RBK/YG B. S. Sarswati IPF/RPF Page 4 of 60 1.6 लालागुडाकारखानेकालेआउर् Layout of LGD Workshop. Page 5 of 60 1.7 प्रमाणनCertifications Achieved: • 5S – Workplace Management System (WPS): 5S recertification done on Feb’20. Validity up to Feb’2023. • Integrated Management System (IMS): (Four International standards). Awarded to M/s.IR Class/ Secunderabad on 31.05.2020. Agreement to be signed, delayed due to COVID-19 pandemic. Firm yet to respond. • Green-Co rating system “Silver”Certificate awarded on 26.04.2017. Valid upto March’2020. Revaluation under process. • ISO 3834 – 2: 2005: (Quality requirements for fusion Welding of metallic materials) Certificate awarded on 26.04.2017 and valid upto 25-4-2020. Agreement for recertifcation to be issued to Firm. Firm yet to respond. • NABL Accreditation for CMT Lab: Certificate awarded on 06.10.2017 and recertified for another two years in Sept’19. Valid upto 5-10-2021 • LEAN SIX SIGMA Certification Certificate awarded on 30.01.2019 A one time certification. Page 6 of 60 2.0 क्षनष्पादन Performance: 2.1 POH Outturn - Target/Actuals (VUs): Target Actual Prop actual up to Oct'20 1669 1733 1734 1637 1583 1247 1331 1111 1111 2018-19 2019-20 2020-21 (up to Dec'20) Note: a)Target for 2020–21 is 1583 coaches as per HQrs and 1605 as per RB. b) In 20-21, actual outturn less due to lock down in April’20 and May’20. 2.2 Type wise outturn –last 3 years in (VUs) Type wise 2018-19 2019-20 2020-21 (up to Dec’20) Tar Actual Target Actual Annual HQ Annual Target Actual Target target as (upto (upto (RB) per arising Dec’20) Dec’20) AC coaches 300 326 324 312 288 288 200 200 Non AC 1008 1019 1080 1085 996 994 739 739 LHB 44 53 45 44 108 86 45 45 EMU/MEMU 82 101 101 65 76 74 54 54 ( incl of PC) DEMU 97 97 175 216 194 60 60 ( incl of PC) SPART 220 09 09 04 17 13 05 05 ( incl of PC) Tower car 16 12 12 06 08 08 08 Total 1637 1669 1776 1734 1605 1583 1111 1111 Page 7 of 60 2.3 Outturn of Power cars: EMU/ DEMU SPART Year MEMU 2017-18 26 47 6 2018-19 21 37 3 2019-20 21 40 7 2020-21 54 60 5 (up to Dec) 2.4 Ineffective Avg. Holding of coaches: Year Avg.holdings 2017-18 74.42 2018-19 79.98 2019-20 74.97 2020-21 57.39 (up to Dec) 2.5 Average Cycle Time (in working days): 18-19 19-20 20-21(up to Dec) 17.12 14.54 15.29 13.64 14.51 13.06 12.5 12.35 11.6 10.69 11.67 10.01 9.16 8.28 8.05 Non-AC AC LHB EMU DEMU 2.6 Average POH Cost/VU ( in Lakhs): 18-19 19-20 20-21 (Q.E.Dec'20) 23.15 19.15 18.95 13.93 14.32 14.52 12.14 11.27 11.79 12.18 9.91 10.81 Non-AC AC EMU DEMU Page 8 of 60 2.7 Average NTXR initial advice (in % age): 17-18 18-19 19-20 20-21(up to Dec) 2.04 1.90 1.81 1.50 % Initial advise Initial % 17-18 18-19 19-20 20-21(up to Dec) 2.8 Fitment of New Bio-Toilet tanks (No.of tanks): 17-18 18-19 19-20 20-21 ( up to Dec) 2339 1525 tanks 920 No.of 20 17-18 18-19 19-20 20-21 ( up to Dec) Note: Bio toilets have been provided on all eligible PCV coaches. Page 9 of 60 2.9 Scrap Disposal (in MT) (Mech. + Elect.): in MT Ferrous Non-Ferrous & others 6124 5003 1374 1315 593 337 18-19 19-20 2020-21(up to Dec) 2.10 Support to Divisions (in nos) 18-19 19-20 20-21 ( up to Dec) 2442 2460 2241 1953 1794 564 430 421 258 354 110 147 IOHed Bogie Fiat Bogies BMBC Wheels Page 10 of 60 2.11 Important modifications undertaken on coaches: S.N Item Cumulative so far (upto Dec’20) 1.
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