Magazine for the Partners

№ 5 12/2010 Magazine for the partners Transmashholding the leanproduction heading towards Manufacturing system: of successful operation O ENGINEERING PLANT: BRY ne and a half centuries ANSK

page 20 page 4 Issues of the magazine "Transmashholding. Magazine for the partners", 2010

Moscow, Butyrsky Val st,26,bld.1 [email protected]. Editorialofficeaddress:127055, Editor K.Dorokhin,phone:(495)660-89-50, Magazine forpartnersofCJSC Transmashholding 8 Contents 18 Edition 999copies I. Popov, M.Fedorova E. Zakharova,Bychkova, Y. Shusherova, Authors: К.Dorokhin,E.Belova,GaelDumetie, one andahalfcenturiesofsuccessfuloperation EngineeringPlant: Bryansk Cover story Corporate news 130th anniversary oftherailwaycarbuildingatBMZ 130th anniversary T heading towardstheleanproduction Manufacturing system: Cooperation KMT automaticandmanualdoors Products and environmentalsafety Rail busesstandforoperational Exclusive OEVRZ hascomedownunderground T andunification modularity Kolomna engines: Innovations from TEMshuntertothemainline2TE25AVityaz BMZ diesellocomotives: Operation echnologies raditions

Phone: (495)234-57-46 www.imars.ru (content, layout,production) The magazineispreparedbyJSCImarsGroup 14–15 20–23 18–19 16–17 12–13 8–11 4–7 2–3 24 12 Transmashh4 NEWS

TRANSMASHHOLDING WILL SUPPLY MAINLINE DIESEL LOCOMOTIVES AND SHUNTERS TO MONGOLIA

CJSC Transmashholding and ZhD, Mongolia) have signed the batch of the rolling stock. The 2ТE116UM diesel lo- JSC Ulan-Bator Railway (UB- contracts for the delivery of In accordance with the docu- comotive is a special modifica- ments UBZhD will be sup- tion of the 2ТE116U diesel lo- plied 35 mainline diesel comotive, in the best way freight locomotives 2ТE- adapted to the operation in 116UM and 13 diesel-loco- Mongolia conditions (high motive shunters ТEМ18DМ. dustiness, highland, consider- By the end of 2010 4 diesel able temperature differences). freight locomotives and 5 die- It is distinguished by the im- sel-locomotive shunters will proved performance values (in- be delivered to Mongolia. The creased capacity and hauling end of deliveries is expected power applied in the highland in June 2011. conditions), increased reliabili- The UBZhD traction rolling ty, fuel economy and also im- stock fleet almost completely proved working conditions of consists of the Soviet and Rus- the locomotive teams. sian diesel locomotives pro- UBZhD belongs to Mongo- duced in various years. By now lia and Russia on the principle the major part of the locomo- of equality. On the part of Rus- tives is worn out and needs re- sia the enterprise is managed placement. by OJSC Russian Railways.

RZD WILL GET NEW CARS FOR THE PERSONNEL TRAVEL IN FREIGHT TRAINS

The Tver Carriage Works will function of the compressed air guishing systems, ventilation cumulator, outer three-phase create the new accompanying supply at the unloading. and air conditioning systems, network and diesel driven gen- cars for the special rolling stock In accordance with the heating, water supply, erating house set. (rolling stock accompanying technical specification the new GLONASS/GPS and even work Specified lifetime of the new cars) for the needs of the OJSC cars will be equipped with ev- bench with jaws. The canteen cars is no less than 28 years. RZD. Such cars are designated erything required for the regular is expected to have the fridge, It is expected that the pro- for the travel of personnel ac- work and normal rest of the rail- microwave, electric hot plate, totype model of the new rolling companying freight and mainte- way men— sleeping compart- TV set. Power supply will be stock will appear in the begin- nance trains and also for the ments, canteen, wareroom, dri- conducted from the self –con- ning of 2011 and from the se drivers of the track machines. In er, shower and toilet. tained system which operation cond half of 2011 series pro- the ballast trains the accompa- The cars will be completed will be supported by the car duction of the new cars will nying cars will also perform the with fire alarm and fire-extin- generator, cadmium-nickel ac- start.

2 № 5 12/2010 NEWS BY 2021 KAZAKHSTAN WILL GET 295 ELeCTRIC LOCOMOTIVES

JSC Locomotive (subsidiary en- establishment of the electric lo- signed. On June 19 in the pres- concluded. On June 26 the first terprise of the JSC National comotives manufacturing facili- ence of the Russian and French stone was laid in the foundation company Kazakhstan Temir ty on the territory of the repub- Presidents an agreement for the of the future electric locomotive Zholy) and Electric Locomotive lic. Components for the electric set up of the joint-venture was assembly enterprise. Assembly Plant LLC (joint-ven- locomotives will be produced in ture between JSC NC КTZ, Kazakhstan and Russia. The CJSC Transmashholding and prototype models of electric lo- French company Alstom Trans- comotives should appear in port) have signed the agree- 2012, the first delivery is sched- ment for the delivery of passen- uled for 2013. ger and freight electric The electric locomotives locomotives to Astana. production establishment in Ka- According to the document zakhstan is the first foreign pro by 2021 Kazakhstan railways ject implemented within the will be supplied total of 295 lo- framework of the strategic part- comotives — 200 mainline die- nership of Transmashholding sel freight AC locomotives and Alstom Transport. A memo- KZ8A and 95 electric passenger randum stipulating delivery and AC locomotives KZ4A. More- location of electric locomotive over, the contract stipulates the manufacture in Kazakhstan was

TMH AND ALSTOM TRANSPORT DESIGN THE INNOVATIVE electric TRAIN FOR THE RUSSIAN RAILWAYS

The cars will have lighter electric train, since 2009 the weight compared to the exist- partners have been developing ing ones which alongside with dual-system electric passen- the application of the asyn- ger locomotive EP20 and chronous drive will ensure mainline electric freight AC lo- higher energy efficiency of the comotive 2EC5. new train. Special attention is Currently Transmashhol paid to the development of the ding is absolutely domineering conceptually new exterior and in the Russian market of the interior design. The electric multiple-unit rolling stock. An- train will be completed with the nually Demikhovsky Engineer- places for the travel of disabled ing Plant, being a part of the persons in the wheel chairs company, produces several and also devices ensuring their hundreds of electric train cars. comfortable boarding and de- In 2009 the holding sold 569

Sketch by Zaur Khalilov training on high and low plat- units of the rolling stock of this forms. type; the plan for 2010 is 630 CJSC Transmashholding to- will make 40 years. The con- The prototype model of units. The current product port- gether with its partner - French struction will probably include ED10 should appear in 2012. folio of the company includes company Alstom Transport the modern asynchronous The train is designed as a basic DC electric trains ED4M and AC started design of the brand traction drive, new bogies en- model which will allow creating electric trains ED9M, high-com- new electric train ED10. suring higher smoothness of new modifications in future. fort local transit trains ED4MK The new electric train is de- movement and decrease of the The project on the construction and ED9MK, DC electric train signed to operate at the speed impact on the track, modular of ED10 is implemented within for intermodal transportation of up to 160 km/h, it can con- cabin. The new train will be the framework of the program ED4MKM-AERO. Establish- sist of 4-12 cars, operate at the equipped with the passive re- of strategic partnership of the ment and mastering of the inno- multiple-unit system. Bodies straint system. ED10 will be Russian and French compa- vative train production should will be will be made with the able to operate on the lines nies by the joint engineering ensure Transmashholding`s application of the corrosion- with both high and low plat- company Rail Transport Tech- leadership in this market for proof steels, their service life forms. nologies. Alongside with the many years ahead.

№ 5 12/2010 3 Cover story BRYANSK ENGINEERING PLANT: one and a half centuries of successful operation

Bryansk Engineering Plant, being a part of CJSC Transmashholding, is the oldest Russian enterprise and one of the largest in the market of the transport machine building. Currently the plant is developing and produ cing mainline diesel locomotives and diesel locomotive shunters, freight cars of various types and modifica tions, marine diesels.

2TE25K diesel locomotive Peresvet. Production

ryansk Engineering Plant has the establishment of the joint-stock com- Danube, barges and steam-boats, freight been sustainably staying up pany. two-axle cars and platforms, railroad tank in the industrial market for al- The first products of the plant were iron cars. In 1880 the plant was producing 30 B most one and a half centu- rails and rail fastenings. In 1875 the manu- of all Russian steel and by 1911 33 out of 49 ries. The first shareholders — merchant facture of more complicated products start- Russian railroads were railed with the rails Petr Gubonin and collegiate assessor Vik- ed- iron bridges and parts for them. Under of the Bryansk Engineering Plant. tor Golubev who founded the enterprise in the order of the Ministry of Railway Trans- The important stage of the plant`s de- 1873 by the name itself defined its future port the plant constructed sections for the velopment became the order of the Ministry diversification and strive for meeting the 366-meter bridge across the river Dnieper, of Railway Transport obtained in 1890 for demand of the thriving railroad building. 1590-meter bridge across the Amu-Darya, the construction of the four-axle freight “Bryansk rail rolling, ironworking and me- landing stages for the Bryansk (now Kiev) steam locomotives of “Compound” type chanical plant for iron smelting, iron and railway station in Moscow and Warsaw rail- (where the steam did work at expansion steel manufacture and production of arti- way station in Saint Petersburg. In the list of twice: first in the high-pressure cylinder and cles for sale out of them» that was the the products during the first decade of the then in the low-pressure cylinder) for the name of the plant in the imperial permit of plant`s operation there were iron pontoons South-Western Railroad. Since then, the the Russian emperor Alexander the II for for throwing of the bridge across the river production of the steam locomotives be-

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came one of the primary activities of the In 1929 BMZ launched production of the economic crisis of 2009 the demand for enterprise. Moreover, from 1945 to 1956 four-axle 50 ton covered freight cars of the the marine diesels declined. However, a the plant was called Bryansk Locomotive riveted structure based on the method of spectrum of measures was taken to pre- Works. uninterrupted installation of pre-assembled serve the unique and the only Russian pro- In 1882, only after nine years since its units, developed as per the project of engi- duction including the capacity utilization foundation, the plant presented its prod- neer A. Merzhanov. In 1932 the plant was with the non-core orders. ucts at the All-Russian Industrial Exhibition the first in Russia to cast the tireless chilled In difficult times of the first Soviet re- in Moscow. Following its results the enter- wheels which were previously delivered forms the plant not only preserved its per- prise obtained the right to put the state from abroad. In 1937 under the personal sonnel and production but strived for devel- Coat of Arms on its products. At the same guidance of the academic E. Paton auto- opment. In 1990-2002 the prototype model time the plant masters tied the Bessemer matic welding under his method was imple- of the DB46 marine diesel was created; the rail in a knot without making any fractures mented at the plant. In 1958 the plant spe- prototype of the two-compartment rail- in it. cialists in cooperation with the scientists mounted refrigerator was produced; the In 1988, for the first time in Russia, the from the Bryansk Institute of Transport Ma- prototype of the NA-34 turbo-compressor plant mastered manufacture of the steel chine Building designed and manufactured which was previously imported was de- cast wheels for steam locomotives and cars the first in the country gas turbine with 3 signed under the МАN Diesel license; the instead of welded, produced manually by 550 hp capacity for the gas turbine locomo- prototype models of the coke-quenching forging. In 1892 the first OD series steam tive. In 1973 the plant`s specialists together car and electric scales car EVV-40B were locomotive with steel wheels was produced with the Kiev Electric Welding Institute fabricated. As a result the plant got the sig- and it became the best achievement of named after Paton developed the method nificant international awards — the prize transport machine building of the end of XIX of cast crank production with the method of "For the Commercial Prestige" and the century not only in Russia but in the whole electroslag refining and for the first time in "Torch of Birmingham". world. the world made the prototype crankshaft. In The big gold medal, the highest award 1986 BMZ obtained the task for the devel- TECHNICAL UPGRADE of the Omsk exhibition in 1905, was pre- opment and manufacture of the first in the In October 2003 BMZ became a part of sented to the cast-iron pipes produced at country rail-grinding complex. In October CJSC Transmashholding and this event the Bryansk Engineering Plant. Many ex- 1980 for the contribution into the develop- inaugurated the start of the enterprise`s re- amples can serve as a proof of the ment of international trade and economic vival. In 2005 production of locomotives enterprise`s diversification and its orienta- cooperation the plant was awarded the in- and cars increased more than twice, sala- tion on the market and national industry de- ternational prize “Golden Mercury”. ries started to grow and the problem of the mands, ability of reorganizing production In 1959 Bryansk Engineering Plant star lack of the workers of various qualifications promptly and efficiently. Thus, at different ted construction of the diesel production fa- arose at the plant. Previously launched op- times the plant manufactured agricultural cility with the area of 52 000 m2. In two years, erations on the perspective projects contin- products (ploughs, seeders), military equip- in 1962, under the license of the Danish ued and new activities appeared. ment (above all artillery projectiles and also company Burmeister and Wain the first ma- Today Bryansk Engineering Plant is one indent carts, siege gun mounts, portable rine diesel was produced. Today this diesel of the largest transport machine building forge shops). In 1919 the plant gained the manufacturing facility is the only one in Rus- enterprises in Russia. The plant occupies a status of the main armoured trains base of sia to produce slow-speed engines for ma- territory of 214 ha. BMZ develops and man- the Workers` and Peasants` Red Army. rine vessels. In 1980 the DB10 engine of the ufactures mainline locomotives and shunt- Cranes and lifting machines, accumulator in-house manufacture was created which al- ers, freight hopper-shaped cars, marine trains, railmotor cars, steam turbines, diesel lowed reducing the license fee. Over 1000 engines and other products. power plants, refrigerator sections and ma- marine diesels have been manufactured. The majority of the plant`s metal struc- rine engines were produced here. The 1000th was triumphantly handed over to tures are in-house produced. 600 enterpris- In June 1911 the French National Office the longtime partner of the enterprise — es are among BMZ partners. They deliver of the Industrial Enterprises issued a patent Murmansk Shipping Company. rolled metal products, electric fixtures, vari- № 429 for the design of the composite steel The vessels with BMZ engines mounted ous materials, tooling, materials for mainte- casting method to the plant. This method on the tankers, bulkers, dry-cargo ships, re- nance needs. was patented in Belgium, England, Italy, search vessels fly the flags of dozens of The necessity of the rolling stock re- Hungary, USA, Germany, Sweden, Spain, countries. The first motor vessel with BMZ newal which was specified as one of the Canada, Luxembourg and Japan. The au- diesel was called Boris Butoma. Afterwards strategic objectives by OJSC RZD imposes thor of the invention was the chief plant`s the motor vessels which obtained the the new operation algorithm on the produ metallurgist engineer Alexander Rozhkov. names connected with the plant were pro- cers. It is not that just many electric loco- In a year, in 1912, the committee of engi- duced — Bezhitsa and Bryansk Machine motives and cars are required. First of all, neers of the French government railroads Builder. The development of engine build- high-grade locomotives and cars with long noticed that “Bryansk Plant was on the ing despite of the violent decline in demand operating life are required. The BMZ team is same level with the best and most out- for the marine engines is not ceasing. In aiming at such a result of work. Challenges standing locomotive works of the Western 2007 a license agreement with the Finnish are met with the help of the good produc- Europe”. company Wartsila was concluded. During tion facilities including own metallurgi-

№ 5 12/2010 5 Cover story

In the BMZ workshop cal production and own blanking facility re- 900 (Germany) with the imbedded measu database in online-mode with the possibili- cently renewed by the modern metal-cutting ring system for ring gears and pinions con- ty of controlling the whole chain of the in- equipment: plasma cutting Cristal ma- trol has been launched. Further purchase ventories movement. This will allow in- chines, MAXIMA 3020 gate shears. and implementation of advanced CNC gear creasing control, efficiency and accuracy of The plant is fitting production for the production machinery (on the operations of the information on the inventories move- manufacture of mainline diesel freight loco- turning, milling of the gear tooth, thermal ment. motives with asynchronous drive model treatment of the ring gears with the cemen- Optical carriers were laid, computing 2TE25А. Certain reconfiguration and rear- tation method etc.) are planned. machinery purchased in order for every rangement of the plant`s areas have been For the manufacture of the basic parts shop to get access to the common data- carried out. Specialized shops and areas of the diesel locomotives vertical machining base. are set up anew. In the course of the prepa- center MCFV1680 (Czech Republic) has ration of manufacture of mainline locomo- been purchased and is operating. Single- BMZ MODERN PRODUCTS tives 835 units of jigs, benches, fixtures, upright milling machine FR-10.000 by SO- Within the last two years over 30 types tooling have been already produced, design LARUCE is being mounted for the machin- of series manufacturing products and arti- documentation has been worked out in- ing of the diesel locomotive bogie frames. cles of the new machinery were certified at cluding technical processes, cutting charts, Whereas the plant`s history makes one BMZ. This year certificates of conformity control software for CNC machines. and a half centuries, it has always been and were obtained for the mainline diesel loco- Metal-cutting, forge-and-press, lifting, is remaining a modern enterprise first of all motives ТEМ18DМ, hopper-cars models wood-working and foundry equipment have because it is constantly applying innova- 19-3116 and 19-3116-04, air reservoirs been purchased and is being mounted. The tions. In 1962 BMZ was one of the first in type R7-78, R7-135 for the cars automatic enterprise`s machinery counts already 2 the heavy engineering industry (in Soviet brakes, horns of the coupling devices, cast 286 units of equipment, 980 of them are times the plant was one of the enterprises disk wheel centers. metal-cutting equipment. Implementation of the Ministry of Heavy Engineering) to put Plans of the enterprise`s technical up- of the brand new, modern, effective tech- in operation Minsk–1 computing machine grade are targeted at the increase of the nologies is continuing. Thus, for example, and create a data-processing centre. And in production technical level by means of the automatic welding of the longitudinal 1970 CAM system ASUP-BMZ was put in implementation of the cutting-edge equip- beams of the main frames is performed on operation. Then the computer-aided design ment, technology and project management. the Fronius machine (Austria) under the system (CAD system) was implemented. Intensification of production, increase of Time-Twin technology (effective technology Today all the engineering departments are production facilities, improvement of prod- for the increase of welding speed and de- completed with computers. uct quality, growth of labor productivity, de- position amount). Machining of the main The plant is heading towards the imple- crease of materials-output ratio and cost of frames and assemblies of diesel locomotive mentation of the production record of semi- products are necessary to feel confident in bogies is carried out at the twin-column finished products at which all the shops will the market of the railway engineering. bed-type milling machine SHW-UF 6L (Ger- be united into a single inventory record sys- Research- and- development activities many). CNC gear-grinding machine RAPID tem. It is planned to keep it in the common and engineering developments contribute to

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solving this problem. In the framework of the ern equipment are applied. The plant put equipped with ISCAR (Israel) tooling is in- research –and- development and engineering high hopes on the production of the diesel- troduced into operation. development within the last three years proto- locomotive shunters with Wartsila diesel type models of the hopper-car with the in- electric set. IN PERSPECTIVE creased body space of 112 m3 model 19- ТEМ18V diesel-locomotive shunter with Workshop buildings are located quite 3054-04 for the transportation of grain and Wartsila W6L20L diesel with the capacity of far from each other at the plant which oc- bulky goods, car for bulky materials with 25 tf 882 kW (1200 hp) with electric DC transmis- cupies great territory. The enterprise`s spe- axial load model 19-3130 have been pro- sion is created on the basis of the existing cialists are trying to concentrate some tech- duced. Operations on the modernization of ТEМ18DМ diesel locomotive with minimal nological processes within production the cars model 19-3054-01 and 19-3054-03 modifications in the structure. It will have workshops. Thus in the machining blank for grain transportation have been completed. the improved cost-performance ratio and production shop where the wheelset and Since 2009 series manufacture of reliability, ensure reduction of costs on die- assembly area has been created already it ТEM18DМ diesel locomotives equipped sel fuel and oil, locomotive servicing, fee for is planned to make an area of gear machin- with data collection and record system, au- the emission of harmful agents into the at- ing, machining of frames and bogies of tomatic alarm system and telemetry system mosphere. 2ТE25А locomotives. For this plane hori- of driver`s vigilance has been launched. The designed diesel locomotive will be zontal milling machining center type FR- The All-Russian Scientific-Research completed with new equipment: diesel 10.000 of the Spanish company SO- and Technological Institute of the Rolling electric set consisting of W6L20L diesel LARUCE — DANOBAT GRUP is installed. Stock carried out benchmark tests of the and flange-mounted traction DC generator Further development of the facilities of the traction motor/axle wheelset with domestic GP-321 MU2, modified cooling system with gear processing area is stipulated in the traction motor support roller bearings of ventilator drive via the bevel gear speed re- business plan for 2011. Several modern traction DC motors for the diesel-locomo- ducer with variable filling liquid coupling. and high production CNC machines will be tive shunters type ТEM18 and mainline The diesel locomotive will be fitted with the purchased- gear-milling, vertical lathe, two 2ТE25К. The prototype model of the trac- reciprocal compressor with the com- internal grinding, cutter grinder, equipment tion motor/axle wheelset will be mounted pressed air purification and drying unit, the for the cementation of the ring gear. on the prototype diesel-locomotive shunter heating system for the Golfstream diesel The enterprise has a big equipment ТEM18DМ delivered by OJSC RZD. heat-carriers, Webasto autonomous cab stock. However the replacement of the The certificate of conformity for two heater and other technical solutions. equipment, modernization and acquisition mainline diesel-locomotives 2ТE25А (№№ Currently the enterprise is actively pre- of the novelties are aimed at concentrating 001 and 002) has been obtained. In 2010 a paring for the manufacture of the new diesel on the more efficient equipment which en- goal is set to obtain the certificate both for locomotives. The new areas are being sures higher quality. That is why the equip- the pilot batch and for the series. equipped, unique metal-cutting, lifting, weld- ment delivered to the plant in 2006-2010 is Interactive classroom for the program ing, control and measuring equipment of the the most cutting-edge, high technology and ming and practical development of control leading world producers is installed. Time- efficient. At that in the equipment of the fa- software for modern systems with CNC and Twin (Austria) welding technologies, desig- cilities the enterprise has a complex ap- visualization of materials processing pro- nated for the automatic welding of the main proach: acquires not only equipment but cesses has been purchased and put into beams of diesel locomotive frames with ser- also technologies, software, tooling and operation. It allows carrying out training of vo-system are gradually implemented. trains the personnel. CNC machines operators simultaneously in A range of German equipment appeared in A new breakthrough has outlined in car groups of 5 people. the workshops — German Schlik combined production- series manufacture of the drop- Slip joint of pipes of the air brake sys- chamber for shot blasting, painting and dry- bottom cars model 12-3090, which are tem and joints of the brake leverage mecha- ing of the main frames of the mainline diesel planned to be produced from the second nism is implemented on the series cars locomotives, milling machines of Machining half of 2011. For the instrumentation of pro- model 19-3054, 19-3054-01. center module type with CNC models SHW- duction it is planned to purchase assembly In the conditions of severe competition 5 and SHW-6, equipped with high-produc- stands, horn machining unit, two radial it is extremely important not only to respond tivity Sandvik tooling (Sweden), ISCAR (Isra- drills and also some welding equipment. to the demand promptly but also, when el) and built-in measuring system. For the The perspectives are associated also possible, to offer the customer new, mod- reduction of the equipment setup time Kelch with the start up of the bogie production ern samples of the equipment. That is why unit, allowing carrying out adjustment of aimed at the manufacture of bogies for all the team of the BMZ specialists continues tooling off the machine, is applied. the rolling stock fabricated by the TMH en- working on the expansion of the product CNC gear-grinding machining centre terprises. It is planned to manufacture loco- portfolio. Currently technical project and model RAРID-900 (Hofler machine plant, motive bogies centrally for the whole hold- common concept of the hybrid and double Germany) is put in operation. It has a built- ing. As early as next year the team is ahead diesel-locomotive shunters type ТEМ35 и in control-measuring system with the im- to produce the underframe for the 2ES5 ТEМ33 are being developed. mediate displaying of the desired and ob- diesel locomotive which is designed to- The most cutting-edge achievements of tained during the grinding shape of the gether with the Transmashholding strategic locomotive building are introduced in the toothing. Vertical machining center model partner — French company Alstom Trans- ТEM35, the brand new solutions and mod- MCFV1680 produced in Czech Republic port.

№ 5 12/2010 7 Operation BMZ diesel locomotives: from TEM shunter to the mainline 2TE25A Vityaz

Bryansk Engineering Plant, being a part of CJSC Transmashholding, is one of the largest Russian enterprises in the field of diesel locomotive building. Bryansk designers were the first in Russia to create a unique machinery — mainline diesel freight locomotive with asynchronous drive 2TE25A Vityaz.

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team locomotives cleared The first diesel-locomotive shunter motives were manufactured. Since the time the way to diesel loco ТEМ1 with the capacity of 1000 hp, accel- of ТEМ1 production diesel locomotive motives and diesel loco erating up to 90 km/h, was constructed in building has actively grown at BMZ. S motive building as an in- 1958. Its prototype was a well-proven die- The most mass family of domestic-pro- dustry. The history of steam locomotive sel locomotive ТE1. But instead of the D50 duced diesel-locomotive shunters was building has many interesting facts. Let`s diesel a new type of diesel — 2D50 started ТEМ2 which series production started in reveal some of them. In December 1936 the steam locomotive SО 17-635 started unprecedented in the world history voy- The first diesel-locomotive shunter ТEМ1 with age. With 1200 ton train it travelled 21 the capacity of 1000 hp, accelerating up to 90 km/h, thousand kilometers from Moscow to was constructed in 1958. Vladivostok and back through the severe Siberian winter and difficult mountain crossings without any breakdowns. Only to be mounted at the diesel locomotives 1968. The body structure of these diesel lo- diesel locomotives turned to be able to re- and it differed from the one applied on ТE1 comotives slightly differed from the body of peat this record. Steam locomotive SО 17- and ТE2 with the arrangement of the gas- ТEМ1 of the first production: side walls of 1613, assembled in 1944 at the facility distributing shaft and turboblower. Main the driver`s cabin were made without slope evacuated to Krasnoyarsk, performed the generator and two-unit mechanical set for the better view on the track. Apart from honorable historical mission – brought the were also previously applied at the ТE1 and the diesel replacement the main generator Soviet delegation to Potsdam to the con- ТE2 diesel locomotives. ТEМ1 diesel loco- was replaced and some other alterations ference. In 30 years it was set up in motives were manufactured from 1958 to were introduced. Total of 6 thousand loco- Dnepropetrovsk as a monument. There is 1968. In June 1964 Bryansk Engineering motives were constructed at BMZ, half of also a monument to the steam locomotive Plant produced the 1000th diesel locomo- them for the Ministry of Railroad Transport. on the BMZ territory. tive of this series. Total of 1946 diesel loco- ТEМ2 were supplied to some foreign

TEM18DM diesel locomotive

№ 5 12/2010 9 Operation

Mainline diesel freight locomotive with asynchronous traction drive 2TE2A Vityaz

countries including Mongolia, Cuba, and diagnostics system. It was ТEМ21 collector systems, they do not cause prob- Poland and Syria. which gave a chance of creating the first lems during movement. But the main thing Over 100 diesel locomotives operate at Russian mainline twin-unit diesel freight lo- is that asynchronous motors allow increas- the Baikal-Amur Mainline, at that, the first comotive with asynchronous drive 2ТE5А. ing the haulage capacity of the locomotive diesel locomotive which passed the BAM But the pioneer of the range of mainline many times and eliminating much heavy golden link in 1984 was the ТEМ2. The die- diesel freight locomotives at BMZ became and energy-consuming equipment which sel locomotive ТEМ2-580 produced in 1970 the twin-unit locomotive 2ТE25К Peresvet controls usual collector engines from the was the first of locomotives to get the na- with electric AC/DC transfer and collector structure. tional Quality mark. Currently it is the most traction electric engines. Later on the basis The new machine reminds its prototype wide spread diesel-locomotive shunter on of this locomotive BMZ built the first Rus- Peresvet diesel locomotive only outwardly. the territory of the former Soviet Union. sian mainline diesel freight locomotive with 2ТE25А has a brand new electric AC/DC The first Russian diesel locomotive with asynchronous traction drive — 2ТE25А transfer. The cutting-edge diesel electric asynchronous drive was ТEМ21, construct- Vityaz. So far this technology was not ap- set 21-26DG1 was designed at Kolomna ed at BMZ in 2000. This machine can be by plied at the mainline locomotives in Russia. Plant especially for the new diesel locomo- right called the locomotive of the new gen- Drift from the collector engines at the tive with asynchronous traction drive. eration at which the state-of-the-art devel- mainline diesel freight locomotives was un- For the first time in the country electron- opments of national specialists are applied. doubtedly a revolutionary process. This ic systems of fuel injection and air supply Its main differences are in the electric AC makes the traction machines practically were mounted at this diesel electric set transmission and microprocessor control eternal. They don`t need to be serviced as which allows decreasing operating costs

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many times. This is for today the most per- adjustment of traction force is designated matic and electrodynamic brake, alarm, fect device for diesel locomotives. 12-cylin- for the drawing of freight trains. The design- communication, fire safety, heating system der V-shape diesel is energy-conserving, ers managed to apply about thousand of ensuring long lay-over in stand-by reserve eco-friendly and ensures sufficient capacity modern design solutions on the locomotive. with the power supply from the depot net- without the application of accelerated For the first time a non-pedestal bogie with work. The locomotive is totally designed on modes. Compared to the diesel electric set radial arrangement of the wheelsets and the domestic engineering base. Traction D49 mounted at Peresvet 21-26DG-01 pos- traction motor support roller bearings were converter which is the Vityaz key innovative sesses much better characteristics. applied. This ensures the life of the tire and element was developed at the Scientific- The field service run of the 2ТE25А die- bearing assemblies for the run of million ki- Research and Technological Institute of the sel locomotive Vityaz finished at the end of lometers without servicing. The motor with Rolling Stock (OJSC VNIKTI) and manufactured by ElectroCI company (Moscow). Switch to the mass use of the new ma- Vityaz with the electric AC transfer is designated chines will signify the sharp increase of the for the drawing of freight trains. The designers labor productivity on railroad transport, will managed to apply about thousand of modern design allow enhancing traffic-carrying capacity of railroads. Due to high lifting power the new solutions in it. diesel locomotives will contribute to the decrease of the quantity of bottlenecks at the December 2009. It drew the consist with the electric fuel injection and blow-off system Russian railroad network. weight of 7,5 thousand tons on the difficult and microprocessor control and diagnos- The machines with asynchronous drive track curve with the slope of 8-12 thou- tics system are applied. For the improve- possess a range of advantages associated sandth. This value is far exceeding the abili- ment of labor conditions of the locomotive with railroad profiles — ascends, falls, ties of the diesel locomotives forming the team a room climate system operating in curves. Minimum 5-7 Russian railroads basis of the fleet of the CIS states railroads the automatic mode is installed in the driv- have composite topography especially in for which the norm is 5,2 thousand tones. ers cab. Siberian regions. Due to this the weight of Vityaz with 2x2500 kW capacity with The diesel locomotive is equipped with the consist for the collector diesel locomo- the electric AC transfer with axle-by-axle the CLUB operation security system, pneu- tives is limited to 4,5 thousand tons. Vityaz performance coefficient in such conditions is one and a half-twice as higher. 2ТE25А will be the main locomotive on the most intense non-electrified sections of our railroads. These are sections of the BAM, sections of the Zabaikalsk railroad where they will operate within the program of pet- rol shipment to China and also in other places with intense climatic and terrain conditions. Moreover, 2ТE25А is the first Russian diesel locomotive complying with the «Euro–3» environmental requirements which are 30-40 stricter than «Euro-2». In the opinion of the railmen Vityaz is really a unique machine created in the post-So- viet Russia for the first time. In technical characteristics 2ТE25А can be compared to one of the best samples of the foreign locomotive building — the Blue tiger freight locomotive. The producers hope that 2ТE25А will become the base model for the construction of several prototypes of diesel locomotives with asynchronous traction motors. The plant plans production of the single unit locomotive with 3 500 kW capacity, three- unit diesel locomotive with up to 9 000 kW capacity for the operation with the consists weighting about 12000 tons in multiple-unit TEM2 diesel locomotive system in the sets of articulated trains.

№ 5 12/2010 11 Innovations Kolomna engines: modularity and unification

the turn of the XIX–XX cen- The main peculiarity of these lines is unifi- diesels of various producers including for- turies the German inventor cation between the models. At the end of eign at the heavy overhaul of the diesel lo- At Rudolf Diesel for the first 1960s Kolomna designers for the first time comotives type М62, ТEP60, ТE10, time created the brand new in the world created the so-called modular ChMEZ, ТEМ2 with the diesels type D49. type of the engine operating process trans- engine arrangement. Today all the largest Kolomna Plant at its facilities on its own forming heat energy into mechanical which Western companies consider modularity to carried out the first diesel locomotive mod- performance coefficient was firstly a bit be the compulsory condition of the con- ernization experiments: replacement of the more than that of the steam engines. For figuration. Modular arrangement is a set of old diesels with the new ones. Such a solu- the first time the process was applied in separately assembled main engine units. tion allowed increasing the life of the exist- the reciprocating motor with the inner car- Such modules are easy to test and fully ing locomotives without purchasing the buration and ignition of the air and fuel check on the special stands before the en- new ones and at that the cost of moderni mixture on exposure to growing tempera- gine final assembly. It is convenient not zation is much less than the purchase of ture at the charge compression. Such pro- only for the production but for the repair the new diesel locomotives. Thus ap- cess possessed huge potential possibili- also. Visiting Kolomna Plant and studying peared the Program of the RZD locomotive ties due to the absence of detonation at the modular configuration the specialists fleet modernization and the railroads ac- the fuel combustion with the densified of MTU company (Germany) noticed that quired a single unified diesel. D49 type fractional makeup. This allowed promptly the structure is «exceptionally balanced diesels give new life to the locomotives realizing far higher cycle performance co- with nothing to add to it». produced 20-30 years ago. The service life efficient compared to the steam machines. Currently medium-speed diesels and of the diesel locomotives, at which now This break-trough turned to be revolution- diesel electric sets of the two power rang- Kolomna diesels of D49 family are installed ary in the technical world: diesel engine es CnN26/26 (D49) in the power range and operating, has expanded by 15-20 having passed a range of evolutionary from 588 to 4 412 kW and ChN30/38 (D42) years and the cost of their life cycle has stages till today remains the most efficient with up to 1850 kW capacity are in series considerably decreased. For this program heat engine — diesel engine performance coefficient reaches 45 and at the consumption of energy of exhaust gas and uti- Development of the new product prototypes is carried lization of heat energy can reach 85. out on the basis of the modern automated design Every type of engine has its own spe- systems, united into computer networks. cific features depending on the sphere of its application. At the given capacity the consumption of fuel, oil, emission and also spe- manufacture. On the basis of D49 diesels Kolomna Plant has developed seven diesel cific weight and dimensional characteristics Kolomna Plant created gas diesel engines modifications including the modernization should be minimized with the simultaneous and gas motors where natural gas, associ- of the diesel locomotives operated abroad improvement of reliability characteristics. ated gas, biogas, mine and wood gas can (in Germany, Uzbekistan, the Baltic states, The customer is interested in getting such be used as a fuel and also engines able to Belorussia, Mongolia). In 2003 the plant an engine at the minimum price. operate on the crude oil. D49 engines are completed performance of the contract for Kolomna Plant was one of the first not operated in 35 countries of the world. the delivery of the engines for 64 electric only in Russia but in the world to master Despite the fact that Kolomna Plant locomotives within the program of the Ger- production of the diesel engines. Engine has a diversified sales market the railroad man railroads diesel locomotive fleet mod- building at Kolomna Plant today is one of industry has been the main consumer of ernization. the main activities, the enterprise manufac- locomotive and diesel products of the Before obtaining the order Kolomna tures diesel engines on the basis of its own plant for many years. In 1995 the Kolomna diesels participated in the comparison tests design and engineering developments. Plant introduced a proposal of moderniza- in Germany at the same type of diesel loco- Kolomna Plant has developed wide tion of the outdated locomotive fleet of the motives with the diesels of the leading diesel engine lines of various purposes. Russian railroads: replace the outdated world producers - Mak-Krupp (Germany)

12 № 5 12/2010 Innovations

Diesel production — one of the key activities of Kolomna Plant and Caterpillar (USA). At the full compliance The engines configuration is constantly basis of modern automated design engi- of the diesel technical level with the cus- improving. The complex of research and neering systems, united into computer tomer requirements Kolomna diesels turned development activities is aimed at the in- networks. Alongside with the traditional, to be more efficient and joint tests with Ger- crease and improvement of the diesel en- the new advanced research methods are man specialists proved that the environ- gine technical level. The main activities applied such as speed photographing and mental performance of D9 diesels complies here are the improvement of the diesel filming of the working process, laser ther- with the European norms. operating process allowing optimizing mometry, vibrography. New production Marine diesel building is the special ac- specific fuel consumption and environ- technologies on the basis of modern soft- tivity of Kolomna Plant. Development and mental performance; development and ap- ware-controlled equipment, ensuring auto- manufacture of the perspective ships and plication of the accumulator type electron- matic quality control of the parameters in- vessels require development of the marine ically controlled pulse action fuel-feed dicated in the drawing, are implemented. power plants. Currently Kolomna Plant is systems; application of register air supply New constructional materials, having such participating in several projects of the Rus- systems with modern turbo-compressors specific properties as high resistance to sian Navy on the construction of the surface and inverter drive; reduction of mechanical aggressive and high-temperature environ- vessels of Corvette and Frigate classes, losses in diesel and decrease of taking off ment, antifrictionality, wear resistance and submarines of the projects 636, 1650, power to the diesel and diesel locomotive life till the reduction of initial characteris- 01570. units; application of local electronic control tics, are applied. Kolomna Plant holds the licenses for the and diagnostics systems for the diesel Today Kolomna designers are working right of designing and manufacturing of the electric set; development and implementa- on the creation of the new series of multi- equipment for the nuclear power plants. The tion of the waste gas neutralizers of mod- purpose engines in the power range from first four 6 200 kW diesel electric sets of the ern construction, with optimal service life 4 mW to 7 mW which are of great interest to second security class were manufactured and modest size. Development of the new the railroad, nuclear, energy industries and for the Bushehr nuclear power plant in Iran. product prototypes is carried out on the the Navy.

№ 5 12/2010 13 Technologies OEVRZ has come down underground

Oktyabrsky Electric Railway Car Repair Plant (St-Petersburg), being a part of Transmashholding, mas tered repair and construction of subway cars, thus becoming the third Russian producer of the subway rolling stock. Since 2011 the plant plans to manufacture up-to-date subway cars meeting the latest requirements.

2007 the enterprise started with the mastering of repair of In the new for the plant type of products — subway cars (together with the formation of the new wheelsets for it and in 3 years the enterprise won the tender for the construction of the new cars for the Novosibirsk subway. Under the terms of the contract a consist of cars mo del 81-714/717, which have a range of specific features, was delivered to Novosibirsk. In accordance with the customer requirements they are completed with BARS system of automated train motion control, traction equipment in original design. The saloon interior finish is executed not of plastic but of metal with powder painting. Fast transition from the repair to the subway cars construction became possible due to the high-capacity manufacturing complex functioning at OEVRZ. Quality heavy overhaul and modernization of the rolling stock including the increase of the cars comfort level are carried out at the plant. The plant`s design office is on its own mastering a wide range of the standard process solutions — modification of car frames and bodies, installation of car ceilings, repair and adjustment of the sliding outer doors, cladding of the side walls, repairing of the wheel set gear-box casing etc. In 2009 56 subway cars were complete- terial and technical base. Recently the en- within the framework of the implementation ly overhauled at the plant. In 2010 it is terprise has acquired three new wheelset of the program of cooperation development planned to repair 72 cars and in 2011 repair machining devices. Formation of the new between CJSC Transmashholding enter- of 90 subway cars is scheduled. wheelsets makes a considerable part of the prises. The subway car repair is made in ac- Currently fullscale manufacturing facility plant`s orders portfolio. Even now the cordance with the technical documentation has been created for the production of cars. OEVRZ fully supplies OJSC Metrowagon- and with the assistance of the largest Rus- In 2011 production of the up-to-date Rus- mash (also being a part of Transmashhold- sian producer of this type of rolling stock — sian subway cars meeting the latest re- ing). The specialists of the new formation Metrowagonmash. quirements for safety, energy efficiency, workshop have successfully mastered for- This is not the only joint work of Okty- noisiness and passenger comfort will be mation of the new wheelsets for the subway abrsky Plant and Metrowagonmash. Today mastered on its basis. cars models 81-717/714 and 81-740/741. the enterprises can offer the customers The plant`s administration pays atten- Heavy overhaul and subway car pro- manufacture of the new subway cars mod- tion to the issues of development of the ma- duction are being mastered by the plant els 81-760/761. The state-of-the-art global

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Subway cars heavy overhaul shop

developments in the field of rail transport successful performance of all types of re- axle boxes. Within 9 months 442 wheelsets are applied at the designing and manufac- pair and modernization of the passenger to the amount of 34 724,2 thousand Rus- ture of these cars. 81-760/761 cars comply rolling stock. Last year the enterprise exe- sian rubles were delivered to it. with the latest technical requirements for cuted a huge order of the Federal passen- The plant also carries out heavy over- fire safety, electrical safety, lean produc- ger company — repair of 26 cars of the haul of the passenger cars for small operation, modern standards of passenger com- branded tourist train Burevesnik which un- tors, which appeared in the market in the fort (complete climate control with air con- dergone repairs in the heavy overhaul -1 last years — OJSC GrandServiceExpress, WagonRemService LLC, Profenergoservice LLC, Electrochemical plant LLC, Korabel- Fast transition from the repair to the subway cars NN LLC etc. construction became possible due to the OEVRZ high- In 2011 Oktyabrsky Electric Railway capacity manufacturing complex. Car Repair Plant will celebrate its 185 anniversary. The plant has still a lot to do and solve many problems. The enterprise`s ad- ditioning of the passenger saloon), they are amount and was painted in house colors. ministration has many plans of the OEVRZ also convenient in service and apply ener- The train is already operated on the route development. Operation in difficult eco- gy-saving technologies (energy consump- Moscow –Nizhni Novgorod. nomic conditions showed that St-Peters- tion is 30 less compared to the currently International cooperation is also devel- burg car repairmen are able to mobilize all operated cars). oping: in January 2010 an agreement with their efforts and responsibly approach Despite the huge amount of work on re- the Ukrainian company Metiz-2007 was modern requirements. The plant passed pair and manufacture of the new cars for concluded under which OEVRZ delivers the test and strengthened its position in the subway, Oktyabrsky Plant continues freight wheelsets of the new formation with the market.

№ 5 12/2010 15 Exclusive Rail buses stand for operational and environmental safety

OJSC Metrowagonmash, being a part of CJSC Transmashholding, has carried out development of the rail buses since 1977 and during this time 7 models of rail buses have been designed, currently series produc tion of the RA-2 family rail buses is conducted.

16 № 5 12/2010 Exclusive

ail buses were created for passenger transportation R on the sections of non- electrified railway tracks with heavy passenger traffic and also for the suburban and interregional traffic. Power unit and main assemblies of the buses are located under the car floor, which allowed obtaining maximum square of passenger saloon. The machines are equipped with diesel engine and hydrome- chanical transmission. The car body is in- tegrated, welded, made of stainless steel. The body masks are made of fiberglass with steel frames. The body is resting upon two two-axle bogies one of which is power-operated. Axlebox suspension stage is executed as two spiral springs, second suspension stage as a pneumatic spring. The cars are fitted with shoe type brake mechanisms. The saloon finishing is made of fiberglass, the saloon is fitted with seats with soft inserts and the system of forced ventilation and hydronic heating. The rail bus which became a new type of the railroad electric multiple-unit stock is constructed on the basis of the body and underframe of the Yauza subway car. Its design ensures passenger boarding and detraining both from high and low Sketch of the diesel train for Serbia platforms with the help of the extending ladder. The bus can be operated by one The comfort level has also changed. tence the rail bus has proved itself as a driver who is in one of the two cabins. The RA-1 type rail buses were not safe type of transportation. All the RAs The machines are designed in such a equipped with toilettes because they were manufactured at the plant are equipped way that maximum fuel economy is en- designated for short routes up to 50 km. with the monitoring and diagnostics con- sured at their operation. It happens due to Due to their efficiency and low cost of ser- trol system providing the key control the efficiency of the power unit and light vicing these buses started gaining popu- functions, diagnostics of the main units load of the rail bus. Due to the increase of larity on the railroads. That is why the fol- and data storage. the reliability of the power unit and appli- lowing models (RА-В and RА-2) were fitted Currently rail buses are operated on 14 cation of stainless steel in the body struc- with toilets. Russian railroads: Kaliningrad, North Cau- ture it became possible to solve the prob- Metrowagonmash started manufacture casian (Rostov and Mineral Waters depot), lem of maximum cutting of costs on of the rail buses РА-2 model 750.05-20 in Moscow (Tula and Kolomna depot), South servicing. Moreover, due to the application 2006. MTU (DaimlerChrysler) single- block Eastern (Otrozhka depot, Voronezh), of the power units complying with the power unit including 360 kW MTU Gorkovskaya (Depot Nizhni Novgorod and «Euro-2» and «Еuro-3» requirements envi- 6H1800R83 diesel engine and hydrome- Kanash), Sverdlovskaya, Volga (Volgograd ronmental safety of the rolling stock is en- chanical transmission Voith T211 rе.4 was depot), South Ural, Northern (Danilov de- sured. In the car saloon the designers cre- located at the head cars. pot), East Siberian, Zabaikalskaya, Kuybi- ated comfortable conditions both for In the course of upgrading of the rail shevskaya, Oktyabrskaya, West Siberian passengers and the driver. bus mechanical engineers tried to improve and also in Lithuania and Ukraine. The new modification of the railroad the body exterior. The side plate became This February Metrowagonmash be- passenger transport — rail buses — has smooth (on the first buses it was corrugat- came the winner of the tender for the de- gained considerable development for 13 ed). The saloon exterior has been im- livery of ten diesel trains for the Serbian years. The first machines RA-1 (models 730 proved, new control system has been in- railways (Zeleznice Srbije). By the time and 731) were single-car oriented on 62 troduced, new units of the ventilation this issue was being prepared the signa- seating places. RA-V rail bus (designed for system and saloon heating have been de- ture of the contract for the supply of the the Hungarian railroads) represents a two- veloped, and hermetical inter-car walkway two additional consists was being ex- car consist with 142 seats and modern RA- has been installed. pected. The first car is to be produced in 2 is a three-car consist with 222 seats. For over 10 year history of its exis- April 2011.

№ 5 12/2010 17 Products KMT automatic and manual doors

Door of the passenger car is the structural component which the passenger comes into direct contact with during the travel on the railroad. It should be maximum safe, hermetic, convenient in service. Door systems for the railroad transport have the domineering share in the total production volume of the KMT company and today this figure makes over 40%.

elcome to St-Petersburg su burb — the town of Lomono- W sov where the Russian leading production of various types of doors for the railroad transport is unfolded.

HISTORICAL INSIGNT Russia purchased the first passenger cars abroad and the first domestic cars of I, II and III classes which differed in the indoor equipment and decoration appeared in 1850 s. Further creation and modernization of the cars was executed considering the climatic factor, safety factor, passenger status and finally the growing speed of the consist movement. In the second part of the XX century the car became much lighter and gained the features of the modern passenger car. At that, it was paradoxical that the cutting- edge technologies were introduced in the industry but some of the car elements Car doors Today КМТ produces the following types of new doors for passenger cars: ● Аutomatic, one-leaf reclining-sliding doors with electric drive (see the picture); ● Аutomatic, one-leaf sliding doors with electric drive; Modern reclining-sliding door for the passenger car ● Аutomatic, two-leaf sliding doors with electric drive; looked archaic. Actually, until recently the the car. The last years became the turning ● Analogues of automatic doors but with doors of passenger cars were analogous to point. Today it`s difficult to imagine passen- manual drive. the ones used in the imperial Russia. They ger railway car building without automatic were swing doors opening manually inside door systems meeting the modern require-

18 № 5 12/2010 Products

ments for safety and comfort, providing the riched by new, modern types of locomo- considerable increase of the consist move- tives complying with the latest requirements ment speeds. for the transportation speed. In Ural, in the town of Verkhnya Pyshma, the Ural Railway FROM SIMPLE TO COMPLICATED Engineering Plant produced its first electric КМТ manufacturing company was locomotives. founded in 1991. Its first products were in- Syndicates with the participation of the tercar high-voltage connections. In 1997 world leading manufacturers: ТMH-Alstom serial deliveries of aluminum plastic win- (electric locomotive ЭP20), Sinara-Siemens dows for passenger cars started and the (electric locomotive 2ES10) have been es- company entered the new millennium as tablished. the leading Russian producer of these com- Thus formed a favorable market situa- ponents. tion for the development of production of The situation changed in 2006 when the the locomotive doors which series manu- first Russian mass production of swing facture never existed in Russia. doors for passenger cars with the capacity KMT, as a specialized producer, at of over 150 car sets per month was a short notice was able to provide its first launched at the plant. For these purposes customers with the samples of the doors funds were invested into the construction of which quality complied with the strictest the new facilities: leaf production shop and requirements for hermeticity, noise — paint and assembly shop. Thus the founda- and heat insulation, fire resistance and tion of the strategically important activity of exterior. mastering mass production of the automat- Today all locomotive building plants in ic door systems was laid. Russia are supplied with the door sets and It should be mentioned that in the be- also in the framework of the indicated inter- ginning of the 2000s КМТ participated in national projects. several projects for fitting the branded Locomotive door trains with automatic doors. They were the PROJECTS AND PERSPECTIVES trains Krasnaya strela, Nevsky express This article would not be complete with- and Burevesnik. It was the first and very out the story of how these or that projects Locomotive doors valuable experience of the structure opti- are created. So what is happening behind КМТ produces the following types of mization though it was not a mass produc- the curtain? new doors for the locomotives: tion. All design works and also work prepara- ● Side outer swing doors (see the In 2007 Tver Carriage Works proceeded tion (development of tooling and control picture); to serial assembly of the new models where software for the CNC machines) is execut- ● End outer swing doors; the installation of automatic driven reclining ed in CAD Pro-Engineer system and associ- ● Cabin fire resistant doors; and sliding doors was stipulated. КМТ pre- ated special modules (stress calculations, ● Inner fire resistant doors. pared for this event beforehand and in due kinematics, electric cables route location). time carried out delivery of the first serial The results are 3D-models with the pos- complex of automatic doors. sibility of computer processing of machines automatic doors is considered as the nea Currently the range of new cars has movement kinematics. rest project. The first working prototype of greatly expanded and the history of their On the basis of the 3D -models the pro- such a door was presented in the beginning construction is the history of the creation of totypes of the products are manufactured of 2010. These are reclining and sliding two the new types of automatic doors at КМТ. which then pass comprehensive tests at the –leaf doors with the combined electropneu- plant and at the independent accredited matic drive. They can be fitted in the new NOT BY the CAR ALONE testing facilities. models of subway and electric train cars. With the collapse of the Soviet Union Implemented into serial production, the Development and manufacture of such plants producing DC freight locomotives door systems are manufactured on the types of cars is carried out at the leading and mainline diesel freight locomotives re- high-precision equipment with the applica- enterprises in the field (OJSC Metrowagon- mained beyond the Russian borders. tion of laser technologies and modern com- mash and OJSC DMZ). In the conditions of the growing pas- ponents and materials. A range of other projects connected senger and freight traffic the wear rate of Accumulated experience, the level of with the Olympics 2014 railroad infrastruc- the locomotive fleet became critical. the door production development and the ture is being considered and put into life. In order to support the increasing trans- scope of business connections allow opti- It all allows looking into the future with portation load OJSC RZD adopted the pro- mistic evaluation of the future perspectives optimism and highly evaluate chances of gram of the locomotive fleet recovery. associated with mastering of the new mar- the KMT company as the leading supplier The list of products of the Kolomna, ket segments. A possibility of equipping not only of the window but also of the door Bryansk, Novocherkassk plants was en- electric trains and subway cars with KMT products for the rolling stock.

№ 5 12/2010 19 Cooperation Manufacturing system: heading towards the lean production

Gael Dumetie, Director for Production System CJSC Transmashholding

CJSC Transmashholding — a leader in the Russian transport machine building market has carried out activi ties on the implementation of lean production at the holding`s enterprises since December 2009.

accordance with Trans- of the single roadmap was elaborated to- procedure of its delivery to the customer, mashholding Strategy of re- gether with defining the priority methods ensuring labor safety and also cutting op- In structuring aimed at the and tools for the implementation in the erating costs. Transmashholding plans to modernization of the manu- main segments of the production system arrange the implementation of the lean facturing system since De- — quality, production preparation, manu- manufacturing system by strengthening cember 2009 the enterprises of the hold- facture, supply and product delivery. The of cooperation and exchanging experi- ing have started preparation for the implementation of the lean production ence between the holding`s plants and al- implementation of the lean production system at the enterprises is aimed at im- so with the enterprises of the partners — system. At the preparatory stage the draft proving product quality, adjusting the OJSC RZD and Alstom.

Key Milestones of the Implementation December 2009 — June 2010

Project launch Roadmap Audit Team selection Training at plants Pilots Dec. 2009 and tools July 2010

 Interviews st  Stepwise  1 Wave with people implementation completed at the enterprises  Roadmap  Detail informing in 3 stages (100 employees) development of plants  Over 30 seminars  Audit executed and administration on the roadmap  Target — cut stock at 5 plants  Establishment  Roadmap approval and pilots by 30% of divisions  3- stage were carried out  5 areas  Implementation implementation plan  Target — at each plant  Recruitment of Lean production tools productivity + 20% to the main team  Audit at 10 pilots (in process) executed

5 plants 48 people Roadmap Training NEVZ 15 pilots involved selected created launched is the winner

20 № 5 12/2010 Cooperation

Alstom experience has been applied at the preparation and introduction of the lean production. Alstom production system has Employees are the center already been implemented at 29 company`s plants. TMH plan on the introduction of the of the TMH production system lean manufacture consists of three milestones. At the first milestone it involves five enterprises — DMZ, MVM, BMZ, NEVZ, TVZ. Production Quality Currently Directorates for Plants` Re- Preparation structuring with the support of the central team — TMH Directorate for Production System have selected the candidates for Production the lean production divisions, carried out seminars on the roadmap with the directo rates of the enterprises, chose the pilots. Internal Procurement Moreover, they managed to organize operation at the pilots, prepare and carry out self-audit and audits under the requirements of the roadmap, define the operation Roadmap strategy and primary tools, which have been implemented or are being implemented at the production areas of the plants. At the initial stage of the implementation of the lean manufacture the method of work arrangement at the production area and the nance (TPM), PDCA (Plan-Do-Check-Act), provement of the working conditions at the following tools have been applied: 5S, Va key performance indicators, roadmap, vi- enterprises. lue Stream Mapping (VSM), Standard Work sual management stand. One of the key ob- A roadmap has been developed for en- in Process (SWIP), Total Productive Mainte- jectives of the lean production is the im- suring the efficient production operation

Pilots: First results

Standard report form Prepared annually and timely

Reports with precise figures Results approved by economists

Cutting of stock:-30% Results from 19% to 85%

Productivity: +20% Results from 12% to 28%

Quality improvement: +30% Results from 1% to 60%

Cutting of production areas:-20% Results from 3% to 30%

№ 5 12/2010 21 Cooperation

and it defines the requirements on the the development of the activities. In of assembly lines and preparation of the improvement of activities in such key «Management» section they are: involve- design documentation in accordance with spheres as production preparation, quality, ment of directorate administration in the the smooth production flow, optimization internal procurement, production. process of mapping of value streams and of production flows, workshops and work In May-June 2010 self-audits and au- cutting of production cycles of product places layouts and also utilization of pro- dits were executed at five plants, degree manufacture, training on methods and duction and auxiliary equipment. In «Qual- of development on the main activities was tools of lean production and arrangement ity» sphere the emphasis is upon the up- defined and the scenario for their im- of advanced experience exchange among grading of the production process internal provement was worked out. Main mea- the enterprises of the holding and other control system, arrangement and control sures on the sections of the roadmap can plants for its further implementation. In of the compliance of the end products be emphasized in solving the problems on «Production preparation» — adjustment with the set norms of the enterprises and

Work place arrangement: “Before” and “After”

22 № 5 12/2010 Cooperation

Milestones of Improvement

Milestone 1 Milestone 2 Milestone 3 Milestone 4

Integration achievements Productivity achievements Control achievements

Traditional Developing Leading World Class

Constant Improvement

method in the evaluation of the outer sup- values are specified in the table. awarded a prize. The best plant`s results pliers. Visual management stands have been are on the section «Production Prepara- Activities in «Logistics» sphere are tar- installed at the production areas with indi- tion» in the roadmap, in the arrangement geted at the elimination of stock of the work- cators showing the progress of the manu- of smooth work at the assembly lines and in-progress and components from the outer facturing plan fulfillment, the level of work- with applied design documentation and suppliers, arrangement of timely parts and in-process, machine load, components also in the arrangement and implementa- components supply to the assembly lines supply, product quality, condition of labor tion of lean production methods and tools and in the necessary amount under the pro- safety, personnel composition, its qualifica- at the pilots. The experience, gained at duction plan requirements. The main events tion and work load and also improvement the first milestone, will be improved and on the «Production» sphere are: implemen- plans on these areas. Currently methods applied at the introduction of the TMH tation of 5S, SWIP, TPM, VSM, PDCA tools and tools of lean manufacture are applied at lean manufacture at the other enterprises in the workshops. In February 2010 two pi- eight production areas at each of the five of the holding. lots were chosen by the Directorates for plants. Successful formation of the TMH lean community will be supported with the training of the enterprises` specialists scheduled Successful formation of the TMH lean community will for 2011. The training will be focused on the be supported with the training of the enterprises` application of the standardized methods specialists scheduled for 2011. The training will be and tools of lean manufacture and quality and it will be conducted by the heads of Al- focused on the application of the standardized methods stom production system in November-De- and tools of lean manufacture and quality. cember 2010. The TMH implementation of the lean Plants` Restructuring together with the TMH Following the results of the audits car- production system at the enterprises is the Directorate for Production System at each of ried out at the first milestone strong and priority objective — the basis of the creation the five enterprises for the implementation of weak points in the enterprises activity of the modern holding production system. methods and tools of lean production. The were defined and the leader among the CJSC Transmashholding administration key criteria in the pilots` selection are — big five holding plants was chosen. In Octo- has approved the project of the implemen- stock of work-in-process, low output and ber 2010 in Novocherkassk at the Confe tation of lean manufacture at the Kolomna big losses due to rejects. The key indexes rence on the TMH Lean Production Sys- Plant, Oktyabrsky Electric Railway Car Re- have been defined by the TMH Directorate tem Novocherkassk Electric Locomotive pair Plant and KMT production company in for Production System in the implementation Plant –a leader in the implementation of the first quarter of 2011. of targets at the production areas and their the THM lean manufacture system was

№ 5 12/2010 23 Traditions 130th anniversary of the railway car building at BMZ

ar building is one of the most dynamically developing activities at the Bryansk Engineering C Plant. For its whole history the enterprise has manufactured passenger cars, covered freight cars, high-capacity cars, refrigerator cars, tank-cars, refrigerator sections which were widely spread — from Moscow to the Central Asian republics. The history of the BMZ car building started in 1880. Then the first two-axle cars and platforms were constructed firstly for the plant`s own needs and then for sale. At that time the car building products made 21 of the total production volume. Up to 3 thousand freight cars and over 100 passenger cars were manufactured annually. In 1883 the Bryansk Plant constructed the first 300 two-axle kerosene-cars (that is Cars for the metallurgical industry and chemical-recovery industry how at that time the tanks for kerosene were produced by the plant till 1962 transportation were called) with 15,2 t capacity under the order of the Gryaze-Tsarit- duced in the car building. — gantry spot modifications had to be introduced into the sinskaya railroad. The manufacture of the welding machine and seam welding ma- design. For example increase of carrying products which were new for the Russian chine. Moreover, section assembly of the capacity, application of the lever mecha- industry was unfolded quickly maintaining, car floor was organized at the plant and nism for the unloading instead of screw — at that, quite a high for that time technical electrogalvanic cleaning of the parts in- type mechanism, application of chemically level of products. In 1895 Bryansk Plant stead of sand cleaning was introduced. resistant coatings. 19-3054-01-1 car is mul- produced 145 four- axle tank-cars with the In 1962 Bryansk Engineering Plant pro- tifunctional it can be easily adjusted to the capacity of 1500 puds of kerosene (24,6 duced the prototype model of a five-car re- customer`s requirements that is why the tons) which no one in Russian constructed. frigerator section for the transportation of specialists think that the hopper will be in Total of 10 thousand tank-cars were manu- perishable cargo and refrigeration of fruit demand for a long time. factured before the revolution of 1917. At and vegetables. Since then this product be- In 2003 the engineering team of the Bry- Soviet times this type of product was re- came very popular, was constantly im- ansk car builders developed original hopper turned to only in 1949. The enterprise`s proved and was awarded the Quality mark. design with the tear-drop shape body mo team quickly increased the volumes of their In the 90s BMZ mastered production of del 19-3116. By now about two thousand of manufacture and already 390 tanks were the wide range of products: hopper cars se- such cars of four modifications have been produced in 1950 , 985 in 1951, 1475 in ries 19-3054 and 19-3116, designated for produced. Over one thousand of cars mo 1958. In addition, a new technology of se- the transportation of grain and mineral ferti del 19-3018 for cement transportation have ries production of tanks was developed lizers, cars for the transportation of cement been manufactured. This is the most popu- with butt welding of all sheets. model 19-3018 and cars for the transporta- lar product today, its monthly production is 100 of the high-capacity tanks, 38 tion of rails, pipes, wood and coal. up to 200 units. of refrigerator cars, 29 of high-capacity The first batch of the hopper cars for the Bryansk Engineering Plant has manu- cars and platforms of the total Soviet pro- transportation of mineral fertilizers was fab- factured 6 234 pieces of refrigerator sec- duction volume were produced at the plant ricated in 1993. First hoppers were oriented tions for the whole period of their fabrica- before the Great Patriotic War of 1941- on the grain transportation but the custo tion. Over 2 thousand of Kapel cars of the 1945. In the beginning of the 60s of the last mers planned to adjust them for the trans- original plant design and 11 thousand of century advanced equipment was intro- portation of mineral fertilizers and some hoppers were produced.

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