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                                                                   AN OVERVIEW

 
   


A bird’s eye view of Workshop Area

 

Introduction of Diesel Locomotives on Indian Railways started in late 50’s, with import of locomotives from M/s. ALCO, USA. With the setting up of Diesel Locomotive Works at Varanasi in the year 1961, the addition to the Diesel Locomotive fleet started at regular  pace. In the earlier years of diesel operation, in addition to imports, a limited demand of spares was met by Diesel Locomotive Works, Varanasi but the demand increased with the increasing size and age of the fleet.

 

It was in the context of the need for indigenous, high precision components  for  maintenance support to the diesel fleet, that in the year 1979, a decision was  taken to set  up Diesel Component Works at Patiala. The Foundation Stone  of  Diesel  Component Works (DCW), Patiala was laid on October 24, 1981 and production started in 1986. A decision was also taken that DCW will do midlife Rebuilding of Diesel Locomotives after a service life of 18 years. Accordingly, Phase-II of the project was also sanctioned and the work of Rebuilding started in 1989. The name of DCW was changed to Diesel Loco Modernization Works (DMW) in July, 2003 to signify the modernization of Diesel Locomotives being done. Till March’20, 2296 nos. ALCO locomotives were rehabilitated/modernized by DMW and the activity has since been discontinued.

DMW started manufacturing new WDM3D 3300 HP ALCO Locomotives in 2010-11 and turned out 227 WDM3D locomotives till 2015-16. DMW also manufactured Multi Genset Locos, having fuel saving of 15-20%. First such loco was turned out in Mar’13 and three such locos were manufactured till Mar’20.

DMW also manufactured new locomotives for Non-Railway Customers (NRC). The first WDG3A freight diesel locomotive was supplied to NTPC in March’16 and thereafter, a total of 24 WDG3A freight diesel locos were supplied to NRCs.

Besides being nodal agency for supporting ALCO locos, it also started rehabilitation of Traction Alternators and AC Traction Motors of HHP EMD locos. During 2019-20, rehabilitation / overhauling of a total of 1160 AC TMs was done, which highest till date. Similarly, first wheel set of HHP loco was assembled & dispatched in Feb’16 and thereafter  it is a regular activity of DMW, Patiala.

From 2017-18, DMW started supporting Electric Loco Sheds by supplying wheel sets for WAG7 electric locos and the first wheel set was assembled & dispatched in July’17. Subsequently manufacturing of Motorized Wheel Sets and Motorized Bogies for Conventional (Hitachi) as well as 3-Phase AC locomotives (WAP7 and WAG9) was also introduced in 2018-19. With this, DMW now covers a wide range of Bogies for different  types of locomotives.

A new feather has been added to its cap when it produced its first 3-Phase, 6000 HP, WAP7 new electric locomotive in Feb’2018. After producing the first two WAP7 locos in 2017-18, Railway Board decided to start manufacturing of new electric locos at DMW on a regular basis. A plan for manufacturing of 60 such locos per year has been issued for four years starting from 2018-19 onwards. It is aligned to the Indian Railways’ plan to electrify  its entire route and switch over to electric  traction in a major way to reduce dependence  on imported petroleum. In 2019-20, DMW has turned out 81 new Electric locos, besides rebuilding the last lot of 6 ALCO Diesel locos.

 

 

       
     
 

3-Phase 6000 HP WAP7 Electric Loco                                      Tower Car (DETC)

 

Adding one more major product, DMW has also been entrusted with the task of manufacturing new Diesel Electric Tower Cars with under-slung engine (DETC U/S). The first two DETCs were turned out in 2018-19 and series production was started from 2019-20. A total of 50 DETCs (including one for NRC) have been turned out till Mar’20. An ambitious target of 80 DETCs has been kept for 2020-21.


 

IMPORTANT MILESTONES

 

 

  • Foundation Stone of the Project laid

Oct’81

  • Loco Components manufacture started

Jan’86

  • First Rebuilt WDM2 Locomotive turned Out

Nov’89

  • First Rebuilt WDM3A (3100 HP) Locomotive turned out

Jan’00

  • First Rebuilt WDM3C (3300 HP) Locomotive turned out

Nov’02

  • First WDM3D ALCO Locomotive manufactured

Mar’11

  • Fitment of Electronic Fuel Injection System in ALCO Loco

Aug’11

  • Fitment of Auxiliary Power Unit (APU) for fuel saving

Oct’12

  • First Multi Gen Set Loco manufactured

Mar’13

  • First WDG3A loco was supplied to NRC (NTPC)

Mar’16

  • First 3-Phase IGBT based 6000 HP WAP7 Electric Loco produced

Feb’18

  • First Diesel Electric Tower Car (DETC) produced

Dec’18

  • First 6FRA 6068 Traction Motor Manufactured in-house.

Dec’18

 

PRESENT ACTIVITIES OF DMW

  • Manufacturing of New 3-Phase IGBT Based 6000 HP WAP7 electric locos
  • Manufacturing of New Tower Cars with Underslung Engines (DETC/US)
  • Manufacturing and supply of Motorized Truck Assemblies and Motorized Wheel sets of Diesel and Electric Locos to Zonal Railways
  • Rehabilitation of Traction Machines of all types of locomotives, DEMUs etc. for Zonal Railways
  • Central procurement of items sanctioned under Bulk RSP of Railway Board and supply to Zonal Railways.
  • Manufacture / Repair of diesel locos for NRC
  • Remanufacturing of Power Packs & Engine Blocks for Zonal Railways (Demand has considerably dropped due to stabling of diesel locos now)
  • Manufacturing and supply of 216 types of high precision & critical engine components to Zonal Railways for maintenance support
  • Manufacturing and supply of Carbon Brushes for diesel locos and DEMUs etc.
  • Nodal Agency for bulk procurement of ALCo diesel loco maintenance spares (BIM items)
  • Nodal Agency for entering into AMCs for critical diesel loco systems

 

WORKSHOP FACILITIES AVAILABLE AT DMW

Shops set up under Phase-I of the project are mainly Manufacturing Shops & Support Shops

 

  • Light Machine Shop
  • Heat Treatment Shop
  • Traction Machine Shop
  • Heavy Machine Shop
  • Carbon Brush Shop
  • Plant Maintenance Shop
  • Tool Room
  • Electronics Lab

Shops set up under Phase-II are

 

  • Loco Assembly Shop
  • Power Pack Shop
  • Bogie Shop
  • Light Fabrication Shop
  • Electrical and Commissioning Shop
  • Air Brake & Pipe Shop
  • Loco Testing & Paint shop

Township is self sufficient in all basic amenities such as Hospital, School, Shopping Centers, Bank, Post Office, Recreational and Sports facilities.


2.0  SALIENT FEATURES

 

  • Turnover of the last three years i.e. 2017-18, 2018-19, 2019-20 and 2020-21 (up to 31st Dec’20):

(in Lakhs of Rs.)

 

SN

Sale

2017-18

2018-19

2019-20

2020-21

Up to 31-Dec-20

1

Sale      to     Indian Railways

170391.09

187867.46

222772.32

121396.94

2

Export Sales

0

0

29.62

0

3

Scrap Sales

5103.91

3927.54

3474.06

2406.00

 

Total Turnover

175495.00

191795.00

226276.00

123802.94

 

  • Total Assets as on 31.03.2020 are as follows;

 

  1. Fixed Assets                                                                         (Rs. Cr.)
    1. Township                                                                      25.08
    2. Workshop including M&P                                           559.87

 

 

 

  1. Floating Assets
    1. Stores Suspense

(Rs. Cr.)

61.80

(ii)        Workshop Manufacturing Suspense (WMS)

167.88

(iii)       Misc. Advances

5.62

·

 

Total staff as on 30.11.2020

 

 

Sanctioned

On roll

(i)

Group – A                                                           79

53

(ii)

Group – B                                                           29

41

(iii)

Group –C other than Level 1                                 3113

2654

(iv)

Level 1(Erstwhile Grp “D” now Grp “C”)                  607

482

 

Total                           3828

3230


 

 

Salient features continued…

 

  • Electrical power requirement

(i)         Average demand (monthly)                                    3262 KVA

(ii)        Maximum demand (monthly)                                  3645 KVA

  • Electrical Energy Consumption incl. Solar (lakh units/year)   136.34
  • Number of H.T. sub stations                                                   11
  • Standby Power generation capacity (DG sets)                    820 KVA
  • Roof-top Solar Power generation capacity                        2150 KWp
  • Water consumption (lacs of liters/day)                               67
  • Workshop area (Sq m)                                                      837936
  • Covered area in shops (Sq m)                                            90718
  • Covered area of other service buildings (Sq m)                  74588
  • Township area (Sq m)                                                      1416800
  • Total staff quarters including qtrs at Patiala station

Type-I                                                                                329

Type-II                                                                               949

Type-III                                                                              274

Type-IV                                                                              86

Type-IV (Special)                                                                  64

Type-V/VI                                                                           52

GM Bungalow                                                                       01

                    TOTAL                                                   1755

  • No of beds in hospital                                                                      50

3.0 PRODUCTION PERFORMANCE:

DMW has achieved its production targets in all major areas of activities  and surpassed  the targets in many items. DMW has achieved a turnover of Rs.2262.76 Crs. in 2019-20. Production performance for last financial years and current year up to 31st Dec is  as under:

 

Sr.

Item

Production 2018-19

(Nos.)

Production 2019-20

(Nos.)

Production 2020-21

up to 31-Dec

(Nos.)

1

New Electric Loco Manufacturing-

WAP7

58

81

36

2

Manufacturing of DETC/8W

02

48*

57*

3

Motorized Truck Assembly

14

113

111

4

Motorized Wheel Sets/ Wheel Sets

544

293

65

5

Traction machines

2177

2276

1349

6

Rebuilding/Over Hauling of Power

Packs for Zonal Railways:

60

77

15

7

Rebuilding of Diesel Locos

45

06

0

8

IOH/POH of Loco (WDM3A/ WDM3D/

WDG3A)

45

03

0

9

New MultiGen Set Loco

01

0

0

9

New WDG3A locos for NRCs

02

0

0

10

Production & Sale of other items (BIM, RSP, Ann-N, Material assistance, Carbon Brush, Reclaimed Engine blocks, MWS etc  (Expenditure  in lakhs of Rs.)

43286

37669

26459

11

Total Turn-over (in lacs of Rs.)

191795

226276

123803

. *includes one 8W-DETC for NRC


 

4.0    NEW INITIATIVES:

Old diesel locomotives were planned to be converted into electric  locos.  The  first prototype of WAG10   loco is currently under manufacture.

DMW has started manufacturing of new Traction Motors for electric locos and plans to ramp up the capacity in next 2-3 years.

5.0    CERTIFICATIONS:

 

  • DMW is an ISO 9001:2015, 14001:2015, IS 18001:2007 (Integrated Management System) certified unit by Bureau of Indian Standards. & also ISO 50001:2018 certified.
  • DMW has recently obtained following Certifications/Rating;
  • GreenCo Certification achieved in Gold Rating
  • Green Building Certification with Platinum Rating for DMW Administrative Building
  • ISO:3834 for welding processes
  • 5S certification for work place management.
  • NABL accreditation for C&M Lab
  • It is in the process of obtaining International Railway Industry Standard (IRIS) ISO/TS/22163:2017 certification for all its business processes

 

6.0    HUMAN RESOURCE DEVELOPMENT:

·Technical Training Centre

A technical Training Centre is functioning in DMW, where supervisors and technicians undergo Initial and Refresher Training Courses. Besides this,  courses on Industrial Safety, Fire Fighting and First Aid are also conducted regularly. In addition, a “Knowledge Centre for CNC Machines” has  also been  set up in 2017, where specialized courses for Programming, Operations and Maintenance of CNC Machines are regularly held, not only for DMW staff but  also for maintenance staff of Zonal Railways. Fifteen such specialized Courses have been held during 2019-20. However, these courses have temporarily being discontinued due to pandemic related constraints.

7.0    FUTURE PLANS:

  • DMW has manufactured 81 new WAP7 electric locos in 2019-20 for the first time and it will be manufacturing 50 new locos in 2020-21 as per production  plan issued by railway Board.
     
  • DMW manufactured 47 Diesel Electric Tower Cars in 2019-20 and there is plan to manufacture 80 DETCs during 2020-21 to meet the increasing demand owing to complete electrification of Indian railways.
  • DMW is planning to develop it as a hub for manufacturing of new Traction Motors for electric locomotives reducing its dependence on trade.

 

8.0    DMW SPORTS ASSOCIATION ACTIVITIES:

 

Sports persons of DMW have brought laurels  to Indian Railways and their performance have  been as follows;

 

1      Ms. Annu Rani

  • Represented India in World Athletic Championship which was held at Qatar from 27th September to 6th October, 2019 and secured 8th place in the event of Javelin Throw with new National Record of 62.34 m.
  • Represented India in Asian Athletic Championship which was held at Doha, Qatar from 21/04/19 to 24/04/19 and won the Silver Medal in the event of Javelin Throw
  • Represented Indian Railways in the 59th National Open Athletic Championship which was held at Ranchi from 10/10/19 to 13/10/19 and won the Gold Medal in the event of Javelin Throw.

2       Ms.Prachi

  • Represented Indian Railways in the USIC World Railways Athletics (M&W) Championship which was held at Czech Republic from 10/09/19 to 13/09/19. She secured 02 Gold Medals in the event of 400 m and 4 x 400 m Relay and one silver medal in 800 m.
  • Represented Indian Railways in 59th National Open Athletic Championship which was held at Ranchi from 10/10/19 to 13/10/19 and won a Silver medal in 4 x 400 m. mixed relay and Bronze medal in 4 x 400 m. women relay 
  • Represented DMW in All India Railways Athletic Championship which was held at Pune from 20/08/19 to 22/08/19 and won Silver medal in 400 m and Bronze medal in 200 m.

3       Ms.Kamalpreet Kaur

  • Represented Indian Railways in the USIC World Railway Athletics (M&W) Championship which was held at Czech Republic from 10/09/19 to 13/09/19. She secured 03 Gold Medals in the event of Discus Throw, Javelin Throw & Shotput event. 
  • Represented Indian Railways in the 59th National Open Athletic Championship which was held at Ranchi from 10/10/19 to 13/10/19 and won the Gold medal in Discus Throw event.  
  • Represented DMW in All India Railway Athletic Championship which was held at Pune from 20/08/19 to 22/08/19 and won the Gold medal in Discus Throw event.

4       Sh.Eknath Sambhaji Turambekar

  • Represented DMW in All India Railway Athletic Championship which was held at Pune from 20/08/19 to 22/08/19 and won the Bronze medal in 20 KM Walking.
  • Represented in the All India Inter-State Athletic Championship which was held at Lucknow from 26/08/19 to 29/08/19 and won the Bronze medal in 20 KM Walking.

5      Ms.Madhu

  • Represented DMW in All India Railway Athletic Championship which was held at Pune from 20/08/19 to 22/08/19 and won the Bronze medal in Heptathlon event.

 



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