RAIL COACH FACTORY
ENTERING INTO NEW ERA OF COACH MANUFACTURING
The foundation stone for the coach factory at
Kapurthala was laid by the Hon’ble Prime Minister on 17th August
1985. Manufacture of coaches was started on 19th September, 1987 and
the first coach was rolled out on 31st March, 1988. RCF production
had progressively gone up and along with ICF, these two Production Units have
been able to meet the requirements of Indian Railways.
The state-of-the-art manufacturing facilities and processes have enabled us to achieve excellence in design, development, manufacture, installation and after-sales services of rail coaches with a view to ensure continued satisfaction of the rail customers.
RCF
has a strong tradition of innovations and developing new products. Many major developments on coaching stock
such as AC-3 tier Coaches, Roof Mounted AC package Unit, IRY/IR20 Coaches, Self
Propelled Accident Relief Train, High Capacity Parcel Vans, Post office
coaches, Coaching Container Flats, Refrigerated Van and MG-DMU etc. have taken
place in RCF. The other variety of
coaches, which have been manufactured at RCF, are Inspection Carriages, Over
Head Equipment Cars, MG coaches, AC coaches for Ministry of Defence, etc.
The first prototype
Refrigerated Van designed and developed by RCF was turned out in October
2002. This has been well appreciated by
the railway customers and during 2003-04, orders for 9 more Refrigerated Vans
have been placed on RCF recently. Two
Refrigerator vans are nearing completion and will be despatched in September
2003. RCF has developed a new product
i.e. MG/DMU, which has already been pressed into service. RCF has also developed MG-GSR, which has
increased the seating capacity.
RCF has been entrusted with the task of manufacture
of modern, high speed, state of the art coaches with a TOT agreement with M/s.
ALSTOM – LHB. The first 4 LHB coaches
of LHB design were dispatched to Northern Railway on 26.12.02. Rail Coach
Factory has further developed and manufactured LHB design coaches for Rajdhani
rake. The design for these variant coaches, including layout, manufacturing
drawings and specifications etc. was entirely prepared at RCF. The first LHB design
Rajdhani rake was flagged off on 23.06.03 during an impressive ceremony. The second LHB Rajdhani rake was also
dispatched in June 2003 and third rake is scheduled for September 2003.
Similarly a special assignment of Railway Minister to manufacture fire proof
coaches, accomplished by RCF and prototype was inaugurated by Honourable
Minister of Railways Sh. Nitish Kumar on 21/9/2003.
SPECIAL
FEATURES OF FACTORY CONSTRUCTION
i) Covered - 1,95,419
Sqm.
ii) Uncovered - 75,318 Sqm.
2.
Bays of 20 mtrs. X
12 mtrs.
4.
Use
of strip lighting.
5.
Excellent
ventilation through vertical rotating louvers.
6.
Mechanically
laid high strength concrete flooring.
7.
Integrated
Sheet Metal Fabrication and Shell assembly shops under one roof preventing
corrosion of work in process material.
8.
Uniform
flow of material.
9.
Pipe
lines for compressed air and carbon dioxide.
10.
Safe
and efficient electric supply through modern bus bar trunking.
11.
Electric
Power Supply received at 132 KV through 2 No. 12.5 MVA 132/11 KV Power
Transformers and distributed through 13 Nos.
11 KVA/415 V Sub Stations.
12. Administrative Block – good architectural design, centrally
air-conditioned, good natural lighting and modular seating arrangements.
PROJECT COST
1. PROJECT:
The project
estimate was originally
sanctioned at the
cost of Rs. 296.04 crore which
was revised to Rs. 451.06 crore.
The
total expenditure under final heads upto March 2003 is Rs. 412.15 crore. This includes expenditure incurred on RCF
project (P-4200), Machinery & Plant (P-4100), Staff Quarters (P-5100),
Amenities for Staff (P-5200) and Other
Specified Works (P-6400).
The
closing balance of floating assets (inventories P-7100, P-7200 and P-7300) is
Rs. 71.70 crore. The break-up of fixed
and floating assets is as under: -
Capital Outlay to end of 31st March 2003
(Fig.
in crore of Rs.)
|
I. Fixed Assets |
|
Break up of Fixed Assets by important
categories:- |
|||
|
a) Project Township |
72.35 |
Fixed Assets |
Amount |
||
|
b) W/s. & Offices |
339.80 |
Land |
7.92 |
||
|
|
|
Road & Permanent Way |
5.37 |
||
|
Total Fixed Assets |
412.15 |
Buildings |
95.02 |
||
|
|
Other Structural Engg. Works |
9.40 |
|||
|
Machinery and Plant |
243.36 |
||||
|
II. Floating Assets |
Electrical Installation |
31.01 |
|||
|
General Charges |
20.07 |
||||
|
a) Stores Suspense |
45.56 |
|
|||
|
|
|
Total Fixed Assets |
412.15 |
||
|
b) W/s. Mfg. Suspense |
24.39 |
|
|||
|
c) Misc. Adv. Cap. |
1.75 |
||||
|
Total Floating Assets [a+b+c] |
71.70 |
||||
|
Total Assets (Fixed & Floating) |
483.85 |
||||
MANUFACTURING
FACILITIES
RCF
is carrying out its manufacturing activities by use of modern state- of-the-art
machines, which ensure high productivity and quality of production. These include 55 CNC machines which form the
core of our main manufacturing facilities. We are continuously upgrading these
facilities to avail of latest technological developments worldwide. Some
important high productivity machines for supplementing manufacture of LHB
design coaches are as under: -
·
CNC
Top Spindle Moulder for edge milling of floor boards.
·
Welding
Manipulator with Automatic Seam Tracking arrangement.
·
CNC
Machining Centre for LHB bogie frame machining.
·
Garnet
Blasting machine with Robots.
·
CNC
3-D Co-ordinate Measuring machine.
·
CNC
Laser Profile Cutting machines.
·
CNC
Laser Welding and Cutting machine for LHB side-wall and roof.
·
NC
Milling/ Drilling machine for bogie components.
·
CNC
Edge Milling machine.
·
CNC
Press Brake 800-Tonne.
·
CNC
Bed Milling machine.
·
CNC
Spot Welding machine for LHB car shell assembly welding.
Also at RCF we are ensuring
high availability and reliability of these vital machines by continuous
emphasis on preventive maintenance rather than breakdown maintenance.
MARKETING
1.
SALES ALREADY MADE:
1.1
Domestic:
|
S.No. |
Customer |
Product |
Quantity |
Year of supply |
Contract Value |
|
1 |
INDIAN
ARMY |
Air
Conditioned 2 Tier (Self
Generating) |
04 nos. |
2001-02 |
Rs.
14.0 Crores (approx.) |
|
Air
Conditioned 3 Tier (Self
Generating) |
12 nos. |
||||
|
2 |
DRDO |
LCC |
02 nos. |
1999-00 |
Rs.
6.25 Crores (approx.) |
|
PSC |
02 nos. |
||||
|
SSC |
02 nos. |
||||
|
3 |
DEPTT.
OF POSTS |
Postal
Van |
28 nos. |
2000-01 |
Rs.
11.0 Crores (approx.) |
|
4 |
DRDO |
LCC |
02 nos. |
Under
execution |
Rs.
6.4 Crores (approx.) |
|
|
|
PSC
– Air Conditioned |
02 nos. |
||
|
|
|
SSC
– Air Conditioned |
02 nos. |
1.2
Export:
|
S.No. |
Customer |
Product |
Quantity |
Year of supply |
Contract Value |
|
1 |
VIETNAM |
MG
Bogie |
72 nos. |
2000-01 |
Rs.
2.5 Crores (approx.) |
2.0
Supply contract recently
secured and yet to be executed :-
|
S.No. |
Customer |
Product |
Quantity |
Contract Value |
|
1 |
DEPTT. OF POSTS |
Postal Van |
25 nos. |
Rs. 11.2 Crores (approx.) |
3.0
TECHNO COMMERCIAL OFFERS
SUBMITTED IN THE RECENT PAST:
3.1 Domestic:
|
S.No. |
Customer |
Product |
Quantity |
Contract Value |
|
1. |
INDIAN
ARMY |
Air
Conditioned Saloon Car |
-- |
Rs. 42.0 Crores (approx.) |
|
Air
Conditioned 2 Tier (Self
Generating) |
11 |
|||
|
Air
Conditioned 3 Tier (Self
Generating) |
21 |
|||
|
Non
Air Conditioned Sleeper coach |
30 |
3.2
Export
3.2.1 Accident Relief Train for Sri Lanka:
RCF has given a techno-commercial offer to M/s. RITES for design, manufacture and supply of Accident Relief Trains to Sri Lanka Railways. Apart from offering IR standard design of Accident Relief Train consisting of 2 coach sets, offer has also been made for 45 ft. long 3 coach set Accident Relief Train for better negotiability in the northern mountainous part of Sri Lanka.
3.2.2 Push Pull Train of 10 Non Air Conditioned Chair Cars for Namibian
Railways:
RCF has submitted a
techno-commecial bid to RITES for design, manufacture and supplyof one number
Push Pull train set consisting of 10 Nos. Non-AC Chair Cars with provision of
driving cab in the leading and trailing chair car. This is for Push Pull
operation in conjunction with a YDM4 locomotive on the cape gauge system of
Namibian Railways.
3.2.3 Meter Gauge Air Conditioned DMUs for Tunisia:
RCF has submitted a techno-commercial bid to M/s. RITES for design, manufacture and supply of 10 train sets of Meter Gauge AC DMUs to Tunisia. Each train set consists of 2 driving Power Cars. The salient features are 130 kmph speed, repetition of signals at the train head, driving even recorder, air conditioned interiors including driver’s cab, underslung power pack, motorized body side sliding doors operated from the driver’s cab, etc.
3.2.4 30 nos. Air Conditioned MG coaches for Bangladesh Railways:
In response to an enquiry received from M/s. RITES for design, manufacture and supply of 30 nos. MG Air Conditioned coaches to Bangladesh Railways, a techno-commercial bid for design, manufacture and supply of these coaches was submitted to RITES on 12/08/2003.
Again, as per Bangladesh
Railways’ subsequent requirement, RCF was asked on 16/08/2003 by M/s. RITES to
revise RCF’s offer to include the “Transfer of Technology”, Alliance 2 type
coupler, stainless steel brake pipes/pipe fittings and improved interior
paneling and with the delivery period not exceeding 15 months.
A revised offer covering
these superior technical features has been submitted to RITES on 25/08/2003.
However, RCF’s consent for Transfer of Technology shall be conveyed to RITES
only after getting Board’s approval to the proposal already sent to Board vide our
letter No. IE 16144-II Dated 21/08/2003.
3.2.5 50 nos. MG coaches (Both AC and Non-AC) for Bangladesh Railways
One more tender enquiry has been received from M/s. RITES for design, manufacture and supply, along with the bidder’s consent for “Transfer of Technology” of 50 nos. MG coaches having 5 variants, for Bangladesh Railways.
A techno-commercial bid for
the same shall be submitted to RITES very shortly. However, RCF’s consent for
Transfer of Technology shall be conveyed to RITES only after getting Board’s
approval to the proposal sent to Board vide our letter No. IE 16144-II Dated
21/08/2003.
4.0
Marketing:
4.1
Expression of Interest for supply of Rolling Stock for
Andheri-Ghatkopar Corridor:
As per newspaper
advertisement, MMRDA had invited expression of interest for implementation of
Andheri-Ghatkopar corridor on BOT, BOOT basis.
In response to this advertisement, RCF has submitted its Expression of
Interest directly to MMRDA. In the
Expression of Interest, RCF has clearly indicated that RCF can design,
manufacture and supply rolling stock components of the project directly to
MMRDA or by supporting any of the party securing the contract and that our
rolling stock supply will be on one time sales basis with full payment to be
made in advance.
Arising out of MMRDA’s
advertisement, M/s Hindustan Construction Company Ltd. Incon House, Lal Bahadur
Shastri Marg, Vikhroli(W), Mumbai had also approached RCF seeking RCF’s support
for rolling stock component of Andheri-Ghatkopar Corridor to enable them
indicate their Expression of Interest to MMRDA. In response, RCF has confirmed its Expression of Interest to
support M/s Hindustan Construction Company Ltd. for the rolling stock component
of the forthcoming Mass Rapid Transit System of Andheri-Ghatkopar Corridor on
non-exclusive basis. It has been
clearly indicated in our Expression of Interest that RCF reserves its right to
support any other contract winning party for design, manufacture and supply of
rolling stock for Andheri-Ghatkopar Corridor and that full payment towards
design, manufacture and supply of rolling stock will have to be made in advance
to RCF.
INFORMATION
TECHNOLOGY
1.
Existing System:
1.1
The
IT Infrastructure in RCF has its genesis in the Project of Setting up of Rail
Coach Factory, Kapurthala sanctioned in 1988.
A network of about 250 Workstations and 50 Printers connected to
Mainframe HP 3000 Servers spread on about 22 km in RCF Campus, is in existence
for processing on-line central database.
1.2
The
IT Department handles the complete MIS requirements and IT needs of RCF and
covers practically all functions and activities of various Departments through
different Application Software Modules specifically developed for this
purpose.
1.3
The
purchase activities at RCF/Tilak Bridge, New Delhi office are also completely
computerized through an independent Server and LAN system.
1.4
To
cater for Internet needs, 64 kbps ISDN media connectivity has been set up at
RCF; similar facilities exist at New Delhi office as well.
1.5
RCF
has its website addressed: http://www.rcf.nic.in
which has been developed completely in-house.
2. Upgradation
of CAD Centre:
The CAD Center in Design
Department having independent Server and LAN had been working against ‘lease’
arrangements with M/s HCL. On expiry of
lease in July 2003, the complete system with Server, 34 Nos. Workstations and 4
Plotters has since been replaced on an outright purchase basis from M/s Tata
Elxsi and commissioned successfully.
Apart, this step towards upgradation of CAD system has enabled adoption
of the latest version of ‘Unigraphics’ software (UGNS) for efficient CAD
management.
3.
Opinion Poll on Indian
Railways website:
· All the active topics on the Indian Railway Suggestions Website (>750 Nos.) have been browsed identifying specifically the ones related to coach improvements and have been taken up for detailed scrutiny.
· A few suggestions like relocation of the hand support bar in toilet straight away identified for acceptance.
4.
Future Plans – Project for
IT Upgradation:
In line with
sanction of Railway Board for Rs.2.83 crores, a Project for
Replacement/Upgradation of Existing System with Fiber Optic Network is already
under execution with M/s CMC. All the
materials for this Project like servers, network equipment, etc. have been
received and installed including the campus wide cabling work.
The entire Application
Software modules for this upgraded System are completely developed in-house on
ORACLE/Developer 2000 platform under user-friendly ‘Graphics User Interface’
(GUI) environments. These have been
migrated on the upgraded servers successfully for field trials.
The Project is in
the advanced stage of implementation.
ISO 9001
(QUALITY MANAGEMENT SYSTEM)
Rail Coach Factory acquired ISO-9001 certification in 1995. RCF was the first production unit of Indian Railways to achieve this distinction. A new version of ISO-9001 standard had come up in year 2000 laying greater emphasis on customer satisfaction, measurable objectives and continual improvement. After gruelling recertification audit by certifying agency M/s Indian Register Quality System in Sept. 2001, RCF has been certified to ISO-9001 : 2000 version.
ISO 14001 (ENVIRONMENT MANAGEMENT)
Sprawled over 1178 acres of semi-arid soil in Kapurthala district in Punjab, the Rail Coach Factory is an oasis that evokes wonder. But the 'wonder' has a history to it that goes back to 17th August, 1985 when the foundation stone of a modern coach manufacturing unit was laid near Hussainpur Railway Station.
The soil at that time was infertile, covered with sand dunes with hardly any vegetation or irrigation facilities. This could have proved disastrous for the sophisticated machinery and plant, to be installed. The result was a massive tree plantation drive and installation of a large number of tubewells.
About 1.5 lakh trees were
planted which have now increased to about two lakh trees. Not only that, the
RCF complex boasts of rare varieties of flowers, fruits and ornamental trees
making the place an environmental management success story. The barren
xerophytic vegetation has now turned into a green patch, where once only
acacia, thorny bushes and sarkanda grass survived.
"The conformity to
ISO-14001 signifies that the RCF lays
stress on eco-friendliness and strives for better environment management".
At RCF, almost every household has individual gardens and residents are
encouraged to nourish flowers and plants.
Plantation aside, an
effective effluent and waste disposal system is in place. For the treatment of
effluents, waste water is collected through a network of sewers in Sewerage
Treatment Plant (STM) and treated biologically. RCF is also using the treated
effluent for irrigating the golf course and other areas.
An effective system for
solid waste management also exists at the RCF. The waste is collected,
transported and disposed off in compliance to ISO-14001 guidelines. Solid waste
is collected separately at source. Biodegradable waste viz kitchen waste and
garden waste etc and non-biodegradable waste like polythene bags, hard
plastics, glass, rubber etc. is segregated at the point of origin.
The biodegradable waste
is transported to nominated places and dumped off for composing. The
transformed manure is then used in horticulture activities. The periphery of
RCF is covered with rows of eucalyptus trees all along which help check noise
and air pollution.