2. Company Profile
Diesel Loco modernization Works was conceived with a view to provide
maintenance supports to zonal railways for the maintenance of over 4500
diesels locomotive, which are in services.
DMW believes that product quality has to be built in during manufacturing.
In accordance with the belief, the quality assurance system forms integral
part of workshop activities.
With quality as its strength factor, DMW is surely and steadily notching up
its market share.
3. Salient Features:
Workshop area (Sq m) 837936
Covered area in shops (Sq m) 87578
Township area (Sq m) 1416800
Electrical Energy Consumption 161.01
(Lakhs of units/year)
4. Strategy Followed In Planning Of DCW
Each workshop has a major area functioning under middle management level
officers, who are totally answerable for their performance.
Layout of workshops is such that there is a smooth flow of jobs from one
workshop to another.
Fully integrated with CNC, NC and NON-CNC machines to overcome the
demand.
Machines are placed according to group technology so that final job comes out
as single.
Inspection and testing is done 100% with very accurate instruments for good
quality.
5. Project Objective
Diesel-Loco Modernisation Works was setup in the year 1981 to extend the
service life of Diesel Locomotives of the Indian Railways and significantly raise
the level of their availability.
Manufacture and supply of high quality components and sub-assemblies as
spares.
Manufacture of Components hitherto imported achieving import
substitution and timely availability
Rebuilding Locomotives and power packs and turning them out in state- of-the-
art condition. Retrofitting the locomotives with systems
7. DMW Is Divided In Two Parts-
Phase 1- Phase 1 was sanctioned in May 1982 and that of Phase 2 in June 1986.
For phase 1 group of shops covering an area of 47,000sq.m has been provided
in which 734 items of different machinery & plant have been installed.
Phase 2- Construction of Phase 2 group of shops, where rebuilding of diesel
loco per annual is to be undertaken was taken up in 1986-87 at an estimated cost
of 46.63 crores. For this purpose covered area of 25,000sq.m and 298 different
items of machinery and seven plants have been provided. Facilities for
rebuilding of power packs & diesel locomotives are provided in various shops
9. H.M.S Heavy Machine Shop
C.L.S Cylinder Linear Shop
P.P.S Power Pack Shop
B.S Bogie Shop
S.S.S Super Structure Shop
L.R.S Locomotive Rebuilding Shop
10. Manufacturing Shops-
Phase 1 shops are also known as Manufacturing shops. There are total
seven shops which come under manufacturing . These shops manufacture
small and heavy parts of loco. The various shops are described as follows:-
Light Machine Shop
About 300 spare parts required by DMW and Zonal Railways for
locomotive maintenance including Camshafts, Gears, Valve gear
components, Equaliser beams, Axles, Armature shafts, Axle box housings,
Gas inlet casings, etc. are manufactured in the Light Machine Shop.
11. This shop is also known as for Manufacture of Rail-cum-Road Vehicle. Here
various tools and components of locomotives are produced with various
machines. Most of the machines are controlled by CNC’s.
12. Heat Treatment Shop
Requisite heat treatment that is induction hardening, case carburizing etc. is
carried out in the Heat Treatment Shop to develop optimum properties in the
finished components.
13. Carbon Brush Shop
The Carbon Brush Shop manufactures 14 types of carbon brushes required
for Traction Generators, Traction Motors and Auxiliary Electrical Machines.
Recently carbon brush CB-48 has been developed for fans of ICF coaches.
14. Heavy Machine Shop
Engine Blocks of diesel locomotives and Traction Motor Magnet Frames are
machined in this shop. Precision machining of the Blocks is carried out on
CNC Horizontal Boring & Milling Machine of PAMA, Italy make CNC
machine.
15. Traction Machine Shop
A wide variety of Traction Motors, Traction Generators and Alternators are
rewound / remanufactured in this shop. Facilities include 500 T Hydraulic
Press for shafting/deshafting, Glass Bead Blasting Machine, Vacuum
Impregnation Plant, HYT Lathe, Dynamic Balancing Machine, etc.
16. Locomotive rebuilding shops
Phase 2 comprises of Loco-rebuilding Shops. There are total five shops.
During Locomotive Rebuilding, besides upgrading output to 3100 HP, the
locomotive is also modernized to incorporate numerous improvements in
locomotive technology.
Power Pack Shop
All the Power Packs from incoming locomotives are sent to the Power Pack
Shop for remanufacturing. In this shop the power pack is wholly dismantled
and rebuilt, tested and then sent to LRS for fitment on the LOCO.
17. The main functions of this shop are-
Dismantling, Reconditioning and assembly of power pack.
Load testing, specific fuel consumption testing and other types.
19. Locomotive Rebuilding Shop
a) Locomotive rebuilding facilities include dismantling, repairs and
reassembly of the complete Locomotive including under frame.
b) A manipulator has been developed for ensuring downhand welding during
the repair of under frame and chasis.
c) Remanufacturing facilities for auxiliary machines and electronic control
harness are also available.
d) Air Brake and Paint Shops constitute the supporting activity areas for
locomotive rebuilding.
e) Power and control cables are renewed and control equipment is
remanufactured.
21. Bogie Shop
The locomotive bogies are rebuilt with new wheel sets, suspension bearings
and remanufactured traction motors. Separate shop has been set up for
machining of wheel sets and assembly of locomotive bogies.
22. Support shops
Above activities are adequately supported by competent workforce of staff
and supervisors of Plant Maintenance Shop, Tool Room, Main Receiving
Station and other support shops.
Electronics Lab
23. • There is a full-fledged Electronic Lab which has been set up to cater to
maintenance need of highly sophisticated CNC machines and component /
subassembly level trouble shooting of PCBs, Servo Drives, Microprocessor
based controllers and electronic units.
• A saving of Rs.1.17 Cr. has been achieved in 2005-06 due to repair of
PCBs.
24. Activities and Products Of DMW
Mid life rebuilding/ reconditioning of WDM2 ALCO locomotive.
Upgrading them from 2600HP to 3100HP and 3300 HP.
Incorporating various modifications to enhance the efficiency, reliability,
safety of locomotive.
Manufacture of various type of carbon brushes used on traction machines of
WDM2, WDM3A, YDM4, WDG4, WDM3C, DMU.
Rewinding/ reconditioning of traction motors, traction generator & traction
alternators of locomotives.
Reconditioning of engine block of ALCO locomotives, power pack and
supply of New Power packs.
26. Machines and technology used in DMW
PAMA Machine
This machine is the most important machine of DMW. This machine is
located here only in all over India.
This machine is a part of Heavy Machine Shop (H.M.S.).
It is used for cutting and boring purposes in a tool.
Mainly an engine block is manufactured and repaired in this machine. One
engine block can be repaired three times in this machine.
The main description can be given as PAMA Horizontal Boring and Milling
Machine (with speed RAM).
28. CNC Machines
Computer Numeric Control machines is a closed loop machine.
As the name depicts these machines use computer for their operation.
Computer Numeric Control machines are controlled by a set of different
ISO codes that helps in proper controlling of the machine.
In modern CNC systems, end-to-end component design is highly automated
using CAD/CAM programs.
30. Vertical Rotary Mill
This machine is CNC operated machine. Vertical Rotary mill is located in
LMS shop. It is used mainly for boring and milling of the tools.
It needs a total power of 35 KW for its operation.
It is worth Rs 17.09322 lacs.
The main components used are- Main Bearing Cap, Connecting Rods,
Casing Lop, Support V/L.
The maximum capacity of it per day is around 45.
It has three axis :– X – Rotating, Y - Horizontal. Forward and backward
direction, Z - Vertical. Up and down direction.
32. Electronic Lab Equipment
Some of the sophisticated workstations and testing equipment in the Lab are:
X-Y, Y-T, 3-Channel Recorders.
Dual Channel 100 MHz Oscilloscope with DMM.
5½ Digit Bench Programmable Digital Multimeter.
Function Generator with Arbitrary waveform generation.
PCB Test Station
Automatic Test Equipment (ICT).
Universal PROM / EPROM Programmer.
Digital / Analog IC Tester.
Surface Mount Component Repair Station.
33. PCB Test Station and Universal PROM / EPROM Programmer
34. Result And Conclusion
The Indian Railway is the most widely used transport system in India. The
production of the parts and units of rails forms an important and integral
part of the proper functioning of the railway system in India.
Its World's largest manufacturer of ALCO diesel loco spares such as Gears,
Cams, Con rods, Pins, Carbon Brushes etc.
DCW manufactures large components such as traction motors and
locomotive power packs, rebuilds engine blocks, traction generators, etc.
They have more recently been upgrading WDM-2 locos to WDM-2C class.
