FIELD TRAINING OF

IRSMEPROBATIONERS

INDEX

1. WELCOME 1

2. GUIDING NOTE 2

3. OVER VIEW 3-9

4. SALIENT FEATURES 10-12

Welcome

RAIL WHEEL FACTORY welcomes IRSMEE probationers to undergo field training. Rail wheel Factory, a production unit of Indian Railways, was established in Bangalore in 1984 to cater to the Wheels and Axles requirement of Indian Railways. It manufactures a variety of railway wheels, axles and wheel sets for the Indian Railways, Other non-railway customers as well as the export market.

RWF strives to build successful and lasting relationships with its customers by consistently exceeding their expectations. Customer focus and quality remain our watchwords.

GUIDING NOTE

The trainees are required to visit shops as detailed below and shall use personal protective equipments like helmet , shoes while they are visiting the shops

1. WHEEL SHOP:

Wheel shop consists of 1. Steel melting Shop.2. Moulding Room.

3. Wheel Final process shop.

2. AXLE SHOP

Axle shop consists of1. Axle forge shop2. Axle machine shop3. Axle assembly shop

3. ASSEMBLY SHOP

Assembly shop consists of1.Wheel seat measuring station.2.Wheel borer3.Wheel set press

4. SERVICE SHOPS

1. Utility shop 2. Electrical ,mechanical Maintenance shop

3. Road Transport Shop

5. MANAGEMENT INFORMATION SYSTEM

OVER VIEW

RWF PRODUCTION TARGET FOR THE YEAR 2010-2011

Wheels : 205200Axles : 73000(units)Out- sourcing axles : 18500(units)Wheel-sets : 67000

1. WHEEL SHOP

Wheel shop consists of 1. Steel Melting Shop.2. Moulding Room.3. Wheel Final Process Shop.

Wheel manufacturing was set up with complete technology transfer from M/s Griffin Wheel Company, a subsidiary of Amsted Industries International, Chicago, USA. RWF manufactures cast steel wheels by controlled pressure pouring process.

In this process, the raw material used is pedigree scrap (old used Wheel sets, axles etc, rejected as unfit for use by the railways). The scrap steel is melted in Electric Arc Furnace. The correct chemistry of molten metal steel is established through a Spectrometer. The wheels are eventually getting cast in the graphite moulds, which are preheated and sprayed. After allowing for a pre-determined setting time the mould is split and the risers are automatically separated from the cast wheel.

The wheel is then subjected to various heat treatments .The wheel

undergoes the process of cleaning, checking, peening and various stages of inspections.

Wheels are produced as per AAR-M 208 Class C, IRS R-19/93 Part 3 Class A, IRS R-19/93 Part 3 Class AV, IRS R-19/93 Part 3 Class B, IRS R-19/93 Part 3 Class BV. The wheel diameter is in the range of 725 to 1100 mm. The wheel manufacturing process involves the following main process stations:

Scrap Charging Steel Melting Steel Tapping & Movement to the pit Casting of Wheels Mould Movement & Splitting Controlled cooling in Hot Wheel Kiln Sprue wash stations Number Stamping Station Hub Cutting Station Normalizing furnace Rim quenching Stations Tempering Furnace Hub cooling Movement to stock Pick up wheel from Stock and bring it loading point for Apex Grinding

(WFPS) Apex Grinding Shot Blasting Inspection

o Magnaglowo Ultrasonico Hardness Testing

Cope /Drag side of wheel grinding Warpage Testing Shot Peening Hub Bore Machining Final Inspection Stocking

2. AXLE SHOP

Axle shop consists of1. Axle forge shop2. Axle machine shop3. Axle assembly shop

RWF makes axles for locomotives, coaches, wagons, crane & EMUs as per following specification of RDSO

a. IRS–R43-1992: Axles for Diesel and Electric locomotives, EMU motor coaches

b. IRS-R16-1995: Axles for Carriages and Wagons.

The axle blooms are procured from1. ASP blooms 2. MUSCO3. TISCO4. VISL5. MSF6. FGK7. BAS

The plant converts steel blooms to axles through a series of forging and heat treatment. Blooms cut to the required sizes are heated in Rotary arc Furnace upto 12000 c. These are carried to the precision long forging machine where the hammers convert billets into the required shapes through computerized control programmes. The forging machines having multiple hammers are used to get required sizes of forgings. After end cutting, the rough forged axles are subjected to heat treatment in normalizing and tempering furnaces.

Rail wheel factory is having three axle machining lines to convert these forgings to the axles .RWF converts BOXN and Coaching axles to wheel sets. Loco axles are generally sent in rough turned condition to the production units and Railways workshops for converting to wheel sets. The axle machining process in line-3 controlled by SIEMENS 840D CNC machines involves the following main process:

a. Cup Turning, Centering and millingb. Rough turning lathec. Drilling, Counter sinking, Tapping and Recenteringd. Semi finishing and finishing of axle journal, dust guard, body, wheel seat and

burnishing of the wheel seat.e. Journal and dust guard grinding machines

3. RWF is having a highly automated wheel set assembly complex supplied by M/s Simmons machine Tool Corporation, USA. Wheel set assembly comprises of following statements.

i. Wheel seat measuring station.ii. Wheel borer

iii. Wheel set press

Wheel seat sizes of machined axles are measured and wheels received from wheel shop are bored to this. The precision borers required interference with the individual axles. After boring, the wheels are carried through automated conveyors to the assembly complex along with axles and wheels are pressed one after another. Finally, the wheel sets are offered for final inspection and dispatch.

4. SERVICE SHOPS

Utility shop caters to the needs of oxygen, HSD oil, compressed air required in the production process.

Road Transport shop caters to needs of industrial vehicles and transport vehicles with maintenance facilities.

Electrical Mechanical Maintenance shop caters to the needs of repair of machinery parts.

5. MANAGEMENT INFORMATION SYSTEM

Rail Wheel Factory is equipped with an online Information Management System (IIMS) covering all major areas viz., Manufacturing Management System, Maintenance Management System, Purchase Management System, Depot Management System. The IIMS has been developed using the modern software technology (.Net) with the MS SQL server 2005 as Database Server. The system is deployed on a Local Area Network having around 268 LAN nodes spread all over the Administrative office and Plant area service through a switched network with Fiber Optic Backbone and UTP/STP connectivity on the client side. The system is powered by Windows 2003 operating system implemented on state of art IBM x3850 4 way dual core processor server implemented on a cluster environment. In addition, RWF hospital is also equipped with a computerized Hospital Management System. An independent Railnet connectivity of 2 MBps through RailTel has been provided to Administrative building, east colony and West colony comprising 200 connections.

To gear ourselves to meet the advent of Internet as a media of communication and to bring about transparency in working, the RWF website is designed with the following important features.

MIS centre is essentially monitoring production highlights online basis and break down , despatch information which is very much acting as vigilant tool for monitoring production performance on a day today basis besides other functions like stores , personnel and welfare are also available in the system

SALIENT FEATURES

QUALITY ASSURANCE:QUALITY ASSURANCE:

Customer delight is the key for assured industrial survival and growth. Realizing the global trend, RWF in tune with other industries, has adopted various quality systems of international standards.

In November 1994, RWF became the first Production Unit of Indian Railways to adopt ISO-9002 Quality Management System and to get certified by BVQI, which is an internationally renowned certifying body.

When this standard was upgraded to ISO-9001: 2000 Quality Management System, again RWF was the first Production unit of Indian Railways to get certified by BVQI in March 2001, within a few months of the introduction of the new standard.

RWF has marched towards bringing in Total Quality Management culture in the organization with a vision to become a world-class manufacturer of railway wheels, axles and wheel sets. In this direction, continuous improvement in the quality of the products manufactured, services offered, employees welfare, environment and customer delight has been taken as the main thrust areas.

In line with the total quality management policy, RWF realized its responsibility towards society for controlling environmental pollution and conserving resources. RWF had set for itself a goal to contain environmental pollution by developing and implementing ISO-14001 Environmental Management Systems (EMS) standards. In June 1999, RWF yet again became the first Railway Unit to obtain ISO-14001 Environment Management System certification by BVQI. This standard was upgraded to ISO-14001: 2004 during September 2005, followed by regular re-certifications.

Like its responsibility towards environment, RWF puts maximum emphasize on employees safety and health. Since the production process of RWF is inherently hazardous, RWF envisaged implementation of OHSAS 18001 (Occupational Health and Safety Assessment series). The certification was complete in February 2005 and again became the first Railway Production Unit to obtain OHSAS-18001 during February 2005 followed by regular re-certifications.

With a vision to have a permanent presence in the global market, RWF has got itself certified by the Association of American Railroads (AAR) as approved manufacturer of railway wheels and axles conforming to AAR Quality Assurance Program M-1003 used in American Railroad Interchange Services. This certification was first obtained in November 1995 followed by regular re-certifications.

In our efforts towards environmental protection and creating environmental friendly ambience, the project for acquiring ISO-14001 Certification from an International Agency for RWF Colony, Hospital and KV was started in the last quarter of 2002-03. RWF Colony was certified for 14001:1996 Standards and the certificate was handed over by the Chairman of M/s. International Certification Services, Mumbai, to GM during the 48th Railway Week function on 15th April, 03.

Yet another feather to RWF was the GREENTECH ENVIRONMENT EXCELLENCE AWARD received in December 2003. The Institute of Indian Foundry men conferred upon a Special Appreciation Award for excellence as a Foundry during 2003 to RWF on 6th February at Hyderabad.

RWF was honored with the Rajiv Gandhi Parisara Prashasthi Award 2003 of Karnataka State Government for Environment on 5th June 2004 at Bangalore. RWF was also honored with the Greentech Safety Gold Award for 2003-04 in Engineering Sector on 21st June 2004 at Goa.

RWF was honoured with the Golden Peacock Award for Corporate Social Responsibility for the year 2004 on 9th November 2004 at Delhi. RWF was honoured with the Golden Peacock Award for Quality for the year 2004 on 15th January 2005. RWF was honoured with the Golden Peacock Award for Health and safety for the year 2008 on 30.10.2008.

DEVELOPMENT OF NEW WHEELS DEVELOPMENT OF NEW WHEELS

1000 DIA – 25T AXLE LOAD WHEEL:

Railway Board envisaged to have RWF wheels on heavy axle load wagons for DFC. RWF has finalized the chemistry, wheel design has been provided by RDSO. RWF has sent 12 wheels and 30 brake blocks to M/s.TTCI for validation tests of the designs. Result is awaited.

TECHNOLOGY CENTRE:- TECHNOLOGY CENTRE:-

Member Mechanical, advised RWF to set up a technology centre, which would act as a repository of knowledge and think tank for RWF. The technology center has since been set up under an experienced SAG Officer. The centre is to document all the production processes; the improvisations RWF has carried out in the last 25 years, maintenance practices, search for new technologies/processes, put in place better maintenance system. The centre has already documented the entire wheel shop production processes, axle shop processes and assembly shop processes.

Office of the SSETechnical training centre

Date: 17/01/2011

IRSME TRAINING PROGRAMME 2010-2011

Action taken

1) CD prepared for study material2) Schedule of training from 24.01.2011 to 28.01.2011 prepared:

Training Schedule:

24.01.2011 Corporate film General visit to Factory25.01.2011 Study of process and manufacturing of wheel shop27.01.2011 Study of process and manufacturing of axle shop

28.01.2011Study of activities MIS, PCO

&Relieving (AN)

SSE/TTC

PRINCIPAL /TTC