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About DMW

 
 
 
ABOUT US
 
INTRODUCTION  
 
·              Introduction of Diesel Locomotives on the Indian Railways started in late 50’s, with the 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 a regular pace.                    
                In the earlier years of diesel operation, a limited demand of spares was met by Diesel Locomotive Works, Varanasi mainly through import, but the demand increased with the increasing size and age of the fleet.
·                     It was in the context of the need for 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 sanctioned and the work of Rebuilding started in 1989. The name of DCW was changed to Diesel Loco Modernisation Works (DMW) in July, 2003 to signify the modernisation of Diesel Locomotives being done in the unit.
 
                                                                                                             
Rebuilt and upgraded 3300 HP Locomotive
 
 
 
 
 
 
 
 
2.0    ROLE OF DMW IN THE GROWTH OF INDIAN RAILWAYS
 
DMW had been rebuilding about 72 Locomotives from 1992-93 to 2005-2006. To meet the challenges of increased traffic, DMW enhanced the productivity of the workshop and was able to rebuild 86 Locomotives in 2006-07, 102 Locos in 2007-08 and 108 Locos in 2008-09. DMW has achieved a Record Breaking Performance of 112 Locos in 2009-10. During 2010-11, DMW has rebuilt 110 locos including 1 new ALCO WDM3D Loco.
During rehabilitation, latest sub-assemblies like Microprocessor Control System, AC-DC power transmission, Fuel Efficient Engine Kits, Roller Bearing Suspension System, Traction Motors, new Crankshaft and Crew Friendly Features like Low Height Control Desk Stand, Roof Mounted DBR, Revolving Chair, Fan, Large size sliding window, etc. are fitted and up-gradation of Horse Power of Locomotive from 2600 HP to 3100/3300 HP is done. This ensures that the trip schedules of Locos are extended to 30/40 days and Locos give better reliability, availability, improved performance during service with better fuel efficiency.
 


3.0 SALIENT FEATURES OF DMW
·         ISO 9001:2000, ISO 14001:2004 & IS 18001 Certified Production Unit
·         Total workforce on roll is 3753 including 89 officers.
·         Workshop area (m2)
837936
·         Covered area in shops (m2)
88194
·         Township area (m2)
1416800
·         Electrical Energy Consumption (lacs of units/year)
200
·         Total staff quarters
1767
·         No. of beds in Hospital
30

4.0   PRESENT ACTIVITIES AT DMW
·         Rehabilitation, Upgradation to 3100/3300HP & Modernization of Diesel Locos.
·         Supplying New/Remanufactured Power Packs to Zonal Railways.
·         Nodal Agency for procurement of BIM ALCO items
·         Supplying 240 types of high precision & critical components to Zonal Railways as Maintenance support.
·         Supplying WDM3A/ WDG3A/ WDM3D Motorized Wheel sets to Zonal Railways.
·         Supply of rehabilitated Engine Blocks & Traction Machines to Zonal Railways.
·         Nodal Agency for Rehabilitation of high HP Turbochargers.
·         Supply of all types of Carbon Brushes of Diesel Locos to Zonal Railways.
 
5.0         WORKSHOP FACILITIES AVAILABLE AT DMW
 

     Shops set up under Phase-I of the project are called Manufacturing Shops
·         Light Machine Shop
·         Heat Treatment Shop
·         Traction Machine Shop
·         Heavy Machine Shop
·         Cylinder Liner Shop
·         Carbon Brush Shop
·         Plant Maintenance Shops
·         Tool Room

           

 
 
 

    TRACTION MACHINE SHOP

 

 

  BLOCK MACHINING CENTRE

 

 

 
 
 
 

 

Shops set up under Phase-II of the project are called Rebuilding shops
 
·         Loco Rebuilding Shop
·         Power Pack Shop
·         Bogie Shop
 
·         Transmission Repair Shop
·         Air Brake & Pipe Shop
·         Loco Test & Paint Facilities

    LOCO ASSEMBLY

 

 

Loco Assembly

 

 

 
 
 

      REBUILT BOGIE

 

 

 
 
6.0         DMW PRODUCTION
 
·         DMW PRODUCTION PERFORMANCE OVER THE LAST SOME YEARS
 

DMW Production in numbers & money value
Year
No.of Locos rebuilt
Number of subassemblies remanufactured
Value of items manufactured in LMS                           (in Cr. of Rs.)
Number of Carbon Brushes produced        (In Lacs )
Power packs
Engine Blocks
TM Armature
TG Armature
Cylinder Liners
2000-01
64
76
126
800
156
7976
41.8
5.5
2001-02
63
79
123
871
121
7826
40.8
5.9
2002-03
73
79
121
848
110
8047
45.8
5.9
2003-04
73
85
127
864
124
8004
46.4
5.2
2004-05
74
87
132
864
125
8402
51.2
5.3
2005-06
73
93
160
872
135
8450
64.5
6.0
2006-07
86
112
172
956
127
9101
76.1
5.4
2007-08
102
136
187
1050
97
10051
81.5
5.5
2008-09
108
139
192
1276
64
10534
87.7
6.1
2009-10
112
156
184
1423
39
8565
117.29
4.8
2010-11
110
142
166
1426
26
15957
154.33
4.9

 
 
  • OVERALL PRODUCTION VALUE
 
6.1 PRODUCTION PERFORMANCE DURING 2010-11

During 2010-11, performance of DMW has been the best ever since its inception. DMW has achieved highest production figures in all major areas of activities, i.e. Loco Rebuilding, Power Pack Assemblies, Supply of Motorised Wheel Sets, Remanufacture of Traction Motors etc. DMW has rebuilt 110 locos and achieved Turn Over of ` 1071.73 Cr in 2010-11 - first time in its history.
 
Production performance vis-à-vis Targets fixed for the year has been as under:

 
 

S.
No.
Item
 
Annual target
2010- 11
Out turn
2010-11
%age improvement
1.           
Locomotives Rebuilt
108
110
2%
2.           
Power Packs(for ZRs)
24
30
25%
3.           
Power Packs (Total)
132
142
8%
4.           
Motorised Wheel sets
400
401
-
5.           
TM Assemblies
1167
1180
1%
6.           
TM Magnet Frames
1271
1284
1%
7.           
Spares(LMS+Trade) (Rs.Cr.)     
142
154.33
9%
8.           
Total out turn (Rs.Cr.)      
 956.28  
1071.73
12%

 
 
 
 

v     First DMW Manufactured WDM3D Loco Rolled Out:
 
DMW rolled out First New WDM3D, 3300HP, ALCO Locomotive on 29.03.2011. DMW had been Rebuilding Diesel Locomotives since last 22 years and for the first time New ALCO Loco has been manufactured at DMW. The Locomotive No. 11360/WDM3D was flagged off by Chief Administrative Officer(R) and sent to Diesel Shed, Pune Central Railway.
 

 
 
 
7.0 SUPPORT TO ZONAL RAILWAYS DURING 2010-11
 
 Supply of Power Packs & Engine Blocks to Zonal Railways:
 

Total 75 Power Packs and Engine Blocks (30PPs+45EBs) have been supplied to Zonal Railways. This has helped Zonal Railways in commissioning locos awaiting for Power Packs.

 

Supply of Rehabilitated Turbo Superchargers:
 
During April’10 to March’11, 193 Rehabilitated Turbo Superchargers have been supplied to Zonal Railways. This has helped Railways in overcoming the problem of running of de-rated diesel locos.

 

Supply of RSP items to Zonal Railways:
All out efforts are being made for timely supply of RSP items to Zonal Railways. In May’10, Railway Board sanctioned the following 3 items for supply to Zonal Railways under RSP. Supply status of various RSP items allotted to DMW is as under:

 

i)                    Turbo Super Chargers                                   260 Nos.
ii)                  Plate type Lube Oil Coolers                           200 Nos.
iii)                Turbo Superchargers for 2300 HP Locos      30 Nos.
iv)               M.B. Radiators                                                  50 Nos.
v)                 Self Cleaning L.O. Filters                                 95 Nos.
 
DMW has supplied last 04 items fully to Zonal Railways in financial year 2010-11. This is the first time, RSP items have been supplied to Zonal Rlys. in the same financial year in about 11 months from the date of sanction.
 
Supply of Motorised Wheel Sets:
A total of 401 Motorised Wheel Sets (290 for WDG3A & 89 for WDM3A + 22 WDM3D) have been supplied to Zonal Railways against allotment of 400 Nos. given by Railway Board. This has helped Zonal Railways in switching over ALCO locos to 30/40 days schedules.
It is the highest ever production of Motorised Wheel Sets by DMW. Earlier, the highest production was 370 Motorised Wheel Sets in 2009-10.
 
Supply of Annexure ‘N’ items:
Almost all critical Annexure-N items have been supplied to Zonal Railways as per their indents. Some Railways have also been assisted by supplying piston pin assembly, GI Casings, Equalizer Spring Sheet, Push Rod Assembly, Armature Shaft and other critical Annexure ‘N’ items beyond their indents.
Total sale of Annexure ‘N’ items in the year has been worth Rs.154.33 Cr. which is the highest ever. Last year, the supply was worth Rs.70 Cr.
 

 
8.0           IMPROVEMENTS AND UP-GRADATIONS IMPLEMENTED ON REBUILT LOCOMOTIVES FOR ENHANCED AND IMPROVED PERFORMANCE:
 

During Rebuilding, following modifications were implemented on all Rebuilt Locomotives in 2010-11:

 

SN
Modification
Implemented w.e.f.
1.              
Tight Lock Coupler & Soft Draft Gears
March’10
2.              
3 RV Piston Kit
April’10
3.              
18 mm Fuel Injection Pump (60%)
April’10
4.              
Roof Mounted Dynamic Brake Resistance
May’10
5.              
Double Ferrule Fittings in Air Brake copper pipes
Feb’10
6.              
Heat Shrinkable Tube on cable terminals
Jan’10
7.              
D-1 EMD type Auto drain valve
May’10
8.              
Modified hand brake assly
March’10
9.              
Improved FIP tube with auto frettage
April’10
10.         
EMD type Modified Dresser Coupling
May’10

 

Following modifications carried out during Rebuilding in 2010-11 on limited locos:

 

SN
Modification
No. of Locos on which fitted during 2010-11
1.            
Computer controlled brakes
23 locos
2.            
REMMLOT
32 locos
3.            
LCD Display on Control Stand (DIALS) 
23 locos
4.            
500 AH Batteries
56 locos
5.            
Gear Case with TPU seal (30%)
50 locos
6.            
EMD type Cut-Out Cocks
03 locos
7.            
EMD type headlight
10 locos
8.            
Sealed conduits for cables
34 locos
9.            
Fabricated Bogies Frames
01 loco

 
9.0 QUALITY, ENVIRONMENTAL AND OCCUPATIONAL HEALTH & SAFETY SYSTEMS:
 

DMW is ISO 9001:2008, ISO 14001:2004 and IS 18001:2007 certified by M/s. BIS, Chandigarh. Single document system has been established to integrate quality, environment and occupational health and safety management systems for implementation, assessment and certification to the respective standards.
Management Review Meetings - Three management review meetings and two internal audits were conducted during the year.
Recertification audit of ISO 14001:2004 and surveillance audit of ISO 9001:2008 were conducted successfully on 31.05.10 and 01.06.10. Certification body M/s. BIS granted ISO 14001 recertification to DMW valid from 25.01.2010 to 24.01.2013. During the audit, BIS also concluded that DMW has implemented the revised version ISO 9001:2008 satisfactorily.

 
10.0                 EXPORT
 
·   Rebuilding of Tanzania Railway Locomotives
 
 

For the first time in the history of Indian Railways, an order for Rebuilding of two MLW Class 88 Canadian built Tanzanian Railway Locomotives was placed on Diesel Loco Modernisation Works, Patiala by M/s RITES. DMW took upon the challenge and Rebuilt these Locomotives by re-engineering design. Horse power of locomotives has been increased from 1880 HP to 2300 HP. 
All major electrical & mechanical assemblies/ sub-assemblies of ALCO Diesel Locomotive design were fitted for ease of maintenance & availability of spares. Driver’s Cab was converted from single control stand to dual control stand to facilitate the driver to drive locomotive in both directions. These locos were dispatched after successful Rebuilding in May 2009. 

 
                 
 
 
 
 
 
 
 
            Rebuilt Tanzanian Railway Loco
 
·      DMW is exporting spares of Diesel Locomotives to countries like Malaysia, Sri Lanka, Vietnam, Bangladesh, Peru, Tanzania & Myanmar through RITES & IRCON. DMW has achieved export sale amounting to Rs.488.63 lacs during 2009-10. In 2010-11, DMW has exported material worth Rs.93.38 lacs.
 
11.0        DEVELOPMENT OF CAD & VENDOR APPRAISAL CELL
In order to enable DMW to become hub of ALCO Locomotives for next three decades, DMW has started the work of Design development & Vendor evaluation, Bulk procurement and distribution of items of ALCO Locomotives hitherto being done by DLW. Action for creation of independent Computer Aided Design & Development facility in DMW has already been initiated for which a work of development of CAD facility at DMW has been sanctioned for Rs.2.88 Crs. by Railway Board and procurement of desired hardware & software is in process.
 
 
 
 
 
12.0            NEW LOCO MANUFACTURE
DMW has planned to become the hub of ALCO Loco manufacturing on Indian Railways. Manufacture of 25 new WDM 3D locomotives has been planned to start from 2011-12. This number would be gradually increased to 50 in 2012-13 and 75 in 2013-14 in accordance with Railway Board’s Vision 2020. DMW is geared up to meet this challenge and manufacture of one such locomotive in 2010-11 has already been made. Complete material and infrastructure planning has been put in place to achieve the targets envisaged under Vision 2020.
 
 
13.0          FUTURE PLANS
 
Ø                  To manufacture 25 New ALCO WDM3D Locos in 2011-12.
Ø                  DMW & Parel to manufacture 50 ALCO locos in 2012-13, 75 in 2013-14 & 100 from 2014-15 onwards.
Ø                  To manufacture 30 EMD Locos from 2017-18 onwards
Ø                  To establish series manufacture of EMD Traction Alternators after rigging up facilities for testing of EMD TA’s.
Ø                  To manufacture 02 Multi Genset Locomotives in 2011-12
Ø                  To develop overhauling facilities of Traction Motors for EMD Locomotives.
 
 
      DMW IS A VIBRANT AND PRESTIGIOUS UNIT OF INDIAN RAILWAYS LOOKING TOWARDS FUTURE WITH CONFIDENCE AND GEARING UP TO BECOME HUB OF ACTIVITY OF ALCO LOCOMOTIVES.



Source : Welcome to DMW Official Website ! CMS Team Last Reviewed on: 19-09-2011  

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