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Workshop

KANCHRAPARA

Departments

Mechanical

LOCO MECHANICAL

MILESTONE

	INTRODUCTION

	ORGANISATION CHART

	MAJOR ACTIVITIES

	ACHIEVEMENT


	M&C LAB ACTIVITIES

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MILESTONE

New Milestone of Loco Mechanical Wing in 2022-23 :

Tasks Performed /Objectives	Targets (2022-23)	Achievement (2022-23)
Overall outturn of Loco wheel shop No-2at Loco Complex.	3771 Sets	4469 sets which is 18.5% higher than the target.
POH of Locomotives wheel sets	444 sets	459 sets which is 3.37% higher than the target.
POH of EMU(MC) and TLR wheel sets	1150 sets	1486 sets which is29.21 % higher than the target
POH of EMU (MC +TLR) Coach	284 Nos.	344 Nos. which is 21.12 % higher Than the target.
IOH of ICF Conv. Bogie	480 nos.	739 Nos. which is53.95% higher than the target.
Divisional Loco wheel assistance	800 sets	989 sets which is 23.62% higher than the target
Disposal of Scrap
Ferrous	2100 MT	2526.535 MT which is 20.31% higher than the target
Non-Ferrous	1.0 MT	1.540 MTwhich is 54% higher than the target.
Shock Absorber/Vertical Damper/Lateral Damper/Leveling & Duplex ValveOverhauling
(a)300 kg Vertical Damper	2520 nos.	2703 nos which is 7.26%higher than the target.
(b)600 kgVertical Damper	336 nos.	432 nos. which is28.57% higher than the target
(c)100 kg Lateral Damper	696 nos.	942 nos. which is 35.34% higher than the target.
(d)200 kgLateral Damper	2676 nos.	2814 nos. which is 2.7 % higher than the target
(e)600 kg Shock Absorber	1750 nos.	2965 nos which is 69.42% higher than the target.
(f)900 kgShock Absorber	500 nos.	532 nos. which is 6.4% higher than the target
(g)Leveling Valve	2400 nos.	2898 nos. which is 20.75% higher than the target.
(h)DuplexValve	600 nos.	654 nos which is 9.0% higher than the target.
Spring Testing :
(a)ICF Primary suspension spring	3840 nos.	6000 nos. which is 56.25% higher than the target
(b)ICF Secondary suspensionspring	1920 nos.	3002 nos. which is 56.35% higher than the target.
(c)EMU (MC) Primary suspension spring	2880 nos.	5509 nos. 91.28% higher than the target.
(d)EMU(MC) Secondarysuspension spring	576 nos.	1230 nos. which is 113 % higher than the target.
(e)Training of Trainees at MDSTC/WDSTC	1500 nos. Trainees	1532 nos. trainee which is 2.1% higher than the target.
Training of Traineesunder RKVY	400 Nos Trainees	426 nos. trainee which is 6.5% higher than the target.
100 daysfailureLoco Mechanical POHed /Repaired equipments/items.	Nil	Nil since last 02 years.
Green-Co Certification	Certification	“Gold” Certification obtained 27.03.2023.

·Up gradation of more than 80%Weldersof Loco complex to “A” category.

·Installation & commissioning20 Ton EOT Crane at Shop-2,

·Installation,commissioning and automation of CNC Surface Wheel Lathe,

·Construction of Ladies room with crèche facility and Supervisors Staff Room with all amenities at shop No-2,

·Construction of conference Room at Shop No-2 for meeting, planning & execution oftargeted outturn,

·Installation & commissioning10 Ton Crane at Shop-4,

·Procurement of01 no. Plasma cutter for cutting of stainless panels of new 3-Phase EMU coaches,

·Conversion of Diesel driven track to eco friendly battery operated Platform Truck for carryingof materials inside shop floor,

·Replacement of old conventional welding machine by 20 nos. energy saving IGBT based Welding machine for replacement of over aged machine.

·Installation of526 nos. Air turbo Ventilator(Natural ventilator,

·Renovation of ETP to “ Eco Friendly ETP Plant” and 28.5% increase of treated water for gardening, irrigation & sanitation.

·First time in Indian Railway , Conversion of old Garden in front of Administrative Building of Kanchrapara Workshop, Eastern Railway to Japanese gardenas“Green Meadow”,

·Installation and commissioning 50 & 30 Kg waste converter,

·Dust free Bearing and axle box assembly Room & Section at shop No-2 for ensuring dust free installation of bearings and axle box assembly.,

·Creation ofCentre of Excellence- I and II and Digitization of Wheel measuring gauges,

·Installation & commissioning Laser engraving machine and phasing out of old Itching machine in Loco inspection Cell,

·Provision of QR code on machines depicting machine uptime, downtime last breakdown etc .

·Installation of Industry 4.0 at 04 no machines at Shop No.2to monitor the real time critical performance parameters

·Jaalvayu : As carbon neutral application,Carbon foot print and production Hydrogenand oxygen which can be used as eco friendly fuel against use of Acetylene gas

·5S certification of 100 % entire shop of all Shops.

·NABL Accreditation of M&C Lab of KPA Workshop for Non-Destructive Testing

·Installation and commissioning Bio-gas converter.

·ObtainGreen–Co- “Gold”Rating Certification which added a new feather in the same crown as well as earning ofgood fame of this workshop.

·Provision of Waste Management Gallery along with waste management plant at all the shops.

·Successful fire audit at Loco complex by outsourced agency NIISFEM and 100% compliance of their observations.

·Installation and commissioning of Dash pot oil centrifugal machine which is recycling 190 L/month of oil and being reused.

·Provision of IOT based water meterat all critical locations at ETP for daily variance analysis of effluent treated and reuse of water

·In-house manufacturing and provision of Bio Toilets for staff.

·In-house manufacturing of belt pulley sludge oil separator at ETP for effective oil separations.

·First time massive plantation of “Beema Bamboo” at KPA workshop, Eastern Railway.

·In-house provision of chip compactor in wheel shop No-2 .

·FRP Cab modification startedin Eastern region from the first time which leads to better aesthetics and durability of Driver cab

·Planning and provision of Fire exit Plan at Main administrative buildingcovering all areas.

·Installation of 71nos fire alarmsfor alarming covering all buildings

·Developmentof Fire Exit management plan

·Development of Disaster management team and First Aiders whish exists only in KPA..

·Developmentof waste management plan all over KPA workshop

·Conversion & modification of condemned MEMU coach to Inspection Car.

·First time Introduction of Disaster Management training with HRE & HRD at MDSTC/KPA

·Conversion of conventional library by e-Library at MDSTC/KPA

·Highest no. RKVY trainingdone at MDSTC/KPA that is 427 nos (highest in Indian Railways)

·Highest No .of training trained at MDSTC KPA i.e 1625 nos. trainees trained at various subjects which is ever highest in Eastern Railway.

·There is no failure for the last five (5) years of Loco wheel set supplied from wheel shop.

·Various initiatives for reduction of carbon foot print. As a result of which. Achievedhighest ever reduction in Carbon footprint that is 27.9 % ever at KPA workshop.

·Six Sigma of wheel increased from 3.23 to 5.82.

New Milestone of Loco Mechanical Wing in 2023-24 :

1.Loco Wheel Shop No-2 has achieved highest everoutturn of 4842 wheel setsduring the year 2023-24. The previous highest ever was 4464 nos. wheel sets in 2022-23.

2.Loco MechanicalShop No-4 has achieved highest everoutturn of 924 nos IOH bogieduring the year2023-24. The previous highest ever was 738 bogies in 2022-23.

Tasks Performed /Objectives	Targets (2023-24	Achievement (2023-24)
Overall outturn of Loco wheel shop No-2at Loco Complex.	3878 Sets	4842 sets which is 24%higher than the target.
POH of Locomotives wheel sets(71 Locos)	426 sets	570 sets which is 33.8 % higher than the target.
POH of EMU(MC) wheel set	1172 sets	1304 sets which is11.26 % higher than the target
POH of EMU MCCoach	262 Nos.	264 Nos. which is 0.76 % higher Than the target.
IOH of ICF Conv. Bogie	480 nos.	924 Nos. which is 92.5% higher than the target.
Divisional Loco wheel assistance	1080 sets	1112 sets which is 2.96 % higher than the target
Disposal of Scrap
Ferrous	2500 MT	2932.945 MT which is 17.31% higher than the target
Non-Ferrous	1.0 MT	3.550 MT which is 255% higher than the target.
Shock Absorber/Vertical Damper/Lateral Damper/Leveling & Duplex ValveOverhauling
(i)300 kg Vertical Damper	2744nos.	3665 nos which is 33.56%higher than previous outturn of the same period.
(j)400 kgVertical Damper	62 nos.	111 nos. which is79.0% higher than theprevious outturn of the same period.
(k)900 kg Vertical Damper	273 nos.	332 nos. which is21.61 % higher thanprevious outturn of the same period.
(l)200 kgLateral Damper	2864nos.	3513 nos. which is 22.66 % higher than previous outturn of the same period.
(m)900 kgShock Absorber	536 nos.	710 nos. which is 32.46% higher thanprevious outturn of the same period.
(n)Installation Lever	518 nos.	898 nos. which is 73.35% higher thanprevious outturn of the same period.
(o)DuplexValve	621 nos.	751 nos which is 20.93 % higher thanprevious outturn of the same period.
Spring Testing :
(f)ICF Primary suspension spring	5999	8057 nos. which is 34.30 % higher than previous outturn of the same period.
(g)ICF Secondary suspensionspring	3001	3904 nos. which is 30.08 % higher than previous outturn of the same period.
(h)EMU (MC) Primary suspension spring	5624	6080nos. which is 8.10% higher than previous outturn of the same period.
(i)EMU(MC) Secondarysuspension spring	1262	1375 nos. which is 8.95 % higher than previous outturn of the same period.
100 daysfailureLoco Mechanical POHed /Repaired equipments /items.	Nil	Nil since last 02 years.

New Milestone of Loco Mechanical Wing in 2024-25 :

Tasks Performed /Objectives	Targets (2024-25)	Achievement (2024-25)
Overall outturn of Loco wheel shop No-2 at Loco Complex.	4022 Sets	4885 sets which is 21.45%higher than the target.
POH of Locomotives wheel sets(72 Locos)	426 sets	426 sets which is 100%against the target.
IOH of ICF wheel sets	1080 sets	1958 sets which is 81.3% higher than the target.
IOH of ICF Conv. Bogie	540 nos.	968Nos. which is%higher than the target.
Overhauling of Bogie Mounted Brake Cylinder	1080 Nos.	1936Nos. which is 79.2 %higher than the target.
Divisional Loco wheel assistance	1080 sets	1367 sets which is 2.96 % higher than the target
No. of M/Coaches berthed for Heavy corrosion repair	47 nos.	53 nos. which is 12.76 % higher than the target.
Disposal of Scrap
Ferrous	2400 MT	3721.114MT which is 55.04 % higher than the target
Non-Ferrous	1.0 MT	18.762MTwhich is 1776.2 % higher than the target.
Shock Absorber/Vertical Damper/Lateral Damper/Leveling & Duplex ValveOverhauling
Overhauling of 100 Kg Lateral damper for Air suspension system	175 Nos.	181 Nos. which is 3.42 % higher than the target.
Overhauling of Levelling valve for Air suspensionsystem	2535 nos.	3091 Nos. which is 21.9 % higher than the target.
Overhauling of Duplex Check valve for Air suspensionsystem	751 Nos.	1367 Nos. which is 82.02 % higher than the target.
ICF Primary suspension spring	8057 Nos.	8406 Nos. which is 4.33% higher than the target
ICF Secondary suspensionspring	3904 Nos.	4151Nos. which is 3.06% higher than the target
LocoSuspension spring	150 Nos.	172 Nos. which is 14.73% higher than the target.
Testing of Sling wire Rope of EOT Crane	157 Nos.	168 Nos. which is 7% higher than the target.
Testing of Bottom BlockofEOT Crane	34 Nos.	43 Nos. which is 26.47 % higher than the target.
Testing of Hoist wire RopeofEOT Crane	37 Nos.	44 Nos. which is 18.91 % higher than the target
Issue of fitness Certificate of EOT Crane	20 Nos.	30 Nos. which is 33.33 % higher than the target.
Ultrasonic testing Wheel Disc	3547 Nos.	4201 Nos. which is 18.43% higher than the target.
Destructive testing of different items	2915 Nos.	3057 Nos. which is 4.87 % higher than the target.
100 daysfailureLoco Mechanical POHed /Repaired equipments /items.	Nil	Nil since last 03 years.

·In-house modifiactionoftwo pieces Centre Pivot Pin arrangement of 20t Axle Bogies into single piece has been done.This arrangement reducesthe chance of crack formation in the welding neck jointof two piecesCentre pivot Arrgt. For 20t Axle Bogies. It ensures no welding failure of Centre pivotjoint and improves safety of Rolling stock andpassenger.

·Modification has been done in End Wall of Jessop make EMU coaches. Earlier, for attending electrical failure, the entire end wall had tostrip. It was complicated and also time taking. Now it has been modified by setting the backrest with Nut & Bolt on End Wall structure & keeping in mind the easy opening of the said End wall to facilitate electrical failure attention. So less time and manpower required during line failure attention.

·43 FRP Cab modification for better aesthetics and durability of Driver cab has been carried out during the period 2024-25.

·Installation & commissioning10 Ton EOT Crane at Shop-2,

·Installation,commissioning and automation of Axle Box cleaning plant at Shop No-2,

·Construction of Ladies room andStaff Room with all amenities at shop No-2,

·Provision of Smart Board with LED projector in theconference Room at Shop No-2 for meeting, planning & execution oftargeted outturn,

·Procurement of one Digital Torque Tightening System. This is a new item and used for tightening bolts of EMU, ICF, Loco Wheel set and digitally recording all data simultaneously.

·Procurement of one Portable Induction Heater of capacity40 KW. This item has been is being usedfor uniform heatingof MSU tube for fitting and stripping tube and accessories instead of flame heating as advised by RDSO.

·Installation and Removal System for Axle Box Bearing WAP4/WAP7 Loco through motorized hydraulic system .It is being usedfor extraction and fitting of loco axle box WAP4 and WAP7 bearings without damaging racer seat.

·Procurement of one Hydraulic Floor Crane, 2000 Kg. It is being used for shifting of heavy components and removal and fitment of axle box in wheel set.

·Procurement of one Heavy Duty Grease Pump with Grease Gun having in line flow meter. It is used for fillingpre-measured quantity grease in EMU, ICF, LOCO Axle Box and MSU regularly. It avoids over or less filling of grease.

·Procurement of 05 nos. Drying oven for Electrodes.

·Procurement of02 no. Plasma cutter for cutting of stainless panels of new 3-Phase EMU coaches,

·Up gradation of more than 65%Weldersof Loco complex to “A” category.

·Dust free Bearing and axle box assembly Room & Section at shop No-2 for ensuring dust free installation of bearings and axle box assembly.,

·Installation of Industry 4.0 at 06 nos. machines at Shop No.2 to monitor the real time critical performance parameters.

·Started testing of Transformer lifting Tackle and tested 03 nos. such Tackle in 2024-25.

·Replacement of old conventional welding machine by 10nos. energy saving IGBT based Welding machine and 05 nos. MIG/MAGwelding machine.

·Nos. of traineestrained at MDSTC KPA is 1025 in 2024-25 which is3.85% higher than 2023-24.

·Six Sigma of wheel increased from 3.23 to 5.82.

·10 nos Rainwater Harvesting Plant have been installed various buildings , sheds at KPAWin this FY 2024-25.

·2000 Nos Plants have been planted at Vacant land of Officers & Ambagan colonies of KPAW.

·Plant 4 Mother’ Campaign at Loco Complex of KPAW, employees of various shops were directly engaged in this campaign.

·11 No. High Mast Solar lights have been installed & commissioned at HLR Cutting yard also 04 No’s at KPA cutting yard on 22-01-2025.

·750 kWp roof top Solar power plant commissioned on December-2024. Total Roof top Solar plant now at KPAW is 3.86MWp.

·65 Nos roof top Green smart Turbo-ventilator have been installed at various Loco Electrical shades under Dy CEE/Loco at KPAW.

·Survey, Design & Drawing and Estimate against installation of STP (02 Nos) at Loco & Carriage Complex of KPAW has been completed.

·100% reuse of ETP treated water at KPAW Construction work is going on. Work will be completed shortly.

·One DGA machine has been procured and installed at M&C Lab/KPAW

Source : Eastern Railway CMS Team Last Reviewed : 27-08-2025

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