Construction of Rolling Stock Component Factory

Railway Board, Ministry of Railways, Government of India, approved the proposal for

construction of a ‘Rolling Stock Component Factory‘ for reconditioning /

remanufacturing of rolling stock components, which was initiated by Central Railway.

Central Railway has entrusted Konkan Railway Corporation Limited with the work of

construction and commissioning of the Factory at a Total Approved project Cost of

Rs.402.65 crore.

The Rolling Stock Component Factory (RSCF) is located at Additional Lote, near

Chiplun in Ratnagiri district of Maharashtra. The site is in the Maharashtra Industrial

Development Corporation (MIDC) area. The Campus is on 50 acres of land, off the

Mumbai-Goa National Highway.

Conceptual Layout of Factory:

Important Features:

Relevance for the future:

• Nodal Centre for supply of Critical Safety components as Unit exchange spares

for freight wagons and coaches of Mail Express trains

• Hub for supply of Cartridge bearings after automated overhaul for freight wagons

for railway zones in Central and Western India.

• Major Railway Unit for Bogie Overhaul for LHB coaches to meet requirements of

Mail Express trains of Central Railway etc.

• The Factory will kick-start Railway rolling stock Industry’s presence in the Konkan

region

• Creation of a Railway led Eco-system around RSCF for skills, employment,

economic development and setting up of medium to small-scale industrial units in

the future

Factory Design:

• All weather PEB Sheds, elevated design of Shop-floor level for monsoons

• Gated Complex with 24X& CCTV surveillance

• Modular Cluster design of Sheds – Adaptability as per change in Product mix

• Focus of Energy Management and Automation

• Ergonomic design of Work Centre design as per IS: 6385

• 5-S Workplace Management System principles

• ‘Divyang’ friendly Complex

Green Initiatives:

• IGBC certified Factory, Building, Interiors, Landscape • Energy Management System (EMS) & Super Category as per ECBC • Water Management- Drip & Sprinkler Irrigation, Water bodies • Rain Water Harvesting, Recycling of Water • Solar Energy – Panels over Sheds & Parkings, Street Lights , Pumps • Wind Mills - Turbines to power Rest House • Waste Management initiatives – Waste segregation, Organic Waste

Converter.etc • Use of Battery Operated Vehicles & Material Handling Equipment.

Automation:

• Automatic Bogie Cleaning Plant for LHB Bogies

• Automatic Manipulators &Turntables for LHB Bogies

• Automatic Wheel Profile & Brake Disc Measurement System

• Automatic Shot Blasting Plant

• Robotic Painting of Bogies

• Automatic Bearing Cleaning Plant for Cartridge Roller Bearings

• Automated Guided Vehicles – Movement and Handling in Wheel Shop, Brake Cylinders etc.

• Motorized Conveyors for handling

• Augmented Reality Training Simulator, PC Based Training

• SCADA ,IBMS and EMS

Amenities:

• Health Unit, Cardiac Ambulance

• Crèche, Bank / ATM, Shopping Complex

• Community Complex – Auditorium, Amphitheatre, Conference Halls

• Sports Complex - Outdoor and Indoor Sports, Playgrounds

• Club, Rest Houses, Trainee Hostel

• Canteen & Cafeterias

Health & Safety:

• Factory as per OSHAS systems & principles

• Fire Detection & Alarm System integrated with Public Address System

• Fire Hydrant and Sprinkler Systems

• CCTV Based Surveillance integrated with Vehicle Management System

Components to be handled at RSCF:

Sr.No Major Component Average Quantity per Month (Nos.)

1 LHB bogie &sub assemblies 200

2 LHB wheel 800

3 LHB springs 2400

4 Damper (LHB) 1800

5 CTRB (freight) 5600

6 Roller Bearing (ICF) 2800

7 CTBU (LHB) 800

8 Roller Bearing (EMU) 2000

9 Shock absorber (ICF) 1400

10 Shock absorber (EMU) 2000

11 Draft Gear (LHB) 1000

12 Schaku coupler (EMU) 500

13 Draw gear (ICF) 700

14 Distributor Valve (freight) 700

15 Distributor Valve (ICF) 350

16 Distributor Valve with panel (LHB) 500

17 Brake cylinder ( freight) 700

18 Brake cylinder ( ICF) 1400

19 Brake caliper unit (LHB) 800

20 Brake cylinder ( EMU) 2000

Site at Additional Lote - 2016 Survey at Additional Lote - 2016

Terrain map indicating RSCF Campus site

(Source: Google Maps) Road Map of RSCF Campus site (Source:

Google Maps)

Bhoomi Pujan by Hon’ble Shri. Suresh Prabhu, Minister of Railways – Dec’16

Tree Plantation after Land development of factory shed complex by Shri. Sanjay Gupta,

CMD Konkan Railway Jan’19

Planning Development of site -2017 Detailing the Construction activity -2018

Land Development in Progress -2018 Rerouting of Power Line -2018

Boundary Wall Works - 2019 On-site Project Monitoring & Review -2019