Carriage Repair Workshop, Hubli 1885 - 2008

Carriage Repair Workshop, Hubli

1885 - 2008

The Loco, Carriage and Wagon Workshop at Hubli was established in 1885
under Southern Mahratta Railway (SMR) headquartered at Dharwar for
maintenance of meter gauge locomotives, coaches and wagons. In 1919 Madras
& Southern Mahratta Railway (MSMR) was formed and the workshop was brought
under the jurisdiction of MSMR. The workshop continued with periodic
overhauling activities of metre gauge rolling stock.

On reorganization of the railways after independence six zonal railways
were formed and in 1951, Hubli workshop was brought under the control of
Southern Railway (SR). During this period IRS type rolling stocks were
introduced and therefore, new facilities were added in the workshop under
modernization plan taken up by SR during the period 1960-66 at a total cost
of about Rs 1.5 crores. Under the plan a new complex with EOT crane for
repair of steam locomotives was set up and a 100t Traverser was installed.
Periodic overhaul of passenger class YP 4-6-2 and goods class YG 2-8-2
configuration steam locomotives and YD 2-8-2 dual class steam locomotives
used on steep gradients were carried out by Erecting Shop and Boiler Shop.
Erecting shop used to first separate the tender and engine and thereafter
from the engine, boiler was separated after cutting the saddle plate,
breather plate. Boiler was then sent to Boiler shop for overhauling of
boiler elements, smoke tubes etc.

Metre gauge IRS type coaches were wooden body mounted on metal under-frame.
A full fledged saw mill was functioning under Carriage Shop comprising
various wood working machines such as log band saw, vertical band saw,
planing, drilling and boring machines. The workshop also manufactured
wooden body inspection carriages, narrow gauge coaches and horse vans
during this period. Metre gauge wagons having riveted construction were
repaired in Wagon Shop. In recognition of the commendable work done by the
workshop, the first meter gauge diesel locomotive rolled out from Diesel
Locomotive Works, Varanasi in 1961 was aptly named as Hubli.

Later in 1966 another reorganization of railways was undertaken and three
more zones were carved out of the existing zones. South Central Railway
(SCR) was formed by merging Hubli and Vijaywada divisions of SR and
Secunderabad and Solapur divisions of Central Railway. Thus on the Gandhi
Jayanti day of 1966, the workshop was taken over by newly formed SCR. In
1969, entire repair work of meter gauge rolling stocks of Central Railway
portion which was previously done in Lallaguda workshop was transferred to
the Hubli workshop. In 1969, the workshop was adjudged the best railway
workshop on Indian Railways for achieving productivity improvement in
excess of ten percent. The financial award was utilized to set up a
community hall on Club road.

Diversification of activities

As part of diversification process, in 1987, the workshop commenced
manufacture of fabricated UIC bogies for BOX wagons. However the UIC bogie
manufacturing activity was discontinued in 1995 due to phasing out of BOX
wagons on Indian Railways. The BOX wagons have been replaced by
technologically superior higher capacity BOXN wagons. Furthermore in 1990
the workshop commenced manufacture of fabricated bogies for ICF type
coaches.

During 1989 under SCR the second modernization plan was undertaken at a
total cost of about Rs 17 crores with emphasis on introduction of new
machinery and plant along with material handling facilities. In 1993 with
the end of steam traction, periodic overhaul of meter gauge locomotives was
discontinued. In the following year, periodic overhaul of meter gauge
coaches and wagons was also discontinued due to gauge conversion. The gauge
conversion work from metre gauge to broad gauge was taken up during 1995-
1996 at a total cost of about Rs 18 crores.

And finally with the formation of South Western Railway (SWR), the workshop
is now part of SWR from 1st April 2003. Hubli workshop, thus, forms the
backbone of SWR for maintenance and repair activities of rolling stock and
its components. An Iron foundry Shop which used to manufacture cast iron
brake blocks was closed in 2003 due to technological switching over to
composite brake blocks. Similarly Brass foundry which used to cast
suspension bearings and bimetallic journal bearings has also been closed.
Ever enterprising and highly motivated staff was redeployed in other areas
of manufacturing activities by providing necessary training inputs at Basic
Training Centre of the workshop.

And now, apart from regular periodic overhauling of coaches, it has also
become a premiere manufacturing hub of Indian Railways for manufacture of
brake vans and container flat wagons and bogies for coaches and
locomotives. The workshop is spread over 26 acres with approximately 37%
covered area and about 6 km of track. Installed load is 9,000 KVA, the peak
load being 1,300 KVA. 11 KV supply is taken from HESCOM. In addition two
500 KVA stand by diesel generating sets are available. Average monthly
consumption is about 1,36,000 KWH. Water storage capacity is about 1,32,000
liters. The workshop employs 3000 staff of which 4% are women employees.
25% of staff lives in railway accommodation

Present activities

Some of the important and critical activities being carried out presently
in the Workshop are periodic overhauling of all types of coaches of SWR, KR
and WCR; Conversion and up-gradation of coaches and manufacture of BVZI
Brake Vans for Railways; Co-Co bogie frames for DLW; ICF type bogies and
bogie frames for ICF, RCF, BPLS, M/s JESSOP and other railway workshops;
air spring suspension bogies for railway workshops and container flat
wagons for CONCOR. Presently the workshop is carrying out periodic
overhauling of 1100 coaches annually and manufacturing of 10 brake vans,
120 ICF type bogies and 10 Co-Co bogies on a monthly basis. The workshop
has also recently started periodic overhauling of coaches with 18 months
periodicity. The coaches for this purpose are being provided with upgraded
bogie materials and upgraded fire retardant furnishing materials. In
addition, all passenger amenity and safety features are being provided
including laptop / mobile chargers etc.


Future plans

As per short and medium term plan, actions have been initiated on key
areas. Workshop layout plan has been improved based on industrial
engineering study of uniform process flow, material movement etc. Material
handling and storage systems have been improved. Work areas have been
improved by adopting improved processes, storage system, worker friendly
work benches, efficient material handling devices, proper tools and plants
etc. Finished goods are being dispatched promptly by road transport. In-
process inventory of materials have been reduced. Workload has been
reviewed and old machinery & plant is being disposed off. Coach POH cycle
time has been reduced by 20%. Productivity and output has improved
considerably.

As part of the future plan of action, a detailed estimate for modernization
& up-gradation project of workshop at a total cost of Rs 80 crores has been
sent to Railway Board for sanction. Work has to commence soon for drainage,
sewerage and road networking, industrial flooring and pathway, demolition
of old dilapidated sheds and structures and construction of new sheds and
gantry etc in addition to procurement new state-of-the-art machinery and
plant and material handling facilities.

On staff welfare front many issues are being addressed. Staff canteen has
been renovated recently and modernized to serve lunch in addition to tea
and snacks being supplied to workshop staff on regular basis. A Crèche has
been sanctioned which would be located near the approach main gate and
would benefit working women employee. North Institute is being renovated
comprising billiards and table tennis room, gymnasium and function hall.
Kitchen hall and cycle stand has been constructed. Integrated drinking
water with RO plant, water cooler & washing facilities is being provided.
Industrial lockers are being procured and provided to staff. SCTRE
Association office premise is being renovated for running library and
computer classes and other welfare activities.


Authors

Suresh D. Mane, CI/ BTC / UBLS
D. Ghosh Roy, CWM / UBLS












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Carriage Repair Workshop which not only undertakes regular periodic
overhaul & up-gradation of Coaches but has also developed itself into a
premiere manufacturing hub for Indian Railways.