CARRIAGE WORKSHOP AJMER, RJ

Gold CArrIAGe wOrkshOp Ajmer, rAjAsThAn

About the workshop

Carriage and Wagon Workshop was built in 1884 for repairs and manufacture of Coaches and Wagons for the Rajputana-Malwa Railway. This workshop has proud privilege of being the first workshop in the country to set up facilities in 1902 for production of steel castings. The manufacturing of new coaching and wagon stock continued in this workshop till the setting up of Integral Coach Factory and till development of certain private & public sector factories for manufacture of wagons. This workshop also carries out periodic overhauling of Palace on Wheels and Royal Rajasthan On Wheels. Presently this workshop is carrying out Shop schedule of LHB coaches. This workshop is ISO 9001:2008, ISO 14001:2007, OHSAS 18001:2007, ISO 50001, ISO 3834-2:2005 and Green Co Gold Level rating certified. The workshop is headed by Dy.CME (C), Ajmer who is assisted by various other Officers. The workforce consists of about 3100 sanctioned employees and spread over an area of 2, 50,000 Sq. meters.

Key Achievements

1. Reduction in electrical energy (SEC) owing to the decentralization of compressors, introduction of IGBT based welding plants, introduction of 100 % LED light fittings,

Optimum Loading of Transformer, setting up of AC’s & water cooler temperature level and many more good practices adopted. 2. First price in Rajasthan energy conservation award in 2018 & 2020 for electrical energy saving. 3. Carriage workshop installed 112 kWp onsite solar installation to meet more than 10% energy demand of the workshop. 4. Reduction in Thermal energy (SEC) owing to reduction of furnace Oil to NIL 5. Three numbers of ETPs installed for re-using water. 6. Machine Bogie frames and Springs are cleaned by Shot

Blasting Machine instead of Water Jet; thus saving in water

Consumption. 7. Installation of Re-using facility of released water in tank testing and repair section. 8. Specific waste disposal of the workshop has been reduced by 10.81%. 9. Carbon sequestration projects through Tree Plantation. 2312 Nos. 10. Transparent sheets used in sheds to save 100 % day lighting electricity consumption. Turbo ventilator are also used in all sheds for better environment. 11. AAC of stock items for 2020-21 is reduced by 37.73 % from base year 2017-18. 12. Carriage Workshop, Ajmer was declared Zero Scrap

Workshop in 2019. GreenCo rating is an excellent way to find areas in your business where you can improve environmentally and make your business sustainable. Ajmer carriage workshop has achieved Gold certification. My team is striving for excellence in GreenCo. system. We are committed to reduce our carbon footprints.

Ashok Kumar Abrol

Chief Workshop Manager

Water Conservation

y Good water metering system is in place - 33 water meters installed. y Total available rainwater harvesting capacity for external pond is approx. 5747 m3 . y The reduction in Specific Raw Water Consumption in year 2020-21 compare to base year 2017-18 is 20.45%. y Installation of bio toilets and reuse of water in irrigation. y Installation of low flow water fixtures. y A sump of 4000 Liters capacity is constructed at RO plant in

Corrosion repair shop in which wastage (rejected) water is stored. This waste water is pumped to a storage tank on the roof and reused in hand washing.

Innovation

y Carriage Workshop has been got best innovation Shield at

NWR Zonal level also got best Rolling stock Workshop Shield in at National /HQ level. y Development of a New Programming to turn LHB Axle by

C.N.C. y Development of LHB brake piston press Machine. y Development of in house test benches.

Energy Efficiency

y Industry leading energy consumption, among Indian Railway

Workshops Leading energy consumption of 4.35 GJ/ECU. y Implemented best in market efficiency technologies IGBT based welding units and conversion in progress from oil furnaces to electric furnaces. y Consistently in top 10 of energy conservation, 1st Prize in

Rajasthan energy conservation award in 2020. y Initiated metering and monitoring systems. Energy meters connected with all Electrical Sub-Stations & all significant energy consumers. y Extensive usage of LEDs in the lighting system. y Load shifting of transformers to increase transformer loading and to reduce no load transformer losses. Total of 1500 KVA capacity reduced. y Reduction of furnace oil to NIL. y Reduction of CD from 2400 KVA to 2100 KVA. y Power factor maintained between 0.970 to 0.984. y 100 % procurement of energy efficient / star rated product.

Material Conservation

y Overall percentage reduction in Specific raw material consumption is 23.89% in 2020-21 from base year 2017-18. y Overall Specific reduction in Consumables(Mechanical) is 17.54% in 2020-21 from base year 2017-18. y Implementation of User Depot Manual (UDM), Workshop

Information System (WISE), Human Resource management

System (HRMS). for better monitoring of materials and resources. y Rupees 22,02,31,142.2 is saved from 2017-18 to 2020-21 by reducing AAC of ICF coach’s items.

Green Infrastructure & ecology

y Use of turbo ventilator for improving indoor air quality. y Fresh air ventilation increased from 13.09% to 24.33%. y Procurement of new CNC machine for Wheel Shop having in built fencing. y At least 1.73% of the total employees have been trained by

“Green Army Ajmer” for environment activities. y Accredited Green professionals increased to 47 in 2020-21 from 1 in 2017-18.

Contact: mr. Pramod rawat, Dy. Chief Mechanical Engineer Carriage Workshop, Ajmer - 305001, RAJASTHAN Phone: 9001196466, 9001196452 | Email: dycmecarriage@gmail.com