In 2018-19, when the Trendy Coach Manufacturing unit (MCF) at Raebareli manufactured round 1,500 rail coaches in opposition to a capability of a mere 1,000, it stunned many. Other than its human workforce, 44 robots are additionally being credited for the stupendous success.
With robots getting used efficiently within the built-in shell meeting line and the robotic bogie fabrication line, MCF and its design guide Ircon have drawn a roadmap to rework the Raebareli unit into the world‘s largest coach manufacturing facility.These robots had been imported from international locations like South Korea, Spain and Germany.
On the again of the robotic success story, the Railway Board has already lined up plans to make MCF the world’s largest coach manufacturing facility, making a minimum of 5,000 coaches yearly. The unit might quickly see its phase-II growth rising its capability to 2,000 coaches. “In the Railway Coach Factory at Kapurthala, we have a staff strength of 7,000. The introduction of robots by Ircon has helped bring this down to 2,000 employees. From welding to cutting to assembling, robots are used in a majority of activities here,” mentioned S K Chaudhary, chairman and managing director, Ircon.
With the present capability, MCF has set a goal of constructing 1,800 coaches throughout the present monetary 12 months.
The place robots are utilized in Raebareli?
The manufacturing facility has an built-in shell meeting line with a really excessive degree of robotic utility (consisting of whole 36 robots). In response to Ircon, this unit delivers a minimal of two coaches in a shift of six hours to satisfy the manufacturing requirement. Equally, robotic bogie fabrication line makes use of eight robots and computerized dealing with of parts to ship 4 bogies in each shift of six hours every.
Along with this, Raebareli has an automatic wheel and axle meeting line facility to supply one wheel set absolutely machined and assembled at an interval of each 18 minutes. “All these are world class facilities and nowhere in India, such robotic technology is used by the Indian Railways,” mentioned Chaudhary. Now, the Railway Board is mulling over the choice to deliver robotic applied sciences to different manufacturing models as properly.
Ircon, which has already requested the railways to allot the MCF phase-II growth venture to it, mentioned the typical welding time of every half dropped almost 70 per cent when robotic welding was used rather than handbook welding.
“As a work piece is replaced on one side, the robot welds on the other, and vice-versa. The operator simply replaces the finished product with component parts to be welded next. In doing so, the robot is always kept in motion resulting in total time savings of nearly 80 per cent,” mentioned a senior MCF official. The benefit additionally contains utilizing robots for a number of duties along with the superior high quality in comparison with handbook wielding.
Roadahead for Raebareli
Chaudhary mentioned the unit will be capable to make aluminium coaches and even Vande Bharat sort coaches that are of export high quality. “Countries like Sri Lanka and Bangladesh are always in need of coaches. Hence, expansion of the unit will help us in getting bulk orders from abroad, too,” he added. MCF may also manufacture bullet practice coaches. Primarily based on its manufacturing plan, a minimum of 240 Memu coaches might be made in 2019-20 and 264 every in 2020-21 and 2021-22.