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Carriage Repair Workshop, Mancheswar (CRW/MCS), a young and dynamic establishmentunder East Coast Railway, discharges the key responsibility of periodic overhauling of allMail/Express/Passenger & departmental coaches of East Coast Railway. Establishment ofthe workshop has helped East Coast Railway to achieve self-sufficiency in maintenance ofpassenger carrying and other coaching vehicles.Construction of CRW/MCS was sanctioned by Railway Board in Works Programme 1977-78.Prof. Madhu Dandavate, the then Hon’ble Minister of Railways, laid the foundation stone on26.05.1978. The Workshop was commissioned with the beginning of corrosion repairs on12.11.81, in presence of Shri K. N. Pandey, the then Hon’ble Minister of Railways. The firstoff POH coach was turned out from the shop on 31.12.1983 in presence of Shri C. K. JafferSharief, the then Hon’ble Minister of State for Railways. Mancheswar workshop celebratedits Silver Jubilee in November 2006.Aerial view of workshopA view of administration buildingTwo major works, (i. work for setting up of an AC Coach POH facility for an outturn of 05 ACCoaches per month sanctioned in 1999-2000 at a cost of Rs. 3.34 Crores, ii. work ofadditional coach POH facility sanctioned in 2003-2004 at a cost of Rs. 7.24 Crores) havetaken the installed capacity of the workshop to 100 coaches (90 non-AC 10 AC coaches)per month.A Group Incentive Scheme was introduced in the workshop from 01.09.2003. Pre incentiveoutturn of the workshop was 720 equated GSCN coaches per annum with 1220 staff inincentive production shop. Introduction of GIS has helped in improving the productivity ofthe workshop from the pre-incentive level of 60 per month to that of 100 per month.The workshop was awarded ISO9001:2000 QMS Certification since 2003. The workshop hasnow been awarded upgraded QMS ISO9001:2008 Certification in Aug’2013.
InfrastructureLand: Total area Workshop area Colony/Service Buildings Covered area in the workshop Permanent way inside the workshopPower Supply: Receiving voltage Connected Load Contract Demand Standby Diesel Generator Set. 314 Acres121 Acres193 Acres38,550 Sq. Mts.14 Kms. 33 KV.6225 KW.900 KVA.500 KVA.Electronic gate attendance system: Mancheswar workshop is among first fewworkshops to have electronic gate attendance system. This has made the task ofrecording attendance of staff reliable and efficient. Staff employed for manualrecording of attendance were released for carrying out productive work. Water Supply: The workshop has 3 ground water pumping stations to supplywater to workshop and colony. Telecom facility of the workshop is maintained by SSE/Tele who is underHead Quarters control. CRW/MCS has a self-contained residential colony with 708 quarters.Mancheswar colony also has Kendriya Vidyalaya, Oriya Medium Primary,Upper Primary and High Schools, Railway Institute and Officers’ Club to caterto the educational and entertainment requirement. The Scouts & Guides and the East Coast Railway Sports Association haveactive units at Mancheswar. ECoRWWO/MCS runs nursery school (Shishu Niketan), dance school andschool of fine arts in addition to a number of other activities.
01.02.201229.05.201331.07.2013Foundation Stone laid by Prof. Madhu Dandavate, the then Hon’bleMinister of Railways.The workshop was commissioned with the beginning of Corrosion repairby Shri K. N. Pandey, the then Hon’ble Minister of Railways.First Off-POH Coach was turned out by Shri C. K. Jaffer Sharief, the thenHon’ble Minister of State for Railways.Group Incentive Scheme was introduced in the workshop.MCSW reached the milestone of 100 coach outturn in a month.The workshop reaches the milestone of 1000 coach outturn in a year byturning out 1092 coaches in 2004-05.Turning out 1st. rake of 18 months POH periodicity.Switch over to 18 month periodicity POH & IOH of Bogies.Implementation of Revised Bonus factor under GIS.POH of BBS Duronto Coaches of Hybrid designFirst LHB coach turned out after attending D4 ScheduleRecorded 120 coach POH and Total 145 coach outturn alongwithproduction of 1001 wheel sets.31.07.2013 Highest ever 404 bogies (202 bogie sets) outturn.31.07.2013 Highest ever 1001 wheel sets outturn.Highest ever Physical outturn of 145 coaches(120 Coach POH, 20 Coach IOH & 5 Coach MRR/ERR)06.08.2013 ISO 9001:2008 QMS Certification31.07.2013 STATUTATORY REQUIREMENTSFactory LicenceValid upto 31.12.2013Consent Order from Pollution Control BoardValid upto 31.03.2014
DesignationGradeBrief description of dutiesWorkshop MechanicalSeniorAdministrativeGradeOverall In charge of the Workshop.Dy. Chief Mech. MechanicalEngineer (WS)JuniorAdministrativeGradeMR for ISO, PIO on RTI matters, Sr. EDPMChiefMangerDepartmenton IT matters. Mechanical Office includingBudget. Planning for Works, M&P andRollingStock.Outsourcing&ContractManagement. Incentive and Time Office.Dy. Chief Mech. MechanicalEngineer (POH)JuniorAdministrativeGradeFactory Manager and Coordination withother Department for coach POH outturn.Planing for monthly outturn. Chief QualityManager (Mech), Material Planning, QualityAudit of all POH activities.Dy. Chief Electrical ElectricalEngineerJuniorAdministrativeGradeEnergy Manager. Chief Quality Manager(Elect.), Material Planning, RSP & WorksPprogramme.Budget,Outsourcing&Contract Management. Maintenance of Airconditioning and Train Lighting of st. AccountsFinance AdvisorSenior ScaleSeniorManagerSenior ScaleMaterial StoresAccounts officer and Financial advisor toChief Workshop Manager.Material Management – Stock & non-Stock.Monitoring of receipt, accountal, custody,stock verification & issue of material.WorkshopPersonnel OfficerPersonnelWorks ManagerMechanicalSenior ScaleHuman Resource Development, IndustrialRelations and staff Welfare.Senior ScaleMaintenanceofM&Ps,Conversionofcoaches, M&S, Corrosion & Shell RepairShops.ADC(BS&G).outsourcingforMechanical Department.ChemistMetallurgistand MechanicalSenior ScaleIn charge of Chemical and MetallurgicalLaboratory, Ultrasound Testing , DPT &MPT.
WorkshopEngineerElect. ElectricalSenior ScaleOfficer In charge of TL, AC & EPDMS shop.Conversion of coaches. Power & WaterSupplytotheWorkshop&Colony.Condemnation & Disposal of scrap.Asst.Works MechanicalManager(POH)Junior ScaleAsst.Manager(F)Junior ScaleWorks MechanicalOfficer In-charge of POH, trimming & Paint.Chair Car coaches. Material planning.Secy to CWM. Function of PRO/MCSW.Asst. Sports & cultural Officer. Officer Incharge of Furnishing & trimming & MT.Material planning.Asst.Works MechanicalManager(LHB)Junior ScaleEDPM. Officer In-charge of Wheel & Bogieand lifting Shop. Basic Training Center.Training of Engg. Students. POH of LHBcoaches.Asst.Divisional Civil Engg.EngineerJunior ScaleOfficer In-charge for civil maintenance ofinfrastructureofentireworkshopandcolony. Horticulture Development. WaterSupply.Asst.ManagerMaterial StoresJunior ScaleAssist SMM for material management.CWMDy.CME(WS)Dy. CME(POH)WMCMTAWM(F)Dy. CEEWEEAWM(POH)AWM(LHB)Sr. AFASMMAMMWPOADEN
Mechanical:Responsible for Periodic Overhauling of broad gauge coaches of EastCoast Railway, South East Central Railway and East Central Railway During PeriodicOverhauling, intensive attention is given to different systems like bogies, air brakesystem, coach body; internal furnishing so as to ensure a safe, comfortable coach forservice for 12/18 months of service.The department is also responsible for overhaulingof bogies for IOH attention at depot at the end of 9 months. It also looks afterImplementation of different RSP works sanctioned by Railway Board. Various shopsunder control of Mechanical Department are as under. CARRIAGE FITTING SHOP – Lifting of coach body, Dismantling ofBogie, Maintenance of Air Brake System, Safety check by Neutral TrainExaminer. The shop is equipped with 30T capacity cranes for coachbody lifting.BOGIE SHOP – Dismantling of Bogie Components and wheel.Complete overhauling of Bogie components, replacement of mustchange and rejectable fittings, testing of critical components, assemblyof bogie. Apart from ICF bogie, now the shop has capacity to overhaulair suspension hybrid bogie and new technology FIAT bogie. The shopis equipped with 10/5 Ton EOT crane for handling Bogie. Apart frominhouse POH requirement, the shop also provide overhauled bogie toCoaching Depots to carryout ‘C’ Schedule after 9 months of service.WHEEL SHOP – Complete overhauling of BG wheels. Machining ofWheel Discs and axle, pressing of Axle & Disc, Profile turning, BearingMaintenance, Assembly of Wheel. Now the shop has developedcapacity to overhaul LHB Wheels. The shop is developing facility tooverhaul CTRB freight wheels. Apart from inhouse POH requirement,the shop also provide overhauled Wheels to Coaching Depots to enablereplacement of defective wheels from service.CORROSION SHOP – The shop is equipped with different type ofWelding and Gas cutting equipments for undertaking corrosion repairof Head stock, Sole bar, Cross members, trough floor, Sheet Panel etc.Corrosion shop also undertake structural modification for conversion ofcoaches.POH SHOP – POH shop mainly undertake the furnishing related repairin the coaches viz. PVC flooring, LP sheet Panels, Lavatory work andprovision of amenities etc.TRIMMING SHOP - The shop specialises in repair and fitting of seat& Berths.PAINT SHOP – The shop undertake painting of Coach exterior andinterior, Painting of Bogie and other components, Lettering and
stencilling of coach particulars. Spray Painting Machines have beenprovided for exterior Painting of coaches. Now, the shop alsoundertakes Poly Urethene Painting.MILLWRIGHT SHOP – Responsible of Maintenance of Machinery and Plant ofthe Workshop including safety certification of lifting Tackles. MOTOR TRANSPORT SHOP –Responsible for maintenance of MotorVehicle and transport equipments viz. Fork Lifter, Front End Loader, PlatformTrucks etc. The shop also maintain a fire tender for fire fighting in case ofemergency. M&S SHOP –Machine & smithy Shop mainly manufactures components forcorrosion shop. It also manufacture and supply small component to other shop andcoaching depots. CMS –Planning and placement of coaches inside various shops. Traversormovement. Monitoring of daily outturn of the workshop. Feedback from thedivision. CENTRAL CHEMICAL & METALLURGICAL LABORATORY –thelaboratory is equipped with various type of testing apparatus for mechanical &metallurgical testing. It also has spectrometer and apparatus for testing of Paint.The laboratory also undertake Ultrasound testing of axle and discs, MagneticParticle Testing & Magnaflux testing of Bogie components.ElectricalResponsible for overhauling of Train Lighting and Air Conditioning systems of the coach,It works in tandem with mechanical department to provide timely turn out of coaches.Electrical department is also responsible for development & maintenance of power supplyin workshop as well as colony. TRAIN LIGHTING SHOP – Undertakes repair and maintenance ofBattery, light, fans, alternator etc of non-AC coaches including strippingand final fitment in the coaches. AIR CONDITIONING SHOP - Undertakes repair and maintenance ofRoof Mounted Air conditioning System, Alternator repair & testing, andrelated system including Generation Testing in AC coaches. EPDMS - Undertakes Electrical maintenance of Machinery & Plant, PowerSupply and Distribution inside the workshop and colony.PersonnelLooks after human resource development and other staff welfare activities forapproximately 1865 staff working in the workshop. Seniority, promotion, retirement,engagement of Act apprentices, industrial relation, salary, leave, pass, loan, advanceand post retirement settlement functions are also looked after by the PersonnelDepartment.
FinanceResponsible for assisting Chief Workshop Manager in considering all proposals involvingfinancial implication, compilation of budget and setting up of a satisfactory system ofbudgetary control. As a management accountant to prepare and interpret financialstatements, compile cost data and prepare cost reports, explore avenues of controllingstaff and material cost, institute and operate budgetary control procedures andparticipate in all capital expenditure rating/pricing decision of workshop.StoresThe department manages the requirements of materials for overhauling of coaches.Around 700 materials are stocked in the depot. It also procures various non-stock itemsas per requirement of workshop. The department also cater to the requirements ofDivisions against their imprest requirement.EngineeringResponsible for development and maintenance of Civil Engineering assets of theworkshop and attached Colony area. It also looks after water supply.*****Manpower Position as on 01.08.2013DEPARTMENTSANCTIONON 1084ENGINEERING422121GRAND TOTAL20361931105E POSITION OF MCHESWAR WORKSHOP AS ON 01.08.2013
Mancheswar workshop has rewritten its history by achieving new milestonesof productivity, efficiency and outturn.COACH OUTTURN:Highest ever physical outturn of 145 coaches was achieved in July’13. There isan increase of above 20% in total POH Coach Outturn and 23.6% in NAC POHCoach Outturn.AC POHNon-AC 13-142012-13REFURBISHING252359602013-14TOTAL POH OH COACH & BOGIE OUTTURN:2012-132013-14IOH outturn in the current year hasbeen phenomenal and there is an increase of above 127% in IOH Coach outurnand 29% in IOH Bogie supplied to the divisions from the workshop.
IOH COACH9070503010IOH BOGIE 013-14WHEEL PRODUCTION: Wheel shop has successfully risen to the challengeand created a new record of crossing 1000 wheels per month benchmark byachieving highest ever outturn of 1001 wheels during July’13.1400Supply to Division 0020002012-132013-1423432012-132013-14POH CYCLE pril - June'13Non-AC19.352012-13April - June'13IOH OF LHB COACHES: 1ST LHB coach ECo 07149 was turned out on29/05/13 after D4 schedule. Next Coach ECo 08920 is taken up and would beturned out in Aug’13.
AC DINNING CAR: A Condemned ACCZ coach converted to AC DinningCar. Now East Coast Railway has its own dining car.
ISO 9001:2008 QMS CERTIFICATION: The workshop has been certifiedwith upgraded version of Quality Management System ISO 9001:2008 inAug’13.PROVISION OF DETACHABLE SS MESH IN KITCHEN OF PANTRYCAR:5 Nos. pantry cars has been provided with stainless steel mesh in thepartition wall to enable cleaning in depot during scheduled maintenance.Mancheswar workshop is the first workshop to provide detachable mesh.COMPLETE REFURBISHMENT OF TOILET: this work is beingundertaken against RSP sanction. The complete lavatory and water supplyarrangement including the amenity items are renewed. 22 coach toiletrefurbishment was carried out till July’1329 against 29 coach toiletsrefurbishment in 2012-13.
24221464April - July'12April - July'13SHOT BLASTING OF BOGIES: The workshop has started shot/grit blastingof bogies to remove old painted surface and scales, dirt etc from the metalsurface. This help in checking the hairline cracks and condition of bogie frame.A total of 2848 bogies in 2012-13 and 1290 bogies till July’13 were subjectedto shot/grit blasting.15151015129071851515April - July'12April - July'13REFURBISHING OF COACHES: Due to constraint of capacity to undertakemidlife rehabilitation of coaches in Bhopal workshop, Railway Board haddecided to undertake complete refurbishment of such coaches in otherworkshops. This includes ‘A’ schedule painting, extensive corrosion repair,complete replacement of PVC flooring, Laminated Plastic sheet panels ofinterior, Seat covering (rexin), (iv) and fitment of amenity items viz. watertanks, mobile charger, emergency light etc.A total of 69 coaches have been refurbished during 2011-12 and 63 coacheshave been refurbished in 2012-13 and 22 coaches refurbished till July’13. Thishas brought in quantum improvement in the condition of these coaches.Refurbishing of VISION OF SUNK-IN TYPE CFL FITTINGS INSIDE LUGGAGEVAN: Sunk-in type CFL fittings are being provided in all SLR during POH toavoid any chance of short circuit due to damage to electrical fittings duringloading/ unloading of luggage. Total 117 no’s till July’13 have been providedwith above modification.
STAINLESS STEEL PIPE FITMENT IN AIR BRAKE SYATEM: 34coaches were fitted with stainless steel pipe till July’13 against RSP sanction.This shall reduce damage to the air brake pipe due to corrosion and wouldimprove reliabilitySS brake pipe N OF MMIS MODULE: Previously MMIS terminals wereavailable only with Stores and Accounts Department, now MMIS terminals hasbeen extended to Mechanical & Electrical Department to enable effectivematerial management.BIOMETRIC BASED ATTENDENCE SYSTEM: Biometric devices havebeen installed for fingerprint based attendance system in the administrativebuilding of Mancheswar Workshop. This system would be commissioned inAug’13.PROVISION OF MODIFIED BATTERY BOX: All AC coaches are nowprovided with 1100 Amp- Hr Battery Boxes during POH at workshop. A total100 Nos. coaches were provided with 1100 Amp- Hr Battery Boxes till July’13.This has improved performance of AC coaches.PROVISION OF EMERGENCY LIGHT IN COACHES: AC & NACcoaches with emergency light to illuminate coaches at time of emergency areprovided against RSP sanction. A total of 784 no’s AC & GSCN coaches havebeen provided with emergency lights. Work is under progress.PROVISION OF MOBILE CHARGING POINT IN PANTRY CARCABINS: All 45 pantry cars are provided with mobile charging socket & 110AC operated exhaust fan.
1)2)3)4)5)POH of LHB Type coaches: - The workshop has started POH of LHB coaches. Theactivity could be started with the existing setup. However additional facilities arerequired for full fledge operation which has been proposed as Material Modificationto sanctioned work “150 Coach Capacity Augmentation work.” The material planningfor LHB coach has been done but about 75 items are available against 268 itemsrequired.Increase POH of AC coaches: - At present the workshop could turnout at an averageof 16 AC coach per month which is required to be increased to 25 coaches per monthto meet future requirement.Increase Corrosion outturn: - The present capacity of shop is for 16 corrosion repairwith internal restructuring and outsourcing of noncore activity viz. cutting ofcorroded metal pane and stripping. This is required to be increased to 24 coachesper month to meet future requirement.Fitments of Bio-toilets: - Railway Board has given allotment for provision of retrofitment of 132 nos. bio toilets in coaches to CRW/ Mancheswar. Material for abovework is to be collected from ICF.PU painting of coaches: - All new coaches are provided with PU Painting. Theworkshop has already started PU painting of coaches through outsourcing.6) Attention to all water tanks:- At present conventional water tanks from only onethird of coaches are unloaded, carried to the section and completely flushed andtested due to constrain in unloading & loading of water tanks. Rest of the watertanks are flushed and tested in-situ. With outsourcing of Refurbishment of Toilets, itis now possible to unload 50% water tanks to comply with the alternate POHattention.
NameDesig.RailwayBSNLSTD (085)STD (0674)S. K. PankajCWM584002748702Dayanand SahuDy.CME (WS)584122748230N.R. SahuDy.CME (POH)584102748067N. Papa RaoDy. CEE585502748640J. V. Appa RaoWM584082748733V. KotySr. AFA584702748183J. N. PattanaikSMM584602748205S. K. MishraWPO584502748061P. K. PradhanWEE58420-Srinibas SahooAWM (POH)58416-P.K.RautAWM (F)58510-Amit SwamiAWM (LHB)58512-T.K.DasAEN58458-S.C.HansdaAMM58468-P. K. BurmanCMT58422-Address:Office of the Chief Workshop Manager,Carriage Repair Workshop, MancheswarEast Cost Railway, Bhubaneswar -751017.Fax: 0674 – 2748702.Email: cwm mcs@ecor.railnet.gov.in
East Coast Railway Women’s welfare organization(ECoRWWO), Mancheswar, isdedicated to the welfare of Railway employees and their family in particular, and tothe society and local community in general welfare activities. The women welfare organization played an active role to bring in and nourish hopesduring the formative years of the workshop in the isolated township of Mancheswar,yet to be touched by development. It runs “Sishu Niketan” which provides quality education from nursery to UKG at avery nominal fee. The care taken at “Sishu Niketan” during the crucial formativeyears of the children ensures laying of strong foundation for future development andcharacter building. School of Music and Dance imparts training in Hindustani Classical Vocal Music,Tabla, Odissi dance and contemporary Dance. The organization also runs school of arts. Inner urge to express oneself throughdrawing is honed to develop children as artists and better citizen. Various competitions are organized in drawing, painting and essay writing in variousage group for the children of the area. This recognizes the talent and encourageschildren to further their interest. The organization comes forward and brings succor and hope to the distressed peopleby extending services during natural calamities, like floods and cyclones that affectthe coastal belt of Orissa frequently. Hot and humid summer with temperature around 470c has been a killer in recentyears. During hot summer, it organizes “Trisha” to serve sweetened cold drinkingwater to the tired path goers. Some of the other welfare activities undertaken by the organization are summerCamps for children imparting short term courses on music, dance, art etc. This helpsin gainfully engaging the children during holidays in furthering their interest. Apart from these, fruits, and food items are distributed to needy on important dayslike Independence Day & Republic Day. Independence Day, Teachers Day, Children’s Day Saraswati Puja, Republic Day, Sportday, Annual day are some of the events celebrated with great fanfare at variouscenters run by ECoRWWO, MCS. Recently, ECoRWWO conducted computer training programmes for Womenemployees of the workshop
International Women’s day was celebrated by ECoRWWO on 5th March 2010. Onthis occasion, a seminar on ‘Women Upliftment’ was held to commemorate TheInternational Women’s Day.President, ECoRWWO visiting ShishuNiketan on 27.08.2013Independence Day Prize Distribution15.08.2013Independence Day Fancy Dress15.08.2013ECoRWWO, Mancheswar Annual Functionon 15.12.2012
work for setting up of an AC Coach POH facility for an outturn of 05 AC Coaches per month sanctioned in 1999-2000 at a cost of Rs. 3.34 Crores, ii. work of additional coach POH facility sanctioned in 2003-2004 at a cost of Rs. 7.24 Crores) have taken the installed capacity of the workshop to 100 coaches (9 0 non-AC 10 AC coaches)
