Detailed Project Report (DPR) on Railway Wagon Manufacturing (Cap: 8 Nos/Day)

RAILWAY WAGON MANUFACTURING (CAP: 8 NOS/DAY) 

[EIRI/EDPR/4730] J.C.: 2950XL

A wagon is an element of the train. It is a type of towed vehicle designed to move along a railway track. Unlike the car which is reserved for transporting people, the wagon is used for the transport of goods or animals. There are many different types, depending on use: wagons for transporting livestock, refrigerated wagons, tanker wagons, crane wagons, container wagons.

COST ESTIMATION

Plant Capacity            8 Nos/Day

Land & Building (80,000 sq.mt.)    Rs. 70.58 Cr

Plant & Machinery                    Rs. 87.11 Cr

Working Capital for 2 Months    Rs. 97.05 Cr

Total Capital Investment          Rs. 258.11 Cr

Rate of Return                          76%

Break Even Point                      25%

CONTENTS

INTRODUCTION

TYPES OF WAGONS:-

CLASSIFICATION OF RAILWAY WAGON

(1) ACCORDING TO IT’S UNDER GEAR

(2) ACCORDING TO ITS UTILITY

TYPES OF WAGON

(1) COVERED WAGON

CONSTRUCTION OF COVERED WAGON

A. SIDES

B. ENDS

C. ROOF

D. DOOR

BCN

BCNA

BCNA-HS

BCCN/BCCNA/BCCNB

BCCN

(2) OPEN WAGON

A. SIDES

B. ENDS

C. DOORS

BOXN WAGON – 

BOXNHA 

BOXNHS 

BOXN CR 

BOXNLW 

LIGHT WT. BOXN WAGON 

BOXNHL 

(3) FLAT WAGON

CONSTRUCTION OF FLAT WAGON 

A. ENDS

B. SIDE STANCHION

FLAT TYPE – 

(4) TANK WAGON

TANK TYPE – 

B.I.S. SPECIFICATION

(1) IS:M-44 SPECIFICATIONSS SHEET FOR WAGON

OVERVIEW OF INDIAN TRADE SCENARIO

COMPARISON OF LOGISTIC COST

A) HIGH SHARE OF ROAD IN INTER-MODAL MIX

B) INEFFICIENT TRANSPORT VEHICLES

C) ROAD INFRASTRUCTURE CONSTRAINTS

OVERVIEW ON INDIAN TRADE THROUGH RAIL MODE

SHARE OF RAIL MODE IN DOMESTIC FREIGHT

OUTLOOK FOR MODAL SHARE AND VOLUME GROWTH OF RAILWAYS IN FREIGHT TRANSPORT

FUTURE POTENTIAL FOR RAIL AS MODE OF TRANSPORT

INDIA’S INVESTMENT IN TRANSPORT INFRASTRUCTURE

CAPITAL EXPENDITURE PLAN BETWEEN FISCAL 2020 TO FISCAL 2025

KEY INDUSTRIES OF INDIA DEPENDING ON RAIL FREIGHT

RAILWAY INFRASTRUCTURE IN INDIA

CONTRIBUTION OF TRANSPORTATION SECTOR TO INDIAN ECONOMY

RAILWAY INFRASTRUCTURE

OVERVIEW ON INDIAN RAIL TRACK LENGTH

FREIGHT AND PASSENGERS CARRIED BY INDIAN RAILWAYS

NO OF PASSENGER OVER THE YEARS

RAILWAY’S CURRENT SHARE IN FREIGHT MOVEMENT – COMMODITY-WISE (AS ON FISCAL 2022)

GOVERNMENT POLICIES FOR RAILWAY FREIGHT INDUSTRY

BUDGETARY SUPPORT

BUDGETARY OUTLAY TOWARD RAILWAY PROJECTS

NATIONAL INFRASTRUCTURE PIPELINE

OTHER INITIATIVES

DEDICATED FREIGHT CORRIDOR (“DFC”)

THE MAIN OBJECTIVES OF DFCCIL ARE AS BELOW:

RAILWAY INFRASTRUCTURE – KEY SEGMENTS

DFCS ARE PROPOSED TO USED STATE-OF-THE ART TECHNOLOGY INCLUDING THE BELOW:

DEDICATED FREIGHT CORRIDOR IN INDIA

DIAMOND QUADRILATERAL NETWORK

INDIA-MIDDLE EAST TRADE CORRIDOR (“IMEC”)

OBJECTIVES:

HIGH SPEED RAIL CORRIDOR

VANDE BHARAT EXPRESS

NATIONAL RAIL PLAN 2030

OBJECTIVES, AND PLANS TO IMPROVE MODAL SHARE OF RAILWAYS IN FREIGHT TRANSPORT

FOLLOWING ARE THE KEY OBJECTIVES OF NRP:

PROPOSED EXPENDITURE UNDER NRP (₹ LAKH CRORE)

STRATEGY TO INCREASE MODAL SHARE OF RAILWAYS TO 45% BY FISCAL 2030

A. STRATEGY TO ADDRESS SUPPLY SIDE CONSTRAINTS

B. STRATEGY TO ADDRESS DEMAND SIDE CONSTRAINTS

WORLD RAILWAY NETWORK

CHALLENGES

VOLATILITY IN MATERIAL COSTS

TREND IN INTERNATIONAL STEEL PRICES

• INCREASING COMPETITION

• HIGH INITIAL INVESTMENTS

• RISKS OF MACROECONOMIC AND SECTORAL POLICY CHANGES

RAILWAY WAGONS INDUSTRY

OVERVIEW

SPLIT OF TOTAL ROLLING STOCK

INDIAN RAILWAY ROLLING STOCK

PAST TREND IN WAGON ORDERS

TREND ON WAGON TENDERING BY INDIAN RAILWAYS

TREND IN NEW WAGONS INDUCTED BY INDIAN RAILWAYS

PRIVATE SECTOR

GROWTH OUTLOOK

FORECAST OF INDIAN RAILWAY WAGON REQUIREMENT

PRIVATE PLAYERS PARTICIPATION

BRIEF INFORMATION ON THESE SCHEMES IS PROVIDED BELOW:

KEY EXPORT DESTINATIONS

• GOVERNMENT THRUST ON RAIL INFRASTRUCTURE IMPROVEMENT

PROJECTED GROWTH IN PASSENGER TRAFFIC

• INCREASE IN DEMAND FROM THE PRIVATE SECTOR

• IMPETUS FROM THE ATMA NIRBHAR BHARAT ABHIYAN

• PLI SCHEME

• AUTOMATION, ADOPTION OF TECHNOLOGY AND TECHNOLOGICAL PARTNERSHIPS

KEY CHALLENGES

• IMPORT DEPENDENCE FOR MAJOR ACCESSORIES AND COMPONENTS

THE BELOW CHART DEPICTS THE IMPORT TREND OF ROLLING STOCK:

TREND IN IMPORTS OF ROLLING STOCK ACCESSORIES

• TECHNOLOGICAL DEPENDENCIES

PASSENGER COACH INDUSTRY

CURRENT SITUATION OF PASSENGER COACHES IN INDIA’S RAILWAYS

INDIAN RAILWAY ROLLING STOCK

MARKET SIZE AND GROWTH OUTLOOK FOR PASSENGER COACH

PROJECTED GROWTH IN PASSENGER TRAFFIC - BY TYPE

FORECAST OF INDIAN RAILWAY COACHES REQUIREMENT

INDIAN EXPORTS FOR PASSENGER COACHES

EXPORTS OF PASSENGER COACHES FROM INDIA (IN VALUE)

EXPORTS OF PASSENGER COACHES FROM INDIA (IN VOLUME) 

METRO RAIL SEGMENT

METRO COACH MANUFACTURING FACILITIES IN INDIA

EXPANSION OF METRO RAIL

INDIAN METRO RAIL COVERAGE

METRO RAIL NETWORK UNDER CONSTRUCTION

METRO RAIL NETWORK UNDER APPRAISAL/APPROVAL

METRO RAIL COACH INDUSTRY OUTLOOK

VANDE BHARAT EXPRESS

OBJECTIVE

VISION

FEATURES AND AMENITIES IN VANDE BHARAT EXPRESS

VANDE BHARAT COACH INDUSTRY OUTLOOK

EXPORTS OPPORTUNITY OF PASSENGER COACHES

MARKET FOR KEY RAIL/ROLLING STOCK COMPONENTS

OVERVIEW

KEY ROLLING STOCK ACCESSORIES MANUFACTURERS IN INDIA

IMPORT DEPENDENCE FOR MAJOR ACCESSORIES

GROWTH DRIVERS AND OUTLOOK

RAILWAY PROPULSION SYSTEM INDUSTRY

GLOBAL INDUSTRY

GLOBAL RAILWAY PROPULSION SYSTEM MARKET

INDIAN INDUSTRY

GROWTH DRIVERS FOR INDIAN RAIL PROPULSION SYSTEM INDUSTRY

• ELECTRIFICATION INITIATIVES

• HIGH-SPEED RAIL CORRIDOR

• SUPPORTIVE GOVERNMENT POLICIES AND GROWING INFRASTRUCTURE INVESTMENTS

• RISING PASSENGER AND FREIGHT DEMANDS

• GROWING FOCUS ON TECHNOLOGICAL INNOVATION AND SUSTAINABILITY

• MODERNIZATION AND UPGRADATION OF EXISTING RAIL INFRASTRUCTURE

• EXPANSION OF URBAN TRANSIT MODE

MANUFACTURING PROCESS FOR BOXNHL WAGON

DESCRIPTION ABOUT BOXHNL WAGON

SALIENT FEATURES FOR BOXNHL WAGON

DETAILS SALIENT FEATURES OF BOXNHL WAGON

2. DRAW AND BUFFING GEAR:-

3. BOGIE:-

4. BRAKE GEAR:-

5. RUNNING GEAR:-

STANDARD FEATURES OF ‘BOXNHL’ WAGON

(1) UNDER FRAME:

MAIN PARTS OF UNDERFRAME ARE:-

(2) CENTER SILL:

(3) SIDE BODY:

(4) END BODY:

(5) DOORS:

(6) BOGIE:

BOXHNL WAGON HAS CAS NUB BOGIE

CAS NUB BOGIE HAS FOLLOWING COMPONENTS

FIGURE BOGIE GENERAL ARRANGEMENT FOR CASNUB

FIGURE BOGIE GENERAL ARRANGEMENT CASNUB

7. CENTRE BUFFER COUPLER

ADVANTAGES OF CBC:-

COUPLER BODY:

KNUCKLE:

(8) BRAKE SYSTEM

AIR BRAKE SYSTEM:

A) DISTRIBUTOR VALVE:

B) BRAKE CYLINDER:

C) CUT OFF ANGLE COCK:

D) DIRT COLLECTOR:

E) RESERVOIR:

F) METAL PIPES AND JOINTS:

G) SLACK ADJUSTER:

PROCESS FLOW CHART

MAIN STEPS FOR FABRICATION

MAIN PROCESS

THE MAIN PROCESS HAS FOLLOWING STEPS ARE GIVEN BELOW

(1) CUTTING

(A) GUILLOTINING

THE FOLLOWING GUILLOTINE CLEARANCE SETTINGS ARE GIVEN FOR GUIDANCE:-

(B) PLASMA CUTTING

(A) PLASMA CUTTING:-

(B) CNC PLASMA CUTTING:-

CUTTING GASES 

(C) ABRASIVE CUT – OFF WHEELS 

(D) ARC-AIR GOUGING 

(E) POWDER CUTTING 

(F) SLITTING

(G) COLD SAWING 

(H) BLANKING AND PUNCHING 

(I) DRILLING 

(2) STRAGHTENING

STRAIGHTENING OF IRSM-44: 

(3) PRESSING

(A) HYDRAULIC PRESS:-

(B) POWER HAMMER:-

(C) DROP HAMMER:-

(4) WELDING

(A) ARC WELDING:-

ARC WELDING CIRCUIT:-

DEFETS OF ARC WELDING:-

1. OVERLAP:- 

2. UNDERCUT:-

3. POROSITY:-

4. SPATTER:-

5. CRATER:-

(B) GAS METAL ARC WELDING (GMAW)/MIG:-

DEFECTS OF MIG WELDING:-

1. OVERLAP:-

2. UNDERCUT:-

3. POROSITY:-

4. SPATTER:-

5. CRATER:-

IN A WAGON, VARIOUS PARTS ARE WELDED AS PRESCRIBED FOLLOWING:-

WELDING OF IRS M-44

(A) WELDING PROCESS

(B) WELD REPAIRS 

(C) POST WELD CLEANING

(D) MECHANICAL CLEANING 

(E) WELDING PROCEDURE:- 

GENERAL PRECAUTIONS IN WELDING OF STAINLESS STEEL 

WELDABILITY ISSUES: 

PREPARATION PRIOR TO WELDING: 

PRECAUTIONS DURING WELDING: 

PRECAUTIONS AFTER WELDING: 

QUALITY REQUIREMENTS OF WELDING – 

FABRICATION OF DIFFERENT PARTS

(1) CENTER SILL

3 FINISHED CENTER SILL SET

Z-SECTION

CENTER PART OF CENTRE SILL

END PART OF CENTRE SILL

FIXTURE OF CENTRE SILL

(2) UNDERFRAME

UNDER FRAME STRUCTURE

(3) BODY END

(5) DOORS

(7) BRAKING SYSTEM

SLACK ADJUSTER AUXILIARY RESERVOIR

DISTRIBUTOR VALVE AND CONTROL BRAKE CYLINDER

LEVER ASSEMBLY PARTS EMPTY LOAD ADJUSTER

SHOE BRAKES

BRAKING PROCESS:-

(6) FINAL ASSEMBLY

PROCEDURE:-

A) REMOVAL:-

B) INSTALLATION:-

GENERAL DATA:-

(7) FINISHING (SHOT BLASTING)

(A) SURFACE PREPARATION

SURFACE PREPARATION OF THE WAGON BODY AND UNDER FRAME 

SHOT BLASTING CHAMBER

(B) PAINTING OF WAGON BODY AND UNSER FRAME 

FOR STAINLESS STEEL 

PRECAUTIONS TO BE TAKEN IN WORK AREA 

PRECAUTIONS TO BE TAKEN IN STORAGE 

PRECAUTIONS TO BE TAKEN IN STORAGE OF IRS: M 44 STEELS

(8) TESTING

(1) RADIOGRAPHY TEST (RT):-

RT MACHINE

(2) DI-PENETRATION TEST:-

(3) COMPRESSIVE STRENGTH TEST:-

SETUP FOR TEST

LOAD PROVIDING MACHINE

(4) WATER TESTING:-

WATER TESTING UNIT

(6) VISUAL INSPECTION:-

(7) BRAKING SYSTEM TEST:-

PRESSURE GENERATING UNIT

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

PLANT LAYOUT

MANUFACTURERS/SUPPLIERS OF RAILWAY WAGON

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF IRS M-44 SS SHEET

SUPPLIERS OF CRF SECTION

SUPPLIERS OF COMPLETE CAS NUB BOGIE ASSEMBLY

SUPPLIERS OF AIR BRAKE ASSEMBLY

SUPPLIERS OF WELDING ELECTRODES

SUPPLIERS OF PAINS MATERIALS

SUPPLIERS OF OTHER MACHINERY AND EQUIPMENTS

POWER PRESS

SHEARING MACHINE

ROLLING MACHINE

FLYPRESS

BENDING MACHINE

MECHANICAL PRESS

FORGING PRESSES

FORGING HAMMER

UNCOILING MACHINE

SHEET LAVELING MACHINE

PUNCHING PRESS

CNC PLASMA CUTTING MACHINE

MILLING MACHINE

CNC LATHE MACHINE

BOARING MACHINE

POWER HACKSAW

GRINDING MACHINE

PROJECTION WELDER

SEAM WELDING MACHINE

SPOT WELDING MACHINE

GAS WELDING EQUIPMENTS

MIG WELDING MACHINE

SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES

EOT CRANE

POWER TRANSFORMER

ELECTRICAL PANEL

ELECTRIC MOTOR

COOLING TOWER

EFFLUENT TREATMENT PLANT

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSORS

PLATFORM WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE FIGHTING EQUIPMENTS

SHOT BLASTING MACHINE

JIGS AND FIXTURE

SUBMERSIBLE WATER PUMP

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF BILLET CUTTING MACHINE

SUPPLIERS OF ELECTROPLATING PLANT

SUPPLIERS OF ANNEALING FURNACES

SUPPLIERS OF HEAT TREATMENT FURNACE

SUPPLIERS OF HARDNESS TESTING MACHINE

SUPPLIERS OF CLOSE DIE HOT FORGING MACHINE

SUPPLIERS OF FORGING DIES

SUPPLIERS OF INDUCTION HEATING FURNACE

SUPPLIERS OF CNC LATHE MACHINE

SUPPLIERS OF CNC MACHINING CENTRE

SUPPLIERS OF METAL TESTING MACHINE

SUPPLIERS OF DG SETS

SUPPLIERS OF EOT CRANES

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF AIR CONDITIONING EQUIPMENTS

SUPPLIERS OF AIR COMPRESSORS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF SHOT BLASTING MACHINE

SUPPLIERS OF JIGS AND FIXTURE

LIST OF DOCUMENTS REQUIRED TO GET FOR LICENSES

DOCUMENTS:

OTHER LICENSES REQUIRED FOR THE SETUP:

IMPLEMENTATION SCHEDULE

ORGANIZATION CHART

STATUTORY APPROVALS FROM GOVERNMENT

DETAILS OF TEST FACILITIES AVAILABLE IN INDIA

STANDARDS OF INFRASTRUCTURE, MANUFACTURING, TESTING AND QUALITY 

ASSURANCE SYSTEM

GENERAL REQUIREMENT

INFRASTRUCTURAL REQUIREMENTS

MACHINERY & PLANT REQUIREMENTS

FACILITIES FOR MOUNTING OF CARTRIDGE/ROLLER BEARINGS

TESTING & MEASUREMENT REQUIREMENTS

DESIGN INFRASTRUCTURE REQUIREMENTS

MATERIAL MANAGEMENT REQUIREMENTS

LABORATORY FACILITIES

QUALITY ASSURANCE REQUIREMENTS

USE OF COMPONENTS LIKE BOGIE, AIR BRAKE SYSTEM, COUPLERS ETC DURING WAGON MANUFACTURING

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSETS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5-10 YEARS)