Diesel Loco Modernisation Works

TECHNICAL TRAINING CENTRE

DIESEL LOCO MODERNISATION WORKS

PATIALA

Information pertaining to Technical Training Centre / DMW/ Patiala

(a)Basic details :-

( b) Details of Faculty – Gazetted and Non-gazetted : As per annexure ‘A’

( c) Calendar of training courses : As per annexure ‘B’

( d) News letter of the training centre : Nil

( e) Photographs of the training centres : As per annexure ‘C’

( f) Any other important activity undertaken by the training centre :

A machine maintenance course (Electronics & Hydraulics) was started for

supervisors and artisans of DMW and Zonal Railway staff.

( g) Study material, lecture notes, case studies, Question bank etc. : As per

annexure ‘D’

ANNEXURE-A

DIESEL LOCO MODERNISATION WORKS, PATIALA

An ISO 901,ISO 14001,IS 18001 Certified Organisation

TRAINING PROGRAMME AT A GLANCE :2012-13

ANNEXURE-B

ANNEXURE ‘C’

TECHNICAL TRAINING CENTRE, DMW, PATIALA

MECHATRONIC LAB

MACHINE SHOP ELECTRICAL LAB

CNC LATHE TRAINER

WORKING CUT MODEL OF DIESEL LOCO HYDRAULIC TRAINER KIT

ANNEXURE ‘D’

COURSE CONTENTS FOR SPECIAL COURSES

01 SUPERVISOR DEVELOPMENT PROGRAMME:

INTRODUCTION

• Introduction to the subject course, need & objectives,
• Short view of the syllabus to be covered during this programme.

FINANCE –1

• Budget, its appropriation,
• Stages of review,
• Continuity of the process.

FINANCE –2.

• Role of audit,
• control function expenditure,
• What is audit, who is competent to audit Answerability to ability.

PERSONNEL MANAGEMENT-1

• Suspension, penalties, disciplinary authorities, applets authorities, reviewing

authorities, serving of orders and noting,

• DAR inquiries, procedures for imposing penalties,
• Do’s and Don’ts for inquiry officers,
• Do’s and Don’ts for presenting officer.

PERSONNEL MANAGEMENT-1I

• Need for industrial relations,
• Healthy workers participation and management relationship.
• A capsule on Factory Act
• Role of trade unions, constitution and election of office bearers, levels of

functioning of trade unions, issues to be discussed with trade unions.

PERSONNEL MANAGEMENT-III

• Personnel function (Scope & Organisation),
• Selection (Process & methods), performance appraisal, wages & salary,
• Administration, selection of Employees, grievances, workers participation
• PREM
• A capsule on Workmen’s Compensation Act.

PERSONS WITH DISABILITY ACT 1995

• Rights and entitlements of persons with disability,
• Sensitization towards disabled staff,
• Creation of free environment for disabled persons,
• Non discriminating environment for disabled persons.

MANAGEMENT - 1

• To manage resources like Men, Machines, Materials, Time & Capital.
• To strive of optimum utilization thereof.
• Planning, Organisation, staffing, controlling.

MANAGEMENT – 2

• Communication process,
• Styles of speakers, Listening, barriers to communicate,
• Communication channels.

MANAGEMENT - 3

• Priority of needs & motivation,, Marlows Heirachy needs, factors, motivation.
• Leadership styles, poor relationship & styles ( Personality, Develop

Leadership, Action wise theories)

• Defining and planning a project, implementation stages controlling, work in

progress, feedback ,project completion.

MANAGEMENT – 4

• Types of Decisions, Steps & aids in decision making, giving choice in decision.
• Common problems (procrastination policy delegator)personal sense of time,

identifying long term goals & plans, planning the day, time effectiveness in offices.

MANAGEMENT – 5

• Stress management counseling,
• Factors responsible for creating stress,
• Life styling and attitudes to cope with stress, relaxation techniques.

MATERIAL MANAGEMENT /INVENTORY

• Organisation and control,
• Material planning and budgeting,
• Codification and standadisation,
• ABC analysis, sources, selection, and inventory of railways.

HEALTH AND NUTRIATION

• Balance diet,
• Medical Check up,
• First-Aid Box,
• Contribution of health of manpower in production

HEALTH EDUCATION & MEDICAL PSYCHOLOGY

• Nutrition, Hygiene’s,
• First-Aid and Medical check-ups,
• Behavior, Emotions & Stresses,
• Attitudes , Learniys habits, Personality,
• Intellegenous and life cycle of family,

PREVENTION OF NON - COMMUNICABLE DIEASES & FAMILY PLG.

• Aids, Obesity, Diabetes, Hypertension,
• Coronary artery diseases and Family Planning.

ROLLING STOCK PROGRAMME

• Rolling stock programme,
• M&P programme, works programme,
• Preparation at preliminary and final stages.

DISASTER MANAGEMENT

• Introduction of disaster management,
• Main type of disasters,
• Preparation for pre-disaster,
• Action during disaster and after disaster,
• Responsibilities of management and responsibility of supervisor.

SAFETY

• Safety precautions to be observed in workshop,
• Legal observation,
• Duties of shop incharge and responsibility of management as per Factory Act.

VIGILANCE

• Role of vigilance, a guide,
• Listening precautions.

CUSTOMER CARE

• Customer care and Courtesy- importance of customer,
• Concept customer friendly, courtesies which may be extended.

FUTURE TRENDS

• Emerging trends on Indian Railways.
• What are the future plans on Indian Railways,
• Production of 3100 HP Loco & 4000 HP GM Loco.

GENERAL

• Organisation of railways,
• Various departments,
• Interdepartmental working and any day-to-day working of railways.

ISO

• Brief introduction to ISO,
• Awareness of Quality Management System ISO 9001:2008, Environmental

Management System ISO 14001:2004 and Occupational Health and Safety

System (OHSAS 18001:2007) ,

• Status of ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 in DMW
• Quality, Environmental and Occupational Health and Safety Policy of DMW.

FEED BACK :

• Feed back of the course,
• Shortcomings & suggestions to improve the course further.
• Discussions on the queries of participants about the course.

02 FIRST AID:

• Introduction & Principal of First Aid,
• Handling & Transportation of Injured Person,
• Respiration & Asphyxia,
• Wounds & Bleeding,
• Fracture & Dressing/Bandage,
• Diarrhea & Fever,
• Management of an unconscious patient & Bites,
• Burns & Poisoning,
• AIDS,
• Don’ts in First Aid,
• Practical Demonstration of First Aid.

03 INDUSTRIAL SAFETY:

• Introduction to Industrial safety,
• Use of personnel Equipments,
• Requirement of industrial safety,
• Right to safety and safety principles,
• Various causes of accidents,
• Prevention of accidents,
• Various types of hazards,
• Types of various kinds of accidents and their reporting,
• Role of management, supervisors & workers on industrial safety,
• Safety Committee Meeting and its functions,
• Conducting of mock drills and any other.

04 FIRE FIGHTING:

• Introduction,
• Identification of unsafe condition for fire prevention,
• Organizing for fire protection,
• Control of emergencies,
• Disaster control organization,
• General organizational consideration.

05 CNC MACHINE PROGRAMMING:

• Introduction to part program,
• What is programming,
• What the programmer has to do,
• Preparatory (G) Functions as: ISO 646 (Fanuc sys & Sinumeric latest), Miscellaneous (M) Function as: ISO 646 (Fanuc sys & Sinumeric latest),
• Common Codes & Addresses for Lathe/ Milling & Drilling Machines,
• Procedure associated with part program,
• Structure of part program in the tabulation with Example,
• Co-ordinates System, Programming Modes,
• Absolute & Incremental Modes,
• Diameter and Radius Programming,
• Program of Step Turning (Absolute),
• Program of Step Turning (Incremental),
• Step Turning & Threading, Taper Turning,
• Step turning with Taper Turning,
• Radius Clock Wise, RadiusCenter Clock Wise,
• Parting Subroutine,
• Milling Circular & Canned Cycle function,
• Milling Rectangular & Canned Cycle function,
• Letter Function A, Letter Function C,
• Circular Angle Function, Mirror Function, Scaling Function,
• Drilling with Repeat Function,
• Pick drilling cycle.

6 CNC MACHINE MAINTENANCE:

• Basic electronics,
• Description of semiconductor devices,
• Visit to electronics lab,
• Block diagram of CNC,
• Detail of PLC of a CNC machine,
• Explanation of plc and CNC faults,
• Shop floor visit for awareness of electronics circuits & practical implications of electronics circuits,
• DC and AC drive of CNC control,
• Different types of controls,
• Feedback devices & troubleshooting of CNC machine,
• Shop floor visit for awareness of electronics circuits & practical implications of electronics circuits.,
• Features of different type of machines.,
• Basics hydraulics, Machine maintenance.,
• Practical on hydraulics in Mechatronics Lab,
• Shop floor visit for awareness of hydraulic system,
• Hydraulic maintenance.,
• Hydraulic trouble shooting.,
• Shop floor visit for awareness of hydraulic system.

REFRESHER COURSES

01 Machinist:

Introduction, Tool Materials & Tool Geometry, General purpose machines & special purpose machines , CNC Part Programming, CNC Tooling and qualified tooling, CNC Machine advantages and disadvantages, Machining operations, Engine Block & Con. Rod manufacturing process, Capacity utilization, Carbon Brush Manufacturing Process, Cam Shaft Manufacturing Process, Gear manufacturing and testing processes, ISO awareness, Disaster Management.

02 Diesel Fitter:

Introduction, Two Stroke & Four Stroke I.C. Engines, Turbo Super Charger, Construction details and specifications of Diesel Electric Locomotive, Fuel Oil System & Fuel Injection Equipments, Air Brake System, Lube Oil System & Water Cooling System, Under Frame Camber, Buffers & CBC Coupling, Bogie Constructional Details, Modifications carried out on Diesel Electric Locomotive, ISO Awareness, Disaster management.

03 Gen. Fitter:

Introduction Engineering Drawing, Limits, Fits and Tolerance, Hand Tools, Jigs & Fixtures, Fasteners, Threads and Joints, Measuring Instruments, Destructive Testing & Non-destructive testing, Power transmission, Bearings mounting & dis –mounting , Heat Treatment, Revision and clarification session & feedback, ISO awareness , Disaster Management.

04 Welder:

Basic knowledge of Electricity, Various type of Electrodes, Gas Welding & Oxy Cutting Welding, MIG & TIG Welding, Welding of Cast Iron & Stainless Steel, Welding defects & its remedies, Submerged & Plasma Arc Welding, Health & Safety aspects in Welding, Arc Welding principles D.C & A.C, Welding Plant & current requirement, Inspection& non-destructive test of welding, Robotic welding techniques/ Automation of welding & its advantages, Heat Treatment Process, ISO awareness, Disaster Management.

05 T&M Fitter:

Introduction to Electrical Engineering, Insulating materials used for rewinding of Traction Motors and Traction Generators, Traction Machines, Commutator and its construction, Armature Winding & Stator winding, Process of manufacturing of Stator & Armature coils, Process of rewinding of Traction Motor and Traction Generator & Alternator, Testing facilities for TM , TG & Traction Alternator, Common defects on D.C. Machines and their remedial measures, EMD TA Manufacturing & repairs, Overhauling of AC Traction Motors (Siemens Make ), ISO awareness and disaster Management.

06 Crane Driver:

Signals & Safety Rules, Construction features of Crane, Functioning of Electrical System, Daily cleaning and lubricating schedule, Working of Crane, Working of Diesel Engine,Trouble shooting of Diesel Engine, Preventive Maintenance of Cranes, Slings, Tackles, Wire Ropes and Knots, Safety and First Aid, ISO Awareness, Disaster Management.

07 Rigger:

Use of Measuring tape and other simple Measuring instruments, Preparation before cutting a rope for Splicing, Length of rope to be left for Splicing, Knowledge of tool used for Splicing, Splicing a wire rope with or without Thimble, How to Splice a Cotton or Manila rope, How to remove slight kinks from wire rope, Strength of wire ropes, Chain / manila ropes, Cotton ropes & Nylon ropes etc, Crane Signal, Different Weight that can be lifted with Crane at corresponding angle of Jib, Crane breakdown & power failure, Rigging Tackles, Preventive maintenance of Wire ropes, Chain Slings & Lifting Tackles, First Aid, Fire Fighting & Safety at work, ISO Awareness and Disaster Management.

08 Driver Tech:

Knowledge about Road rules and Symbols, Knowledge of various parts of vehicles which are important with respect to safety such as brakes, steering, gear and control etc, Working and difference between two stroke and four stroke engines, Control and knowledge of speed, acceleration and tyre pressure and driving on all types of roads, Knowledge about all types of dashboard meters such as oil pressure, temperature, ampere meter, charging of battery etc, Working and difference between Petrol Engine and Diesel Engine, Awareness about allowed and safe load. (Carrying capacity of vehicle.) Knowledge of daily maintenance of Battery such as terminals cleaning, electrolyte level and general safety, Knowledge about running maintenance such as oiling, brake adjustment, ignition adjustment and oil level etc, Knowledge of driving of all vehicles such as car, fork lifter, truck, bus etc and knowledge of their parts, Knowledge about starting, stopping & driving of vehicle, should hold heavy duty driving license, Knowledge about lubrication. (Parts which are not lubricated automatically), ISO Awareness, Disaster Management.

09 Carpenter:-

Introduction, Classification of Timber. Types of timber, Structure of a Timber tree, The specific uses of different types of timber. Conversion and market forms of timber, Seasoning of wood. Common defects in timber, Plywood and preservation of timber, Carpentry marking and measuring tools, Carpentry cutting tools. Sharpening of wood working tools. Care and safety precautions during working, Carpentry processes such as making, sawing, planning, boring, grooving etc. Safety in carpentry shop, Types of wooden Joints & precautions while making joints, Auxiliary materials used in wood making, Wood polishing materials as Paints, Varnish and Lacquers etc, Estimation of cost, ISO awareness, Disaster Management.

10 Painter:

Knowledge of colours and paints such as primary and secondary colour, synthetic enamel, deco paint, stowing paints etc, Knowledge of various types of putties, their preparation and specific use, Knowledge of various types of thinners used in painting, their specific use and knowledge of other solvents used in painting, Knowledge of methods for removal of old paints, Procedure for painting interior and exterior surfaces. Uses of under coat and final coat, Knowledge of stencil cutting and working, letter writing in English, Hindi and Colour-coding, Knowledge of various types of equipments such as sanding disc, putty applying tool, putty cutting etc, Knowledge of various types to machines and their maintenance used in painting such as cup gun, pressure feed, air less painting etc, Knowledge of calculating the quality of paint required for specific use under standard conditions, Knowledge of simple drawing used in painting and preparation according to the drawings, ISO awareness, Disaster Management.

11 Electrical Fitter:

Basics of Electricity, Power factor improvement, causes of low power factor and losses of low power factor, Indian Electricity Rules, Electrical Accidents, Earthing and safety, Maintenance of Electrical sub station and transformers, Testing and Commissioning of Electrical installations, ISO awareness, Disaster Management.

12 RAC:

Basics about Air Conditioning & Refrigeration and its definition, Comfort Air Conditioning for human being, Refrigeration & Air Conditioning equipments used in DMW, WAC, Split AC, Refrigerator, Deep freezer, cooling cabinet, Water cooler Panel AC’s central AC plant, Types of compressors used in Air Conditioning / Refrigeration i.e. open type, semi-sealed, thematically sealed, Rotary, Introduction of different parts of central AC Plant i.e. DX type, Chiller type, Latest developments in Refrigeration & Air Conditioning, ISO awareness, Disaster Management.

13 Telecommunication:

Ohm’s Law, Series and Parallel connection of resistance, Basic Electricity, Maintenance of telephone instrument, Maintenance of power plant, Maintenance of line plant, Knowledge of PA system microphone, amplifier horn type and box type speaker, Basic knowledge of FAX machine operator console, Type of telephone exchange there facilities and uses, General knowledge of walkie-talkie set, VHF set etc, UHF & Microwave equipments, Cable jointing, General knowledge of fault finding of under ground and overhead cables, Knowledge of OFC cable, General knowledge of PRS, ISO awareness,.

14. M W Mechanic:

Features of different types of machines, Types of machine maintenance, Maintenance tools, Machine Foundation and Leveling, Power Transmission mechanism, Automobiles, Lifting Tackles, Fluid Power & Hydraulics (Training in Mechatronics Lab), Pneumatics (Training in Mechatronics Lab), Bearings, ISO Awareness, Disaster Management.