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Enhancing Rail Industry Efficiency: Achieving Higher Output and Quality with Custom Automation

Higher Margin, Higher Volume at Lesser Cost & Lesser Space!

Rail Industry Suppliers in India (MSMEs especially) are competing relentlessly for winning orders at ever reducing prices. With the cost of material and labour being fixed it is desirable to undertake customised automation! This will substantially reduce the variable costs associated with Fabrication, Assembly, Cycle-time, Material-handling, Inventory and Factory Space (especially covered but also open). Simple and appropriate manufacturing automation of coaches, locomotives and structures can now be implemented effectively in big, small or phased measure to boost Productivity substantially and increase Quality and Safety significantly aiming for nothing short of perfection. Further, this can be achieved in very quick time at low costs enabling recovery if investment even within 1-2 years!

Reduce costs of:-

• Fabrication!
• Assembly Big/Small!
• Cycle-time!
• Material-handling!
• Inventory!
• Shed/Open Space!
• Carbon Footprint

Methods can give an exponential boost to Productivity!

Early in my career when a workshop outturn was 1/3rd of the target and the excuse was Men, Materials, Machines etc we could use “Methods” to increase outturn by 4 times within a year! Yes, You Can easily increase productivity with simple automation solutions in a big, small or phased manner!

Make-In-India!
Previously, the Railway industry heavily relied on global markets for solutions, often sourcing machinery and expertise from renowned global players. However, a significant transformation is underway. Indian MSMEs have rapidly evolved to meet and even surpass global standards, offering innovative solutions tailored to local manufacturing conditions. Now, thanks to the growth of numerous MSMEs in India, local companies provide cutting-edge solutions that not only match but often exceed global standards. These solutions offer high productivity at a fraction of the investment previously required.

Innovation for Better ROI: The rise of local MSMEs has ushered in an era of innovation, resulting in solutions that deliver superior Return on Investment (ROI). By leveraging indigenous talent and expertise, these companies offer cost-effective automation solutions that enhance productivity and efficiency across the railway industry.

Local Solutions for Local Needs: Indian MSMEs specializing in automation for railways understand the unique challenges and requirements of the local manufacturing landscape. They provide comprehensive services, including site studies, conceptualization, 3D design, customization, warranty, and Annual Maintenance Contracts (AMCs). Moreover, they excel in developing proof of concepts and delivering tailor-made solutions that optimize operations and drive growth. This shift towards local expertise not only fosters self-reliance but also strengthens the Indian railway ecosystem. By partnering with local MSMEs, the industry can achieve greater agility, responsiveness, and cost-effectiveness, ultimately propelling India’s railway manufacturing sector to new heights of excellence.

Image credit: Arm Welders

Therefore, with appropriate investment in a small, big or phased manner, the way forward is perhaps as follows: –

  • Robots (Simple and Complex)
  • Assessing existing pain points, methods, space, overheads, safety, business plan and vision
  • Business plan for quick return in investment by New Methods inter alia as below:-
  • Welding Automation (multi-axis) too
  • Special Purpose Machines (SPMs)
  • Manipulators / Jigs / Fixtures
  • Hoists (Lateral and/or Longitudinal)
  • Precision Machine Power Tools
  • Integrated Work Centers with above
  • Data Logging towards Industry – 4.0
  • Skilling, Warranty, Support, AMC etc in very quick time
  • Returns in one or two years!

In this manner we can target Higher Margins, Higher Volumes, Higher Productivity as well as Better Safety and Better Quality and reduce the significant costs associated with the following: –

  • Assembly Big/Small!
  • Cycle-time!
  • Material-handling!
  • Inventory!
  • Shed/Open Space!
  • Carbon Footprint

Thus; appropriate investment in a small, big or phased manner by Rail Industry Suppliers (as we have also seen in the MCF example) can rise to standards as achieved or even higher than Auto standards.

Make-it-Happen!

You are welcome to give me your valuable feedback, suggestions and interest; to take this forward together in quick time and accomplish the satisfaction of substantially higher margins and exponential higher volumes at a significantly lesser cost, reduced space requirement and reduced pain-points.

Further; the Quality and Safety can be configured nearer to Perfection!


Author:
Mr. Rajesh Agrawal,

Former Member (Rolling
Stock), Railway Board,
Indian Railways

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