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 20f 9-209o

PREFACE

"suggestion Scheme for Best Innovation of Indian Railways" is operated by

Ministry of Railways with the objective of identifying and awarding the
creative employees who are working tirelessly to bring improvements in
Indian Railways (lR). This Scheme is intended to improve the morale and
motivation of IR's workforce and to encourage them to come up with low
cost innovations for improving the productivity, quality and efficiency over
Indian Railways. The Scheme is. operated at three levels viz.
DivisionAfforkshop, Zonal/ Production Units and Railway Board's level. A key
characteristic of this Scheme is that only innovations which have been
practically implemented and have proved their usefulness are considered
underthis Scheme.

Every yea[ best 3 innovations are recommended by GMs of Zonal Railways

and Production Units to Railway Board by 31st of March. Following
Committee of Railway Board evaluates the innovations and recommends the
1st,2nd and 3rd Awards: ED (E&R) (Convener), EDl C&lS, EDIPM, ED/TD,
EDlEEM, EDlCoaching, EDCE/P, EDIFX-I, DER/ME (Member Secretary)

This Booklet contains the details of the Best Innovations awarded in FY 2019-
20 and the teams behind these innovations along-with their contact details.

4
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 gfr {rqt srqtr\qIgorffiqffi,
i suuerr SH.ARMA ffidd
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CHAIRMAN & CHIEF EXECUTIVE OFFICER,
RAILWAY BOARD
E--{+{ wq} EX OFFICIO PRINCIPAL SECRETARY
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

Message
Indian Railways (1.R.) is playing a key role in the development of the country
by providing a safe, financially viable.and environmentally sustainable transport
for both goods and passengers. I.R. is steadily working towards modernizing its
network and assets, increasing capacities and improving safety of train operations.
In this highly competitive world with ever increasing customer expectations,
it is essential to constantly strive to improve the quality of services, improve
efficiency of operations, reduce costs and attract new sources of revenue.
Innovation plays a key role in achieving allthese.
Suggestion scheme for awarding the best Innovations is an excellent
platform motivating Railway employee to proactively engage in a creative process
with the ultimate aim of bringing improvement in quality, productivity and
efficiency of various aspects of Railwayworking.
It is heartening to note the enthusiasticparticipation in the Suggestion
Scheme for FY 2019-20, and seven entries have been awarded. These entries
pertain to various areas of Railway working viz operations, maintenance, safety
and revenue generation. I congratulate all the winners. I am happy that Efficiency
& Research Directorate of Railway Board is brining out this Booklet which contains
the details of the awarded Innovations. This will be beneficial to the Railway
employees across the country who can replicate these innovation as applicable in
theirwork areas and bring improvements.
I once again congratulate all the Award winners and encourage all Railway
employee to participate in this contest in the future.

(Suneet Sharma)
Rail Bhawan, New Delhi-110 001.
Tel.: 011 -2338401 0, Fax : 011 -2338'1 453, Email : crb@rb.railnet.gov.in

u
 CONTENT

N Prize Innovotion ZR/PU

I
DivlUnit

Centrol
lst Prize IOT Bosed Energy Monogement ond Southern
I Workshop, 5-7
(Group-1) Condition Monitoring System Roilwoy
Ponmoloi

OTP Bosed Reloy Room Access North s&l

lst Prize
2 Authenticotion & Monitoring -System Eostern Voronosi 8-r 0
(Group-2)
(oRR/,AMS) Roilwoy Division

.-r D_:_^ Adoption of Cold Roll Forming Shell Division

3. ::o "t':, Technology Process for Corline & Roof rcF rr-13
[uroup- I ) Flonge of iHg cor Body side woll Ponel & LHP Shqp

Test Setup for Trqin Communicotion West Electric Loco

4.
2nd Prize
(Group-2)
Network Centrol shed, wcR 14-16
(TCN) (CDAC) VCU Roilwoy TKD

Electricol
Cooching
3rd Prize Mointenonce of LHB Troins Northern
Deportment, 17-19
5
(Group-1) in Woshing Line Through HOG Supply. Roilwoy Delhi
Division

S&T
3rd Prize Semi-outomotic Pre-Tension Mochine for Southern
Workshop, 20-21
6
(Group-2) Fixed Springs-Q Series Reloys Roilwoy
Podonur

Tronsportotion o[ e-Com merce

3rd Prize Eostern SDAH
7 Consignment Through Suburbon 22-24
(Group-3) Roilwoy Division
Roilwoy

D
 20,,

IOT Based Energy Management

and Condition Monitoring Systems
(Developed by Central Workshop, Ponmalal Southern Railwayf

THE CHALLENGE:
In Golden Rock Workshop, as a continual improvement in Energy Efficiency and
also to meet out the standard requirements of ISO 50001:2011 (EnMS) and
GREENCO certifications, smart Energy Meters have been provided in all
substations, shop feeders and identified Energy intensive machines. Hitherto,
collection and analysis of energy consumption data was carried out manually and
after provision of around 300 Energy Meters, collection of energy consumption
data from all the meters has become a daunting task which takes additional man
power and difficulties were being faced. When approached, the suppliers of
Energy Management system gave Budgetary Quotations (BQs) for around Rs.24
Lakhs for Data concentrator units, excluding the cost of communication cables,
industrial PC, software and cloud storage.
THE INNOVATION:
After analyzing the cost and drawback of vendor manufactured Energy
Management System, it was decided to develop an energy management system
with the knowledge of supervisor of Electrical wing using Raspberry controller for
collection of data and uploading the same to cloud. Development of software was
done in JavaScript (NodeJS) for Data analysis and acts as an Application Protocol
Interface (API) for storing data in cloud database (DynamoDB). For visualization of
processed data through PCs and mobile phone, a web application has been
developed usi ng Reactjs

After development, the system was installed in substations and various shops in
Golden Rock Workshop. Temperature sensors were also installed along with the
system to observe the shop and substation feeder temperatures. After processing
the same, data is passed back to identified mobile phones and emails for further
Ana lysi s a nd i m pl ementati on of corrective/preventive actions.

BENEFITS & COST:

. Elimination of restriction of number of meters and length of communication !:

cables.
. Total elimination of dependency on suppliers for software since software is
developed in-house.
SUGGESTION SCHEME FOR BESr INNOVATION 2A19-ZA?G

. Huge reduction in cost of the project since it was developed and installed at a
meager expenditure.
. Using the system as a platform for development of condition monitoring
system for passenger coaches, batteries and on-board AC and TL
components.
The cost of this Innovation is Rs.750 0/- per substation. Saving effected per month
is Rs.21.75 lakhs.

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 201.9.209s

INNOVATION TEAM

S. No. Name & Designation Photograph

1 Name L. Balaji (Group Leader)

Designation : Trainee SSE/GS (EIGOC
Phone Number : 9791105717

2. Name : S. Ganesa.n '

: SSE/EMWGOC
ne Number

3 Name : J. Ravikumar
Designation Retired SSE/PH/GOC
Phone Number : 9791105717

4. Name : M. P. Karthikeyan
Designation : Technician I/EMWGOC
Phone Number : 8055905217

5. Name : P Sekar

Designation : TechnicianVTSltPHtGOC
Phone Number : 9443O72379

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SUGGESTION SCHEME FOR BEST ]NNOVATION 2019,-2020

OTP Based Relay Room Access Auth orization

& Monitoring System (ORRAAMSI
(Developed by S&T, Varanasi Division, North East Railwayf

THE CHALLENGE:
Unauthorized opening of Relay Rooms is a grave safety hazar;d. Many accidents
all overlR have happened on this account.

THE INNOVATION:
OTP based Relay Room Access Authorization and Monitoring System
(ORRAAMS) has been developed forthe first time in Indian Railways to ensure only
authorised person may access relay room. This system is cloud based with
analytics feature.lt has been implemented for opening and closing of relay room
over Vara nasi Division.

BENEFIT & COST:

. Hassle free implementation of JPO, regarding opening of relay room,
without human intervention, results saving in manpower.
. No waiting time in opening the relay rooms under OTP system, as presently
being faced.
. Phase wise elimination of allthe seven registers.
. Dashboard has the feature to send daily reports automatically to concerned
officer's emaillDs.
. Dashboard to have historical data & analytics on cloud, which can be
analyzed to get meaningful insights e.g. purpose wise, designation wise,
' frequency wise, opening time wise etc.
. Cloud based system ensures web access of dashboard on -
+ Anydevice
+ Any browser
+ Any where
. Only authorized members can receive OTP for a particular station. System
also keeps track of all unauthorized requests.

ILWAY
SUGGESTION SCHEME FOR EEST INNOVATION 241

. Pin-points individual who received OTP to open the Relay Room.

. Internet is not required to request access and get OTP. Only mobile network is
required.

r I
:
I

The cost of innovation is Rs.4.62 lakhs

-1 3
I suGGESftoN SCHEME FOR BEST TNNOVATTON 2A19-2020

INNOVATION TEAM

S. No- Name & Designation Phatograph

1 Name :
Designation :
Ashutosh Pandey
SnDSTE/BSB
(Currentlyworking as
#i
Dy.CSTE/Con/BSB)
Phone Number z 9794844855

2 Name : Yashveer Singh

Designation : DSTE/BSB (Currentlyworking {-G
as Dy.CSTE/HQ)

Phone Number : 9794840810

3. Name
Designation
Phone Number
Mayank Gandhi
SSE/Sig./Works/BSB
9794843833
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4. Name : H. M. Tripathi,
Designation : SSE/Control/BSB
Phone Number : 9794843808
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 2019-2A2* -

Adoption of Cold Roll Forming Technology

Process for Carline & Roof Flange of LHB
Car Body Side \Vall Panel
(Developed by lntegral Coach Factory, Chennai.f

THE CHALLENGE:
LHB Car body side wall panel parts viz. Carline & Roof flange are pressed
sections of approx.2.7mto 3.2m length. Making and joining of sub assemblies of
carlineand roof flange parts bywelding in a specialfixtureto make 18 metre length
Car body side wall panel is a laborious process which also causes weld distortion.
Obtaining wrinkle and dents free skin surfece (acceptable undulation level; 1.5 mm
per metre and 2.5 mm over the entire length) of 1 8 metre length by 2.6 metre width
car body side wall panel is a challenge faced during fabrication. Use of shorter
length press formed roof flange member and carline parts demands more
assembly labour; weld joints, post welding processes and Electric Overhead
Travelling (EOT) crane handling. These processes involve multiple handling of
components, more number of welding joints which are time and energy
consuming and affectthe quality and productivity.
THE INNOVATION:
The constraints and challenges to increase the productivity, improve quality and
reduce material handling in manufacture of sidewall panel of LHB car body was
discussed with the team. It was conceptualized and decided to reengineer the
manufacturing methodology of carline and roof flange member of LHB car body
side wall panels, avoiding weld joints during making of carline and roof flange
member parts and eliminate post welding treatment processesviz, straightening
and exterior flush grinding and fitment in sidewall panel by use of 20.3 metre
single piece carline and 18.3 metres single piece roof flange member made
through adoption of latest Cold Roll Forming (CRF) technology process.

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Cold roll formed roof flange and carline

/
Side wall panel with CRF items
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SUGGESTION SCHEME FOR BEST INNOVATION 2o-19-2A2A

BENEFITS & COST:

. The overall cycle time of Car body side wall panel reduced by 20o/o dtrdoverall
productivity has increased from 04 coach sets per day to 06 per day.
. Through adoption of single piece CRF Carline assembly and CRF roof flange
member in sidewall panel, the structural rigidity and dimensional stability
ensured and undulations on visible area (carline area) brought down to
acceptable level of 1.5 mm in one metre and 2.5 mm over the entire length of
coach.
. In addition to above, this has resulted saving in cycle time, labour; energy and
net saving of Rs 1 .42 lakhs pei dry. Total savings has been estimated at Rs 4.26
Crores per year cohsidering 1500 LHB coaches per year from 2020-21
onwards.
SUGGESTlON SCHEME FOR BEST INNOVATION

INNOVATION TEAM

S. Ne- Name & Designation Photograph

1. Name
(Group Leader)
6E
"#
Designation : SnMech.Engineer/DesignfiCF FS
-t",'a
Phone Number : 9003141434

2. Name
Sr.Sec. En g i n eerlPla nn ingfl CF

Phone Number : 9003149599

3. Name : G.JothiBaskar
Designation : Sr.Sec.Engineer/Planning/ICF
Phone Number : 9003149488

4. Name : N. Sudhahar

Designation : Sr.Sec.Engineer/LHB/ICF
Phone Number : 90031 49682

5 Name V. S. Sridharan
Designation S r. Sec. E n g i n eerlDesi g n[C F

Phone Number 9003149833

1?
 Test setup for Train communication Network
{rcN, {cDAcl vcu
fDeveloped by Electric Loco Shed, West Central Railway, Tughlakabadf

THE CHALLENGE:
Three phase Electric locomotives employ a distributed architecture for control
and data communication using Microprocessor Automation System (MICAS)
which was proprietary in nature. In order to sustain the control system in a rolling
stock during its lifetime, i.e. over 35 years, it becomes necessary to update the
technology and tackle the obso[escence. Indian Railways in association with
Centre for Development of Advanced Computing (CDAC), Thiruvananthapuram
developed Vehicle Control Unit (VCU) with technology termed as TCN (Train
Com mu nication Network).

RDSO has issued 5M10277, TC 1 34 for testing of MICAS VCU cards but for TCN
VCU there were no testing guidelines by RDSO. TCN VCU fitted locos were giving
Transients faults which were resulting in failure of locos and without testing JIG
loco sheds were facing lots of problems in proper trou bleshooting of locos.

THE INNOVATION:
Electric loco shed, Tuglakabad developed testjig for testing DIO cards of CDAC
TCN based vehicle control unit with help of D413 tool and CDAC VCU Rack. DIO
(digital input output ) cards receives various digital signal (e.g. panto status, VCB
status etc.) and gives desired output signals (e.g. VCB ON/Off command, Panto
Raising command etc.) based on the logic performed in processor cards.

For testing TCN VCU, close loop system has been made using connector in
which output of one works as input of other. Connector is provided on DIO Card
which requires testing. BURN-lN test software runs and if card is perfectly healthy
then predefined values come after each cycle of 30 seconds and if not then
respective card is unhealthy. Using this test bench, all 4 cards can be tested
simultaneously which saves a lot of time without compromising on reliability. It's a
very compact system and doesn't require any types of loop box or load. The Shed is
testing DIO cards of locomotives giving trouble on line and till date 1B cards are
found defective
 t

BLOCK DIAGRAM FOR CDAC VCU

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BENEFITS & COSTS:

Transient Loco failures have been avoided by detecting faulty VCU DIO cards of
TCN CDAC VCU in Three phase locomotives which improved reliability of
locomotives on line along with less hours of detention, increasing loco outage and
its earnings. Till date 18 DIO cards are found defective. By detecting line failure at
shed level, approx Rs 1,876,140 per month saved at ELS, Tuglakabad. Thiswill be
further increased as CDAC VCU locos are increasing. This innovation is also sent in
39th MSG New item no24.

-1 t)
+ SUG€ESfION SCHEME FOR BESr INNOVATION 2019-2020

INNOVATION TEAM
S- I\tro. Name & Designation Photograph

1 Name : Gaurav Kumar Srivastava

#'
t
Designation : DEE/TRS/TKD
Phone Number : 971TG4T7ZT E

2. Name : Navneet Raju

Designation : SSE/TRS/IKD
Phone Number : 9377G75197

3. Name : PKMishra
Designation : Sr.Tech./[RS/TKD
Phone Number : 8700485714

4. Name : Mahesh Kumar

Designation : Tech-IU/TRS/TKD [-*
Phone Number : 7891295921 ltt

5. Name : Mohd Zia Ul Haque

Designation : Tech-III/TRS/TKD
Phone Number : 933482G256

6. Name Ms. Neelam Kumari

Designation Tech-III / TRS/TKD
Phone Number 8745940238

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I SUGGESTTON SCHEME FOR BEST TNNOVATION 2019-2O9.i

Maintenance of LHB Trains

in Washing Line Through HOG Suppty.
( Developed by Electrica I Coaching Department,
Delhi Division, Northern Railway|
THE CHALLENGE:
To start diesel free primary maintenance for all its LHB rakes at washing lines of
various maintenance depots in order to make the DelhI/NCR region deisel free.

THE INNOVATION:
Delhi Division created facility for Diesel free Primary Maintenance with HOG
supply from OHE/Loco for 34 LHB trains at washing lines. To create this facility,
shifting of Pathways, Rake Test Rig (RTR) facility & required modifications of OHE
were carried at NDLS, HNZM, ANVT, DEE, DLI depots over Delhi Division. Total
expenditure incurred for these modifications was Rs. 1 1 Lacs.
BENEFITS & COST:
System has following financial, operational & environmental benefits:

' The division will be saving approximately 3000 KL HSD oil annually, due to
reduced operation of DG (Diesel Generator) sets of power car at washing
line. Maintenance expenditure of DG sets will be reduced owing to less
running hours, which will result in a net saving of approx. Rs. 16.0 Cr. per
annum.

' In the HOG system operation, failures occurred while shifting from EOG
(Power car supply) to HOG (OHE/Loco supply) before the departure of
trains- Such failures either compromise the punctuality of train departures
or the train has to run on EOG due to scarcity of time to attend to the
failure. Therefore, facility of primary maintenance with HOG has enhanced
the reliability of HoG operation as well as punctuality of trains.

' This system will eliminate noise and air pollution at the platforms and
washing lines. There will be a reduction of approx of 8000 tons CO2
emission in environment due to less burning of HSD oil.Cost of Innovation
is Rs.1 1 lakhs with an expected saving of Rs.1 .3zcr.per month.

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F SUGGESTTON SCHEME FOR BESr NNOVATION 2019-202t

INNOVATION TEAM

S. t\to- Name & Beslgnation Photograph

1 Name : pardeep Kumar (Group Leader)

Designation : ST.DEE/Chg/Dtt
Phone Number : 9117631301
a -t'..

2. Name : Bipln Kumar

Designation : ST.DME/ChglOU
Phone Number : 9717630419

3. Name : Sartash Kumar

Designation : DEE/ChgIDLI d
I
Phone Number : 9717631 31 O {

4. Name : Rajneesh KrChauhan

Designation : IOWNDLS ;}4F

Phone Number : 7982O64629

5 Name : R. C. Meena

H
Designation : CyM/NDLS
PhoneNumber : 9717631931

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6. Name : Paramjeet Singh

Designation : SSE/Chg/Raj/NDLS
Phone Number : 9717631364
i

Name
Designation
Phone Number : 9717636009

8 Name Neeraj Kumar

Designation CLI/RSO/NDLS
Phone Number 9717632062

9. Pankaj Yadav
Designation : JElChg/NDLS
Phone Number : 971764s118
:

10. Name Surender Kumar

Designation Wireman/Chg/1r|P15 -i'i+

Phone Number 9717636262

17.

Phone Number : 9717 53i27 59

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2O1,9-20Pr

utomatic pre-tension
Sem i-a
Machine for Fixed S prings for O-seri es Relays
(Develo ped by S&T Vorkshop, podanur, Southern
Railwayf

THE CHALLENGE:
S&T workshop, Podanur is pioneer in the
manufacturing of e series relays with
a production capacity of 60,000 relays per year.
owing to increased demand from
various zonal Railways, RVNL and other organisations,
production capacity is
planned to be increased to 1,00,000 rerays p"ry.rrfrom 2ozo-21.
THE INNOVATION:
with the implementation of new semi-Automatic pre-Tension
Machine, each
Fixed spring used in the Relays is formed to
the desired profile to attain a pressure
of 50 to 60 Grams in one single stroke and checking
of pressure is also done after
every single operation automaticatly. Thus 1o}o/oquality
is ensured. Fatigue of the
operator is elim inated considerably.
BENEFITS & COSTS:
The output from the new semi-Automatic
Pre-Tension Machine is 2200 Nos. of
Fixed springs per day as against of 1100 Nos. per
day done manuaily, thus
achieving 100% increase in productivity. By commissioning
the above machine,
the additional one manpower required for pre-tensioning
operation for the
increased production target can be saved.

Cost of Innovation is Rs.4,72,000/_. The savings

effected per month is
Rs.1,09,526 and increased earning per month
is Rs.3,63,7g0/-
 INNOVATION TEAM

S. No. Name & Designation Photegraph

1. Name : R. Sridharan (Group Leader)

Designation : SS E/Relay Sh op S&T/WS/PTJ
Phone Number : 9994517755

Name : K. R. Suresh

S8.T/WS tPTt
Number : 9488459979

3. Name : R. Prabu
Designation : Ex-CadreJE/RelayShop
S&T/WS IPTJ
Phone Number : 9025130772

4. Name S. Sekac

5 Name : H. Nanda Kumari T.No. 3204

Designation : Tech.Gr.lllFitter/RelayShop
:
Phone Number : 9025529190

::)
 SUGGESTION SCHEME FOR BEST INNOVAT}ON 2019.20?O

Transportation of e-Commerce
Consignment Through Suburban Railway
(Developed by Sealdah Division, Eastern Railwayf

THE CHALLENGE:
While India has witnessed surge in e-commerce market, there has been
generation of huge potential in area of transportation. In densely populated cities
like Kolkata where last mile connectivity is a challenge, Eastern Railway, with the
help of its suburban services, emerged as premier transportation partnerwith one
- of the popular e-commerce companies.

THE INNOVATION:
In collaboration with M/S Amazon India Transportation Ltd, Sealdah Division
conceptualized a pilot project for transportation of e commerce consignment in
EMU trains. The project has been conceived, developed and commenced by
Eastern Railway (Sealdah Division) with the idea of mutual benefit and has proved
to be a win-win situation for both the partners; Railways and e-Commerce
Company.
aa
BENEFITS & COSTS:

With the start of this project, railways get benefitted through new avenue of
traffic whereas e-Commerce Company got benefited through quick
transportation of consignment and lesser transit time. This has helped them in
arranging quick deliveryto final customers creating goodwill and trust forthem.
While this innovative idea was implemented, utmost care was taken that there is
no disturbance in present system of working and it does not put any stress or
burden on the existing system. So as to provide a hassle free and safe
transportation of consignment, it was mutually decided to carry the consignment
in non peak hours of traffic along with other vendors so that coherence between
old and new traffic can be maintained.
This project has proved its efficacy in quicktransportation and deep penetration
in suburban area of cities like Kolkata and Mumbai.

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 2A19-2020

INNOVATION TEAM

S. No. Name & Eesignation Fhotograph

1 Name : Hemanta Basak

Designation : Sr. DCM/ER/SDAH

Phone Number : 9002021950 A

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2 Name : Rakeih Kumar

Designation : ACM-II/ER/SDAH
Phone Number : 9002021964
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3. Name : SoumiBanerjee
Designation : CTI/LEASE/ER/SDAH
Phone Number : 9002021981

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Rail Bhawan, Raisina Road New Delhi-1 10001