This is the Inplant Training Review of my training of two weeks at Integral Coach Factory, Perambur, Chennai. The general processes regarding the manufacturing of railways coaches has been discussed.

1. IN-PLANT TRAINING
REVIEW
INTEGRAL COACH FACTORY
INDIAN RAILWAYS
Sudarshan. M
RA1411002040113
Mechanical – ‘B’
IIIrd Year

2. Introduction
• INTEGRAL COACH
FACTORY IS THE ONLY
MANUFACTURER OF RAIL
COACHES LOCATED IN
CHENNAI. IT IS OWNED
AND OPERATED BY THE
INDIAN RAILWAYS.
• ICF is the first of its kind to be established after Independence for the
manufacture of light weight, all steel and all welded Integral railway
passenger coaches.
• The plant employs about 13,000 people and manufactures about 1500
coaches per year.
• A total of 50,000 coaches had been produced till 18 Aug 2015 by ICF
since its inception

3. A Brief History Of Icf
THE INTEGRAL COACH FACTORY WAS SET UP IN
1951 WITH THE HELP OF M/S SWISS CAR AND
ELEVATOR MANUFACTURING CORPORATION LTD.,
SCHLIEREN-ZURICH (SWITZERLAND).
IT WAS INAUGURATED BY THE THEN PRIME
MINISTER OF INDIA PANDIT JAWAHARLAL NEHRU
ON 02 OCT 1955.
PRODUCTION BEGAN IN A MODEST MANNER IN
1955 WITH THE MANUFACTURE OF SEVEN THIRD
CLASS COACH SHELLS

4. INTEGRAL COACH
FACTORY
Shell Division
Furnishing
Division
SHOP 10 & 11
SHEET METAL
PROCESS
SHOP 22
SIDE AND END
WALL ASSEMBLY
SHOP 21
ROOF
ASSEMBLY
SHOP 30
FURNINSHING
SHOP 37
AIR BRAKE
ASSEMBLY
SHOP 54
PAINTING

5. SHOP 10: SHEET METAL PROCESSING
• STAGE 1: STRAIGHTENING BY ROLLERS
• STAGE2: RELAXATION
• STAGE3: CUTTING OF SHEETS
MATERIALS USED
• COR-TEN Steel 6mm
• Mild Steel 6mm
• Stainless Steel 4mm

6. SHOP 10: SHEET METAL PROCESSING
• CUT TO LENGTH MACHINE
• ECCENTRIC PRESS
• PROFILE BENDING
• SEAM WELDING
• BLANKING USING HYDRAULIC PRESS OF TONNAGE 300-1000
TONS.
• LASER CUTTING CNC USING N2,H2, CO2

7. SHOP 11: SIDE WALL ASSEMBLY
• THE SIDE WALLS OF THE
COACHES ARE BEING ASSEMBLED
HERE.
• THE SHEET WHICH ARE CUT IN
SHAPE AND BENDED IN REQUIRED
PROFILE FROM SHOP 10 IS
WELDED TOGETHER HERE.
• SPOT WELDING AND SURFACE
WELDING ARE USED.
• THE WALL FIXTURES ARE MOVED
BY OVERHEAD HEAVY TONNAGE
CRANES.
• IT TAKES ABOUT A WEEK TO
PRODUCE APPROX. 4-5 COACHES.

8. SHOP 21 AND 22: MAIN ASSEMBLY

9. SHOP 21 AND 22: MAIN ASSEMBLY
• Shop 21 – Roof Assembly
• Roof is assembled by placing the
sheet on special fixtures called
Roof Jigs
• Electric Arc welding is mainly
used.
• Minor joints are welded by Gas
Welding.
• Shop 22 – Body Assembly
• The body of four different
coaches are made here.
• They are General Coach,
Second Day coach, Second
Class Night Coach and Second
Class Loading Unloading

10. METRO BOGIES SIDE FRAME

11. SHOP 30:FURNISHING
• 1. PREPARATORY – BODY IS
LINED WITH FOAM AND
INSULATION
• 2. FLOORING – PLYWOOD
FLOORING IS DONE. MICA
SHEETS
• 3. WIRING – INTERNAL
WIRING AND OTHER
ELECTRICAL FIXTURES
• 4. PVC PASTING
• 5. PANELING – I

12. SHOP 30:FURNISHING
• 6. PANELING –II
• 7. MOLDING
• 8. FITTING – THE
FRAMES FOR SEATS OR
BERTHS ARE FIXED
• 9. SEATS AND WORKS
• 10. PIT LINE
INSPECTION – MANUAL
INSPECTION IS DONE

13. SHOP 37 - BRAKING SYSTEM
• Air brakes system is
generally used.
• Vacuum Brakes are used
for minor braking
purpose.
• Air brakes is classified into three parts
1. Auto Brake
2. EP Brake
3. Emergency Brake

14. SHOP 37 - BRAKING SYSTEM
• Electro Pneumatic Unit
is used to control the
system
• In this the brake
assembly is made as
designed.
• Leakage check is done using soap water.
• The limit for verification is a 0.2kg pressure drop in 15
minutes.

15. SHOP 54 : PAINTING
• DEWHEELING OF BOGIES
• FIXING OF DUMMY BOGIE
• MASKING
• SHOT BLASTING – SHOTS OF
2 – 3 MM DIAMETER
• DEMASKING
• EPOXY PRIMER – A.K.A METAL
PRIMER (2 COATS)
• ENAMEL
• OVEN

16. SHOP 54 : PAINTING
• POLYESTER PATTY – TO COVER DENTS
• DUST CLEANING – AIR HOSE
• SURFACER OR BASE PAINTING – TO
COVER PINHOLE GAPS
• SURFACER FLATTENING – DONE USING
EMERY PAPER MANUALLY
• WINDOW AREA SATIN GLUE ENAMEL
• AC BLUE ENAMEL
• WHEELING
• DISPATCH

17. THANK YOU FOR
LISTENING