1. In house repairing of HHP Clutch assembly.

Due to crisis of repaired clutches, DLSS has dissembled a defective clutch assembly in
house and successfully repaired it with an expense of Rs 12000 and saving Rs 2,00000 per
clutch.

2. Turbo Supercharger repair:

15 nos. of TSCs having casing crack issue were repaired by Mechanical Heavy Schedule/
SGUJ/Shed. Now all these 15 locos are running normally. It also saved valuable money and
time for Railways as the repairing cost of 1 TSC as per present rate is almost Rs. 16.7 lakhs.

In FY 2021-22 total savings was Rs 1.16 crores (7 TSC) and in FY 2022-23 total savings
was Rs 1.37 crores (8 TSC). Thus with respect to cost, SGUJ shed has saved almost
Rs.1670000 x 15 = Rs. 2.5 crores approx.

1. In house developed CCB 2.0 test bench:

The air brake section of DLSS has built a test bench in house for checking the operation
of all the valves of CCB 2.0 system. The system is integrated to the LCC which can
provide real time fault analysis & diagnosis.
2. Electric Stacker:

To have proper housekeeping and clear up more shop area for sections, DLSS has
arranged to design and make vertical stacking arrangement for overhauled and in service
components and assemblies.

3. Schedule Extension:

Due to material crisis ( Turbo & Clutch) many HHP Locos of SGUJ shed are lying in
shed premises. To meet up the demand of locos for traffic, schedule extensions have
been done for selected locos which have a good performance history (based on lube oil
consumption and no. of failures for last 2 years).
On this basis the trip schedule for the selected passenger locos have been extended from
15 days to 25 days & the T1 schedule for goods locos have been extended from 30 days
to 45 days. This has ensured more availability of locos for train operations at any given
time.
4. In-house repair of HOD:

DLSS has successfully rectified 22 Hot Oil Detectors and fitted in locos. This has
increased the outage of shed as well as saving of approximately Rs 8 lakh.

5. Opening of ALCO simulator for public:

 The basic aim is to open the simulator for a firsthand experience to general public so as
to create awareness regarding railway operations among them and also to earn non-fare
revenue for railways out of the sessions.

6. Smart washer machine:

Due to the excess time taken to clean the component and health hazards related to
cleaning by ORION, this new technology is adopted at DLSS which can clean
mechanical components in just 15 minutes using bio-chemicals.

7. LP/ALP electric loco courses:

The electric loco conversion, promotional and refresher courses for crew of NF railways
have been started and 436 ALPs/LPs of NFR have completed their training.

8. Increasing wheel life:

To reduce the wheel life, under gear clearances sch as Thrust pad clearance are set in
such a way to increase wheel life by reducing flange and root wear thereby increasing
wheel life. Wheels are also interchanged in its position to adjust the overall clearances
within limits.

9. Endoscopic Camera:

DLSS shed has procured an endoscopic camera to see and detect any internal damage of
a component without dismantling the assembly. The system produces real time image in
any smart device and very easy to handle by the operator.

10. In house repairing of 6 AC machines.

6 AC machines have been repaired in house and retrofitted in 3 classrooms by STC/SGUJ

so that students can be comfortable during sessions.

11. Provision of lifting of single cab locos has been made in the bogie repair shop. Now
3 lifting bays work simultaneously instead of 2 which has made the heavy schedule work
for locos smoother and faster and ensure timely attention.

12. Electronic Torque Wrench:

The bolted joints which require high torque are now being bolted by only one operator
in less than 10 min by using an electronic torque wrench machine against 4 man hours
used earlier.