The Integral Coach Factory is one of the earliest production units of independent India. It was inaugurated by the first Prime Minister of India Pt. Jawaharlal Nehru on 2nd October, 1955. Later the Furnishing Division was inaugurated on 2nd October, 1962 and the production of fully furnished coaches steadily increased over the years. Spread over nearly 511 acres, it has about 10,408 employees to turnout more than 2000 coaches every year which includes conventional and self propelled coaches.
ICF is capable of manufacturing many types / variants simultaneously. Every year new variants are added to the product mix. ICF invented and experimented with new type coaches such as, self propelled or special type coaches. ICF has produced 58,554 coaches since its inception in 500 plus different designs.
ICF has turned out a record outturn of 2503 coaches during the year 2017-18 consisting of more than 63 variants. ICF was awarded the Environment and Cleanliness Shield for the year 2017-18 and also received the second prize in Best Transformation Initiatives from Shri Piyush Goyal, Hon’ble Minister of Railways.
ICF has bagged an export order from Srilanka for supply of 78 DEMU coaches and the first rake consists of 13 coaches has been shipped.
ICF – GREEN PRODUCER:
ICF is known for its efforts in the eco – preservation front be it creation of exclusive green forests in the ICF surroundings, installation of windmills and solar panels for generation of electricity. ICF is a Zero discharge factory and also a ‘Green Workshop’. ICF has developed Green houses in its premises, where it would develop saplings and it is supported by a Poly House where the seeding process for the saplings would be undertaken. ICF has become the only organization in Indian Railways to have completely neutralized green house gas emission due to its industrial activity and achieved Carbon Negative status.
At 63rd Railway Week – National Awards Function was held at Bhopal, ICF has been awarded the Best Environment and Cleanliness Shield for the year 2017-18 from Shri Piyush Goyal, Hon’ble Minister of Railways. An abandoned lake located inside the ICF campus has been revitalized and turned the water body in an eco friendly manner. In the 9th edition of Waste and Resource Management Summit 2018 held at New Delhi, ICF received the GreenCo GOLD shield and Certificate & a Platinum shield for IGBC green schools was awarded to ICF Silver Jubilee Schools from Confederation of Indian Industries – Godrej Green Building Council. To add green to the ICF admin premises a unique roof top garden has been set up on the terrace of the admin building.
Milestones of ‘Team ICF’:
ICF had completed glorious 60 years since inception and celebrated Diamond Jubilee in the year 2015 and had turned out 50,000 coaches, the highest by any rail coach manufacturer in the world and thirdly, dedicated a new unit to the Nation with state-of-the-art infrastructure to manufacture stainless steel LHB coaches. Today, ICF is the forerunner in the manufacture of self-propelled coaches viz. EMU, MEMU and DEMU in the country.
ICF has bettered the existing facilities and added new facilities for the ICF employees both within factory/Office premises and in residential colonies. These are dedicated by the senior most employee of that area. That boosts the morale of the employees. 500th such inaugurations is planned to be held on 29th December.
Production of indigenously manufactured all steel all welded railway coaches started in the year 1955 with an installed capacity of 350 coaches per annum. The production was steadily increased duly augmenting infrastructure over the years and 1000 coaches were turned out in 1990. ICF surpassed the magic figure of 2000 coaches in 2016.
In tune with the policy of IR to completely switch over to stainless steel body coaches, ICF is gearing up to modernize the infrastructure. The new unit set-up to manufacture stainless steel LHB coaches has a capacity to turn out 300 coaches a year. This unit has the state-of-the-art infrastructure like Robotic spot welding centre, Robotic MIG welding centre, 5-axis machining centre, Laser cutting cum welding machine, other CNC machines, jigs and fixtures to manufacture stainless steel coaches with precise quality. Under Complete Switchover Project CSP-1, two new bays of size are being added. This shall envisage additional 300 LHB coaches. Under CSP-2 ICF would convert its existing Shell Division from Corten steel car body making shop to Stainless steel car body making shop. This project shall start during the current year. Once completed, ICF would become a mega stainless steel coach manufacturing unit of IR.
Rolled out products:
This year saw the rolling out of ‘Deendayalu’ and ‘Antyodaya’ coaches from ICF. These are coaches announced in the Budget 2016 and are provided with improved amenities like water dispenser, mobile charging points, LED lights, additional hand holds, vestibules and with better interior ambiance. These are aimed at providing improved amenities to the common man. While Deendayalu is made as loose coaches on ICF conventional platform for mail-express train services, Antyodaya is meant to be run as a train capable of MU operation. The exterior of these coaches were given distinct colors and anti graffiti coating.
ICF started series manufacture of stainless steel 3-phase transmission DEMU train sets with 1600hp Emission Compliant Engines (EU stage IIIA standard) from 2015 after terminating the manufacture of conventional DC drive 1400hp DEMUs. ICF has also made 1600hp DEMU train sets during the current year. ICF continued its portfolio of other Diesel powered vehicles viz. SPART, JDCC (Jet Deflector Crane Car for Military) during the current year.
ICF has successfully completed the prestigious order of 72 train sets stainless steel 3-phase EMU coaches under MUTP-II project by Feb 2017. All these rakes are put into commercial service on the suburban section of Mumbai Western Railway. Plans are foot at ICF to make more and more 3-phase EMU train sets for other metro suburban section such as Chennai, Kolkata and Delhi.
ICF is in the process of production of new generation metro coaches for Kolkata underground metro. These are 3-phase propulsion system based metro cars made on par with the other imported metro trains in India. Many new features like modular systems for brake and electrics, stainless stell aesthetic body, large gangways by using underslung inter vehicle couplers, plush interiors, diffused lighting are available in these coaches.
Train 18 – the flagship Semi High Speed Trainset from the Stables of ICF
The new age flagship Trainset code-named Train 18 has been rolled out from the production shops of Integral Coach Factory (ICF) by the end of October, 2018. The 16 coach semi-high speed Trainset consists of 16 coaches and is designed for Maximum Operating speed of 160 kmph.
The train has been conceived, designed and has been developed in a record of time of about 18 months, as against the industry demand of about 3 to 4 years, for designing and developing of such type of new design coaches. The Train 18 Trainset has made at an approximate cost of Rs.100 crores per rake about half the price of importing such a rake from abroad, with about 80% Indian origin components in alignment with the Hon’ble Prime Minister’s call for ‘Make in India’.
Train-18 has Two Driving Trailer Coaches with Aerodynamic Driver’s Cab (Nose Cone) on both the ends which will be enable quicker turn-around time at destinations. Every alternative coach is motorized, to ensure even distribution of Motive Power and Faster acceleration/deceleration. All the equipment are underslung i.e below the chassis of the coach leaving the complete on board space for the passengers. Moreover,, all the coaches are connected by Fully Sealed Gangways with integrated bridge plates, where passenger can walk across freely .
The train has better passenger amenities such as on-board Wi-Fi infotainment, GPS Based Passenger Information System, plush interiors, bio-vacuum toilets, diffused LED lighting, charging points beneath every seat, individual touch based reading lights Intelligent Air-conditioning system that will adjust the cooling according to the climate conditions/occupancy, concealed roller blinds, facility for PWD passengers to enter the driving trailer coach using their wheel chairs, PWD friendly toilets, auto sensor taps in the toilets, modern pantry and food service facilities, Rotating seats to match with the direction of the train in Executive Class, Automatic Sliding Doors inside the coaches, modular luggage rack with glass bottom, etc. The advanced state of the art suspension system will also ensure smooth and safe journey for the passengers.
The total seating capacity of the Train 18 is 1128 (44 × 2 Driving Trailer Coaches + 78 × 12 trailer/motor coaches + 52 × 2 Executive Chair Cars) that’s more than the conventional AC chair car trains due to availability of seats in the driving coach and removal of 2 power cars.
On safety front, the Train Management System provided with the Driver’s Cab will ensure precise brake control and Automated doors Control. The Automated Plug Doors Provided on the coaches will open only when the train reaches 0 Kmph speed and the train will start only after closing of all the doors. Automated sliding footsteps will also form a temporary bridge between the train and the platform to prevent any accidental slip or fall of the passenger. Moreover Emergency talk back units (through which passengers can talk to crew in case of Emergency) and CCTVs are provided in all coaches for safe and secure travel.
Further, CCTV cameras on both the sides of driving cab would help the driver to monitor the movement of passengers on the platform before closing the doors and taking off. The train is also designed in such a way to save Diesel by dispensing with the power cars and about 30% electricity saving thanks to advanced regenerative braking system.
The Train 18 is sure to elevate the Passenger Experience of train travel in India to never before levels.
ICF MAHILA SAKTHI:
There are 9 Mahila sakthi teams comprising of 130 members in the factory premises. The women teams manage the toughest works where only men could possibly do and how they sweat it out in one of the top class factories of the country and arguably the biggest train manufacturer in the world. They are engaged in the toughest works such as welding, fitting, harnessing, Arc Welding, Painting of motors and single phase motor winding work and also engaged in light electrical activity of interior fabrication of coaches, harness preparation, cable cutting and other electrical related work. Welders and fitters are involved in manufacture of doorway stiffener for underframe of AC EMU and contrail for roof of DETC and Kolkata Metro and also engaged in manufacture of cross bearer for underframe for EMU and AC passenger coach(general), assembly & welding of LGS modular frame. They also handle light electrical activity of interior fabrication of coaches, harness preparation, cable cutting and other electrical related work. Mahila Shakthi team in Depot Shell/Furnishing Ward consisting of Depot material superintendents and helpers are engaged in issuing of materials to shop floor and diesel filling, receiving of materials from Receipt Branch, handling of material stocks, managing of Automatic Storage Retrieval System and supplying of raw materials to Shop Floors.
Aluminium body high speed train set called ‘Train -21’ will also be started. This will be the first-of-its-kind train set fully made in India when it rolls out from ICF in 2021. This fully air conditioned train set will contain self-propelled electrical multiple units running on under-slung 3-phase power packs. Best-in-class features like automatic plug doors, wider sound proof gangways, semi-permanent couplers, comfortable sleeping berths, infotainment, CCTV, fire detection systems, aerodynamically profiled driving ends and body will be incorporated.
ICF strongly believes in ‘Customer first’ approach. Several passenger and maintenance friendly initiatives are being done as part of continual improvement. Large windows for non-AC coaches, ergonomic hand holds, rubberized flooring; modular systems are some of them. ICF also bagged an order to export DEMU train sets to Sri Lanka for which design work has been taken up.
As always, Innovation Continues Forever at Team ICF.
ICF has been patronizing the sports among the ICF employees & their wards. The administration has been creating and improving the sports facilities all over ICF premises including the residential colonies. There are world class sports facilities such as floodlit cricket stadium and the Mohd. Shahid AstroTurf Hockey Stadium, the only second such facility in Chennai city, an Air Conditioned Multipurpose Indoor Stadium inside the ICF Arun Sports Complex (ICF Stadium) and Synthetic and Clay Tennis courts. The residential colonies have various sports facilities such as modernized gym Tennis courts, Volley Ball courts, Basket ball courts, Badminton courts etc.