Liluah Workshop – Organisational Excellence per International Standards.

East Indian Railways (EIR) had initially set up a Locomotive and Carriage Workshop in 1853 near the Howrah Station with the idea of maintaining its assets after the inauguration in 1854. The Locomotive portion was shifted to a new and much bigger workshop at Jamalpur in Bihar in the year 1862, and the Howrah works was upgraded to a Carriage and Wagon Workshop in 1863.

However, success was at bounty – far from the anticipated projections. As a result, the site at Howrah felled short of the magnitude of works & unsuitable for further expansion. The facility was finally shifted to its present site at Liluah around 07 kms from Howrah Railway Station.

The prime responsibility of this workshop was to manufacture rolling stock excluding locomotives. Only Carriages and Wagons were initially manufactured. Manufacturing of coaches were done till 1972 and Liluah has 3000 coaches to its credit. Wagon manufacturing was however discontinued in the post-independence era and Coach manufacturing was also stopped when sufficient infrastructure was built throughout the country to cater for the ever-growing demand.

A noteworthy feat is that apart from manufacturing rolling stock, Liluah made immense contribution to the war machinery of Allied Forces during the Second World War. Apart from rolling stock required for transport of military equipment’s Liluah also produced hundreds of Ambulances, Water Cars, tanks, armoured vehicles and lorries. Ammunitions were also produced for the Royal Army and Royal Air force. Minor items like tent pegs etc. were also in thousands. All the above reiterates the technical expertise and skill developed within the work shop. The accolades were published in the form of an essay in East Indian Railway Magazine by D. K. Whitworth in 1945 demonstrating the core competencies of the railwaymen at Liluah between 1938 and 1942.

The Workshop is presently engaged with the following activities:

• POH of Eastern Railway coaches both ICF & BEML including all Air-Conditioned coaches;
• POH of units pertinent to North Eastern Railway Coaches;
• POH of units pertinent to Western Railway Coaches incorporating modifications as issued from time to time.
• Conversion of DMU coaches.
• Repairs of Electrical Components viz. Alternators, Motors. Transformers etc.
• Overhauling of DG sets of Rajdhani and Shatabdi Power Cars.
• Fiberglass Reinforced Polymer (FRP) processing activities for railway sleepers;
• Sliding Mode Control (SMC) processing activities.
• Moulding of components like axle box covers, louvre shutters etc.

Milestones: The early achievements could not be traced out due to lack of proper documentation. The later achievements however are as follows:

• The Great Indian Rover (GIR), a luxury tourist train was conceived by IR in January 1983 and the stupendous task of converting a few old tourist cars to prestigious GIR train were assigned;

• Liluah converted six IRS type tourist cars, one lounge car and one restaurant car to suit the purpose being extensively modernised with Public Address System, intricate furniture’s, high quality lighting and upholstery. The first GIR puffed out from Howrah for Gaya on 10th. February 1983, just within a month.

• With growing demand for commuter trains in non-electrified areas of West Bengal and Bihar, Railways decided to operate Diesel powered multiple unit trains (DMU), similar to EMUs, in non-electrified areas and this task was given to Liluah Workshops in February 1992, with only two months’ time frame. In absence of any prototype, model, drawings and materials, Liluah shops started from scratch. With assistance of material from DLW-Varanasi the first indigenous Push-Pull type Diesel Multiple Unit was dedicated to service on 30th. April 1992 comprising of 10 coaches.

• Indian Railways decided to run a special Train christened as “Exhibition-on-Wheels”  with exhibits of the history railroad development in India, for which some parcel vans had to be modified with extensive modification and Liluah had to work with three such conversions which was a stupendous task.

• Liluah Works had always exhibited sheer excellence in a challenging scenario. After the successful execution of GIR; during Bodh Parikrama, Liluah Workshop had converted 12 coaches to suit the prestigious Tourist Train keeping in view the international standards for the foreign customers.

Liluah Workshop at a glance: The workshop is considered to be the Oldest & Biggest Railway Carraige Repair Workshop in India with a Total Area of 2,99,000 Square Metres, and the Covered Area is of 1,04,471 Square Metres.

The operational milestones of this workshop rank parri passu with other foreign railway workshops.

On 26^th. January, 2025 when the entire was commemorating with valour the 75^th. Republic Day, his goodself Mr. Milind K. Deouskar, General Manager, Eastern Railway, conducted an inspection of the Liluah Workshop, highlighting the workshop’s continued excellence and innovation in railway maintenance and sustainability initiatives.

During the inspection, Shri Deouskar inaugurated the first-ever computerised RMPU (Roof Mounted Package Unit) testing facility in Indian Railways. This state-of-the-art maintenance facility enhances the efficiency and accuracy of RMPU testing, setting a benchmark for other railway workshops.

Shri Yatish Kumar, Chief Works Manager, Liluah Workshop, in presence of Shri Sheelendra Pratap Singh, Principal Chief Mechanical Engineer, Eastern Railway, showcased its first Mid-Life Rehabilitation (MLR) of an LHB (Linke Hofmann Busch) coach. The MLR process transformed the coach into a state-of-the-art asset, comparable to a brand-new coach. Key upgrades include new berths and panels to enhance passenger comfort, upgraded toilets with advanced fittings for better hygiene, amenity fittings improved to meet passenger satisfaction, anti-graffiti coating protecting the coach’s aesthetic appeal and durability. These enhancements ensure an elevated passenger experience and extended service life of the coach.

The event also marked the launch of Eastern Railway’s first air-conditioned Railway Camping Coach (RCC), specially designed for track maintenance staff. Key features of the RCC include air-conditioned comfort ensuring better living conditions for staff during operations., equipped with modern fittings, machinery, and plants for track maintenance.

Shri Yatish Kumar also highlighted two innovative monitoring systems developed by Liluah Workshop, water level monitoring system for real-time updates on water levels in coach water tanks, ensuring uninterrupted water supply, and temperature monitoring system ensuring optimal air-conditioning for improved passenger comfort. Shri Deouskar lauded the Liluah Workshop for its advanced rolling stock maintenance practices, which ensure passenger safety and satisfaction.

During the inspection, Shri Deouskar inspected several critical areas of the workshop, including Shop -A, the Carriage Shop, the Welding Shop and the Coach Component Shop. He also inspected key sections such as the CBC & Draft Gear Section, Tank Section, MRL Section and the RMPU (Roof Mounted Package Unit) Section, which included window fittings and door closers of LHB coaches, to ensure proper functionality and enhance passenger safety.

The General Manager reviewed repairs in the Non-AC battery box section to improve efficiency and maintain operational reliability. He also inspected the overhauling of LHB coach springs to provide smoother rides and better shock absorption, along with static bogie load testing to ensure structural stability and the safety of critical coach components. Additionally, he assessed the workshop infrastructure development layout for future upgrades. Shri Deouskar also inspected the CCTV control room to strengthen surveillance and security measures within the workshop premises.

Several new initiatives were inaugurated by GM/ER during his visit like:

1. Goliath Crane with a Capacity of 5T: Strengthening the workshop’s operational capabilities;
2. FIBA System (Failure Indication cum Brake Application): Enhancing brake efficiency and safety;
3. Modern Camping Coach Facility for Track Machine Staff: Providing improved living conditions for track maintenance personnel;
4. Computerized Roof-Mounted Package Unit (RMPU) Plant: Introducing advanced technology for air-conditioning systems;

Shri Deouskar had advised the Chief Workshop Manager (CWM) and other concerned officers to focus on better maintenance practices and infrastructure upgrades for the workshop. He also held a meeting with union representatives and directed the CWM to address the basic requirements of the staff promptly. The General Manager had also emphasised the importance of maintaining high standards of safety and efficiency in coach repairs and development. He appreciated the dedicated efforts of the workshop staff and management, encouraging them to adopt innovative solutions to further enhance passenger safety measures.

This inspection highlights Eastern Railway’s commitment to prioritizing passenger safety and delivering superior travel experiences through continuous improvements in infrastructure and maintenance practices.

Mr. Deouskar, along with Additional General Manager, Principal Heads of Department, DRM/Howrah Division, DRM/Sealdah Division, and CWM/Liluah Workshop, honoured and awarded the dedicated staff for their relentless & tireless efforts. The visit underscored Liluah Workshop’s focus on technical innovation reinforcing Indian Railways’ commitment to providing world-class services.

Team Maverick