The railway industry along with its related component sector continues to grow rapidly as urbanization meets the ‘Make in India’ initiative. However, DC motors operated locomotives at considerable maintenance costs through demanding electrification systems that converted DC to AC power. Furthermore, the fragile brushes in DC motors get worn out and eventually lead to commutator failure. Hence, the swap from DC motors to AC motors has created a growing demand that needs to be met. This is where Bangera Products steps in.
Today, the company has created a niche for itself as one of the most competent railway component manufacturers. The railway transportation sector made a significant transformation after C.K. Jaffer Sharief implemented AC motors from Switzerland into service. Post its research and development phase, Bangera Products achieved approval status to manufacture AC motor components among only a few manufacturers.
The Bhopal-based manufacturer and supplier Bangera Products was established back in March 2019 and now operates as a prominent national manufacturer of railway industry’s essential components. The company produces accurate motor components that serve locomotive motors and especially concentrates on stator frame and rotor production.
Carving a Competitive Edge
Bangera Products enhanced its market presence after the emergence of 15 new motor manufacturers when it expanded its supply base from two initial companies to all 15 manufacturers.
The CTQ (Critical to Quality) motor components operate as critical elements for train functions since the breakdown causes cumbersome operational disruptions. Each component manufactured through the previous production process in Bombay factories showed multiple defects as it used six to seven machines over three days.
The advanced technology at Bangera Products enables faultless component production through a single machine within three hours thus eliminating complete rejection rates.
The production team at Bangera Products has manufactured more than 6,000 components made of stator frames and rotors without encountering any manufacturing defects. The technology provides superior quality because it eliminates dimensional problems resulting from operating several machines.
“The use of DMG MORI, the world’s number one machine, ensures the process is foolproof and no longer dependent on craftsmanship, marking a major achievement for Bangera Products”, states Vijay Suvarna, Managing Director, Bangera Products.
Driving Needed Innovation
The last machining operation in component manufacturing requires totaling the process within one setting to reach perfect product results which meet quality standards. Previously manufacturers needed up to three separate setups because a single machine lacked the ability to machine all six surfaces of a component which required five or six axis machine to complete the same.
Bangera Products introduced an innovative approach which allowed single-setting machining of components, thus producing faultless products free from any quality problems. The innovative method received widespread approval from railway authorities as it proved to be effective.
Furthermore, the Japanese team starts collaborating with the delivery of components to understand critical part requirements that the R&D team utilizes for process development activities. Time studies and SOPs become available near machines after process completion for the purpose of maintaining strict adherence to procedures. Monthly Zoom meetings with RDSO, CLW, and others address failures, innovations, and improvements.
Metro trains along with Train 18 have caused permanent changes to railway motor design which introduces complex difficulties. New trains create prototyping obstacles because they need different motors as well as shafts frames and components.
“To tackle this, CAD CAM programming has been adopted, to design, verify, and test the components digitally before production, streamlining manufacturing, ensuring accuracy and reducing manual intervention”, signifies Vijay Suvarna.
Robust Road Map Ahead
Going forward, Bangera Products aim to develop smart rail components while catering to the Indian railways, metros and upcoming bullet train projects, expanding their market and upgrading their operational efficiency to become the leading producer of railway components in India.
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