Train 18 series: Where were we?

I have mentioned that the sanction of the project was formally received in April 2017. But how? We had done our bit to present our case to the Board, from minions to the top, and it appeared a done deal. Merely two days before the presentation of the budget, however, I learnt that the project had been turned down, and ironically, primarily because it did not find support of the department which was to be the owner of the train. I was given this news when I was abroad. I was bewildered and clueless for some time; it was fruitless to convince people who did not rise above their petty jealousies and biases. There was only one way forward, go to Sri A.K.Mital, the Chairman, with folded hands. As soon as I landed in Delhi, I met the Chairman; I had met him many times earlier and he was generally in agreement. I pleaded that he must give ICF this chance and that we were going to make sure that he would not be disappointed. He agreed and overruled everyone to grant us the sanction within days.

That done, the spirits in ICF soared high. At this stage, as we began our work, it was necessary that a buzz about the project be created externally as well as internally. Both the Chief Design Engineers (Mechanical & Electrical), Sri Srinivas and Sri Vavre, were the architects of the series presentations on the project to the Board; they had already studied the subject thoroughly and had enough material, culled from across the globe, on the trend of train sets. They took a series of meetings, stressing the outline and proposed time line of the project. Everyone in the team, including the members from Stores and Finance wings were sensitized about the Train 18 project. And indeed everyone, barring some, rose to the occasion. It was clear across the departments that ICF was attempting something new, at least to some degree.

An aside. I mentioned that everyone, barring some, rose to the occasion and therefore I had to send a message to these barring some. Every organization has people who just do not see the importance of action and delivery but are more concerned about being safe or some other personal agenda. They do not say No and they do not say Yes; they just cavil, equivocate or procrastinate. Such a delaying tactics is called jalebi-making, due to its similarity with the round and round process of making this sweetmeat.  Whenever, I came across any such instance, I would call for the file, make my own judgement and if indeed there were people delaying the case unnecessarily, invite them to my room. I would order jalebis and offer it to them, saying that they had really earned this honour. I do not know whether the concerned officers improved their working or not but a message certainly went down.

Item	So how did we start?
Car body shell design and manufacture including painting	We had to go a quick consultancy contract on a European or Japanese firm, as they are the trailblazers, for making our designs, tooling and processes amenable to more accuracy and better quality. We zeroed on three companies, one in Poland and two in Switzerland, who did similar work for European majors. In a quick process, the consultancy contract was awarded to the Polish company.
Fully suspended traction motor bogie fit for 180 km/h	In an exercise dissimilar to above, a novel way of combining the consultancy with another major procurement case was in hand. We moved quickly to finalize the contract, incidentally, on the same Polish company.
Modern 3-phase IGBT propulsion	The train set electrics were tendered for as a part of separate electrics tender for value more than Rs 1000 crores, which was languishing due to indecision for nearly a year. There was no pressure on anyone for a particular result in the tender but indecision or delay was not an option any more. We finalized this contract in three months flat. It was for the first time that ICF had awarded contract of this magnitude; it was earlier dealt by Board and the norm for finalization was eighteen months to two years!
Train Control and Management System, PIS and Smart Train concepts	As above
Pleasing interiors Toilets to match the best in the world Special facilities for differently-abled passengers	Since interiors would get designed after the shell design was ready, we had some breathing space here. We identified some companies in Europe and a series of presentation were held at ICF. Eventually, the consultancy contract was awarded to a firm based in Spain and France.
Brake system	In respect of modern brake systems, the globally is between two major companies. The specifications were frozen quickly with the clear mandate that there would be no compromise on capability and quality irrespective of the price. The contract was finalized early as ICF, the brake supplier and the manufacturer of electrics had to work very closely, given the multitude of mechanical, electrical and software interfaces.
Minor structural assemblies Mechanical and electrical assemblies	We started identifying the core team in ICF to do these works.
Cabling	As mentioned earlier, our attempt to get a consultant on board failed, primarily due to unreasonable price offers and also lack of capability in the country. We decided that this work would be done ICF in consultation with the manufacturer of electrics.
Miscellaneous	To be worked out as we move along
Imported bought outs Aircraft type seats, including rotatable ones for Ex class, Plug doors with retractable steps & Contactless Sliding Doors etc.	We identified the global sources and procurement action was put on fast track

Summarising, by mid 2017,

1)    three major consultancy contracts were in place:

· New bogie design with fully suspended traction motors

· Improvements in design, tooling and processes for shell

· Interior styling concepts

2) A major contract for supply for electrics and allied systems was in place on an Indian company

3) All preliminary design work had started at ICF

4) Contracts were bought outs were moving at a fast pace, for import as well as indigenous. For the indigenous bought outs as well, judicious selection of vendors is a major factor in successful development of a rolling stock. The key team decided the list of such vendors and whether through open, limited or single tendering, no scope was allowed for dilly dallying. We had to order on only those forms which the team considered capable enough for this project and we did precisely that and in record time. 

I remember, at this time, circa June 2017, our PR department took out a write-up:

The Train 18 will be a semi-high speed (180/160 Km/h) train set with fast acceleration and world- class passenger amenities. All coaches will be inter-connected by fully-sealed gangways affording smooth passage from one coach to another. It will have auto plug doors which will open and close automatically at the stations, wide windows for panoramic view and ergonomically-designed seating. Equipped with sleek energy-efficient under-slung 3-phase IGBT based propulsion system, the train will have much more space for passengers. To make Train 18 travel more joyful, all coaches of the train will be provided with on-board wi-fi, infotainment & GPS-based passenger Information System (PIS). The train will have plush interiors and diffused LED lighting. The Toilets of these coaches will be fitted with zero-discharge vaccum-evacuation bio-toilets and touch free fittings. To keep the jerks and vibrations at bay, the train will be equipped with improved mechanical couplers and modern bogies with fully-suspended traction motors, pneumatic secondary suspension and anti-roll bar. The train will have a modern electro-pneumatic microprocessor-based brake system capable of providing safe braking with reduced braking distances. This train will have many features not seen on Indian Railways before and provide a fast and wholly new travel experience.

Bingo! They did get it right! At that stage, however, a well wisher confidante, an old ICF hand, comforted me that the target for June 17 turnout was very much achievable. I am sure he had not read Much Ado but I threw Bendick at him, nevertheless, “I would my horse had the speed of your tongue’’. 

(to be continued..)