Savli Site

Delivering excellence

The Climate is Right for Trains

Administration building

Final Assembly hall

World-leading

rail investment in India

Savli in Vadodara is home to a new world-class rolling stock manufacturing plant. With 55,000 square metres of covered production facilities, located within 165,000 square metres of land, the Savli site in Southern Gujarat is already proving its merits as an integral part of world-leading rail equipment manufacturer, Bombardier. Making the transition from a greenfield site to a modern, fully-equipped and production-ready factory in just 18 months, as well as handing over its first vehicles from a prestigious contract, Savli has been performing from day one. Delivering its first production vehicle in May 2009 for Delhi Metro and the manufacture of the 500th car in August 2011, Savli site has been contributing to the modernisation of Indias transportation network. The latest new BOMBARDIER* MOVIA* metro trains for the city of New Delhi will help to move over 4 million passengers every day. A highly skilled team, consisting of around 700 employees, complemented by the latest manufacturing technology and a strong management team, ensures that Savli can deliver the highest levels of quality demanded by the worlds modern railway operations today. Savli site has facilities and capabilities to manufacture cars for all gauges including broad and standard gauge and wide cars of 3,650 mm width.

Foreword from

the General Manager

We are now committed to strive for flawless execution in all our projects and I have a highly motivated team which is focused to realise the above goal. We are determined to make Savli site as one of the best in the world with a common and focused goal to be a lean site with flexibility, innovation, respect for the environment and a customer-oriented approach. The four main cornerstones of our philosophy are: to ensure top quality of our product and all deliverables; to deliver to schedule; to develop a trusted and quality network of local suppliers and last, but not least, to provide a cost-competitive product without compromise to quality. Dilip Jadeja, General Manager
Celebrating the manufacture of the 500th car

In an industry first, Bombardier Transportation demonstrated its strategic commitment to the Indian market by becoming the first foreign multinational company to set up a wholly-owned rail vehicle manufacturing site in Southern Gujarat, India in 2007. Following an investment of 33 million euro (Rs 200 crores), this state-of-the-art facility in Savli has comprehensive capabilities for the manufacture and final assembly of carbodies and bogies and is equipped to rival the worlds finest in the production of modern rail vehicles.

Having established a modern coach building facility at Savli in mere 18 months, Bombardier accelerated the development of this greenfield project to reach the current manufacturing rate of one car per day. This is indeed a remarkable achievement by global industry standards.

Savli, Gujarat is home to our railway vehicle manufacturing site, propulsion systems manufacturing facility and software development centre for signalling and traction applications in India and for other Bombardier Transportation projects around the globe.

Celebrating the manufacture of the 500th car

Committed to being the best

In every stage of its development, the Savli site has been planned and supported to deliver excellence. 55,000 square metres of custom-designed, covered facilities accommodate three large production and assembly halls. The production area consists of more than 30,000 m2 for car body manufacture and final assembly, around 8,000 m2 dedicated to bogie production and around 3,000 m2 allocated for testing. In addition, 2,000 m2 of office facilities house Bombardiers highly skilled team of local engineers and management staff. State-of-the-art Spot welding The new Savli carbody manufacturing hall incorporates some of the most advanced production equipment available today, including robotic manufacturing equipment enabling precision-based automated spot welding of carbody components, as well as spot welding jigs, carbody completion fixtures and roof-rotary fixtures for pre-assembly of interiors of the carbody shells. Final Assembly The Savli site is destined to be a Bombardier centre of excellence for stainless steel metro vehicle production in India and the region. The modular approach to carbody manufacturing adopted for our MOVIA metro cars allows optimum efficiency and ease of final assembly as it enables work to be carried out simultaneously on different parts of a vehicle. Operating two parallel production lines, Savli has the capacity to produce around 32 cars in a typical 6 day week.
1,036 FLEXX Metro 3000 bogies have already been delivered out of Savli factory

Our final assembly hall is based on the world-renowned cell manufacturing concept, which provides a flexible approach to accommodate customised production of different designs. At each station of the assembly process a quality check gate ensures inherent performance is built in at each stage. Other facilities on the site include cranes and compressors, a modern traverser for broad and standard gauge rails and a road/rail shunting truck with push/pull capacity up to 200 tonnes to move trains or cars around the site. Testing The test facility at Savli enables testing of up to 8 car-sets as well as an initial high voltage testing of DT cars. Our 2.7 km rail track provides a connection with the main Western Railway line. Bogie production Equipped with the latest technology and equipment, our bogie production hall was constructed and productionready in record time. It was the first of our workshops to be completed in October 2008 and we have already manufactured 1,036 BOMBARDIER* FLEXX* Metro 3000 bogies in Savli. Our site is capable of producing 1,500 assembled bogies a year. Critical elements such as welding, final assembly and testing are carried out by our trained and certified technicians. With many of our skilled personnel trained to the latest bogie technologies and best practices in our European Bombardier Bogies sites, our bogie production site has become a centre of expertise for

Savli site layout and production process flow

production and servicing of bogies across the region. The Savli site is well integrated in the Bombardier Bogies Business Unit network and benefits from the companys extensive experience gained over more than 160 years in developing and manufacturing reliable and innovative bogies that combine safety and reliability with low maintenance costs. In terms of our bogie products, Bombardiers FLEXX portfolio is the most comprehensive in the world. Our FLEXX bogies cover the complete range of railway vehicles, from metro to high speed trains, from light rail vehicles to heavy haul locomotives. With a worldwide reputation for quality and dependability, the FLEXX bogie families focus on bogie designs with valuable benefits for the operator: safety, reliability & robustness.
Bogie assembly

Roof assembly

Project Reference
The first prestigious contract undertaken by the Savli site has been the production of MOVIA trains for Delhi Metro.

BOMBARDIER MOVIA Delhi Metro

For this landmark project, as part of its commitment to localisation, Bombardier invested in its new purpose-built site in Vadodara, India and transferred its leading-edge technology to create fully localised production at Savli. International collaboration Around 60 employees were seconded in stages from Savli to Bombardiers Grlitz site in Germany to receive extensive training alongside their colleagues in Europe. Similarly, supervisors and assembly staff from Europe travelled to India to assist in the training required for localised production. This enabled the local Savli team to replicate Bombardiers approach to delivering the highest standards of quality in metro vehicle production. The first 36 vehicles were produced in Europe, with the remainder of the fleet of almost 500 vehicles manufactured in Savli. Bombardiers global standards and processes have also been applied to the design and layout of the site in Gujurat supported by comprehensive investment in equipment and training. This project is a prime example of collaboration between Bombardier and its customer across cultures, countries, continents and sites. Involving 10 Bombardier sites, the international team developed and supported the introduction of a brand new vehicle in just 18 months, while at the same time establishing a new production plant in India. MOVIA customised for Delhi The MOVIA metro vehicles integrate the worlds most advanced technologies in metro vehicle manufacture, such as stainless steel car bodies and the latest BOMBARDIER* MITRAC* propulsion and control system. At 3.2 metres wide and around 22 metres in length, the Bombardier MOVIA train for Delhi Metro is designed to comfortably accommodate large numbers of passengers with capacity of around 1,480 passengers in a four-car train. Its longitudinal seats are also designed for high capacity. Made from sand-blasted stainless steel, the seats are physiologically moulded for comfort. In a design specially customised for the Indian market, the new trainsets include air-conditioning for the passengers and also in the drivers cab. CCTV and open gangways ensure security and visibility throughout the train. Also, emergency speaker units provide the opportunity for the passengers to communicate directly with the driver. Another new feature is the inclusion of a safety egress door via the drivers cab for passenger evacuation in the event of an emergency. Four double sliding plug doors per car provide maximum reliability and ensure that passengers can board and disembark quickly and efficiently. The passenger information system includes predefined messages and notification of upcoming stations, as well as a digital route map, highlighting journey progress. Atypically for a Metro, power is provided by 25kv AC, with trains incorporating a pantograph and circuit breaker. The flexible, modular MOVIA for Delhi Metro is equipped with our FLEXX Metro 3000 bogies, an extremely robust and reliable design, specifically adapted by our engineers to suit the existing infrastructure. The lightweight design of the FLEXX Metro bogies enables maximum vehicle capacity utilisation with minimal energy consumption. Designed for maximum reliability, safety, maintainability and low-life cycle cost, the MOVIA trains are already making their mark in Delhi and a tangible difference to passengers commuting in this major city.

In July 2007, Bombardier Transportation was awarded the contract by Delhi Metro Rail Corporation Ltd (DMRC) to supply 340 MOVIA metro cars for operation on New Delhis rapidly expanding metro network. Additional orders for 84 and 114 MOVIA cars were placed in April 2008 and July 2010. Subsequently with the new order of 76 metro cars in August 2011, DMRC will be operating a fleet of 614 Bombardier MOVIA metro cars, one of the largest in the world, benefiting from economies of scale in both acquisition and maintenance costs. Already in operation in major worldwide cities including Shanghai, Guangzhou, Shenzhen, Bucharest and Berlin, MOVIA metros have a track record for high performance and reliability. In Delhi, these new trains will help to transport over 4 million passengers daily.

A completed Delhi Metro train ready to be tested

Bombardier MOVIA Delhi Metro train approaching the station

Quality

and the Environment

Already the Savli site has achieved the highest international standards for the management of its safety, quality and environmental processes including: production at Savli continues to meet the essential standards of quality and environmental practice. Bombardiers quality processes are also applied to its local suppliers to ensure that they too meet the international benchmarks required by the company. Engineering Excellence The local team of engineering specialists encompasses around 30 managers with a strong track record in the rail sector together with an implicit understanding of the products and processes. Areas of expertise include electrical and mechanical systems, as well as carbodies and installations. With 15 Computer Aided Three-dimensional Interactive Application (CATIA) workstations in place and 15 engineers with CATIA background, the team is already supporting its international colleagues in Bombardier with other projects around the globe.

IRIS certification EN ISO 9001:2008 OHSAS 18001:2007 EN ISO 14000:2004 ISO 3834-2:2005 EN ISO 15085-2

Quality Management Quality Health & Safety Environmental Management Quality for fusion welding Welding of railway vehicles & components

The achievement of these certifications is a testament to the strong management of operations, documentation and processes. Bombardiers highly motivated management team, backed by the strong foundation of the Bombardier Operation System will ensure that
Spot-welding robot

Testing of bogie

Environmental Performance Bombardier has a commitment to producing vehicles that are best-in-class in terms of their environmental performance, which is reflected in the vehicles produced at Savli. BOMBARDIERs* ECO4* formula for train performance balances the four cornerstones of Energy, Efficiency, Economy and Ecology. The MOVIA vehicles produced for Delhi Metro fit perfectly within this portfolio as they feature low energy consumption, minimal noise emissions and are up to 90% recyclable. Bombardiers Design for Environment principle is based on a vehicles entire lifecycle, from development to recycling, with a focus on continuous improvement according to sustainability criteria. By enhancing our products in terms of environmental friendliness, noise reduction, safety, efficiency and most importantly, low life-cycle cost we also create a competitive advantage for our customers, the rail operators. 8

Investment in People Representing its largest ever investment in Asia, Bombardiers Savli site has created around 700 skilled jobs in India. Additionally, around 3,000 job opportunities have been created in the local supply community. Given the excellent prospects for expansion and modernisation of the rail sector across the region, this growth is set to continue. Bombardier has a strong focus on the quality of its welding activities in Savli, with around 60 certified welders and fitters trained according to EN 287-1 and ISO 3839-2 for vehicle carbody production and around 53 welders employed in bogie production.

The Climate is Right for Trains

Bombardier Transportation

Best Practice
Bombardier is committed to bringing out the best in its products and in its people. That is why, for each project, a multi-national team is brought together to ensure the optimum combination of skills from relevant specialisms to harness Bombardiers extensive global knowledge base. In addition to its Propulsion and Control and Software Development Centre in Vadodara, Bombardier is supported in India with an Engineering Centre in Hyderabad, 4 Sales and Marketing offices in New Delhi, Mumbai, Kolkata and Chennai, as well as project and depot offices in New Delhi. Committed to customer satisfaction Our production activities are complemented by after sales service, with both on and off-site training and regular correspondence between our technical experts and railway personnel. These measures have strengthened our understanding of the customers needs, thereby improving reliability and extending product lifespan. This, in turn, has resulted in a great increase in customer satisfaction and confidence in our products. Bombardier is poised to support India to become a world leader in rail transportation. With a rapidly developing rail market, India is also strategically located to supply our state-ofthe art locally built Bombardier trains and components to its neighbouring markets. With the production of high quality made-in-India trains, Bombardier believes that India can become a hub for railway expertise for the region. Bombardier Transportation is dedicated to developing, manufacturing and servicing advanced transportation solutions for todays and tomorrows railways. Over 100,000 vehicles in operation worldwide attest our unique strengths in project management and innovation, design and technology. For decades we have enabled millions of people every day to reach their destinations in comfort and style. Bombardier is a truly international business, which provides local support. Present in more than 60 countries and with some 35,000 employees worldwide, we strive to be the partner of choice for all the worlds rail operators. Headquartered in Berlin, Germany, Bombardier Transportation is part of Canada based Bombardier Inc. It generates annual revenues in excess of US$ 9 billion.

Equally, Bombardiers goal is to promote localisation, to ensure proximity to its customers for ongoing product support. The bigger picture Bombardier has been in present in India for over 40 years, supplying India with many advanced rail products, from the WAP5 and WAG9 electric locomotives to highly sophisticated Traffic Management Systems in Mumbai, managing one of the densest commuter rail networks in the world. Gujurat is also home to Bombardiers Propulsion Systems Manufacturing Facility and Software Development Centre for signalling and traction applications in India and also for other Bombardier projects around the globe.

As a global leader in rail technology, Bombardier places environmental sustainability firmly at the top of the agenda. Our products and services combine energy conserving technology with optimal safety, reliability and cost efficiency. They are designed for sustainable mobility throughout their lifecycle. Our portfolio of rolling stock and services encompasses passenger vehicles for urban and mainline operations, locomotives, bogies, rail control solutions, propulsion and complete transportation systems, as well as vehicle modernization and maintenance.

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Bombardier Transportation has an active set of environmental print guidelines, for further details click onto: www.transportation.bombardier.com Learn more about our commitment to sustainable mobility on: www.theclimateisrightfortrains.com If you no longer require this data sheet please recycle it responsibly.

Bombardier Transportation Plot no.724, GIDC Industrial Estate Phase III Savli, Vadodara 390013, India Tel +91 265 235 30 68/69 Fax +91 265 235 58 91 www.bombardier.com
*Trademarks of Bombardier Inc. or its subsidiaries.

2010, Bombardier Inc. or its subsidiaries. All rights reserved. Printed in Singapore/10991/PGR/09-2011/en