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Extraaaz Innovative Tech Solutions
Technical Proposal · Indian Railways · Central Railway / Mumbai Division
WSP Digital Intelligence
Platform for LHB Coaches
A comprehensive digital solution to eliminate wheel shelling through real-time WSP data analytics, predictive fault detection, and structured maintenance workflows — built for Indian Railways field conditions.
1054
Shelling Cases
FY 2023–24
The Problem We Are Solving
Wheel shelling in LHB coaches remains one of the leading causes of terminal detachments and OMRS alerts across Central Railway depots. In FY 2023–24, a total of 1,054 cases were recorded across LTT, MZN, and NCC WB depots — with 26 distinct fault categories ranging from dump valve defects to WSP card failures. Despite RDSO circulars and check sheets, the root cause persists: maintenance data lives on paper, WSP fault downloads are manual and irregular, and there is no centralised visibility for the Sr. DME office.
Extraaaz proposes a fully integrated WSP Digital Intelligence Platform — a mobile + web system that digitises every step of the brake and WSP inspection workflow, auto-downloads WSP CPU data at first instance of shelling, and gives the Sr. DME real-time depot-wise dashboards to identify systemic failure patterns before they escalate.
The Numbers That Demand Action
1,054
Total Shelling Cases FY 23–24 across LTT, MZN, NCC WB
783
Cases at LTT depot alone — 74% of total detachments
26
Distinct fault categories identified by maintenance engineers
3
Brake system OEMs (Escorts, Faiveley, Knorr) with different fault codes
Sr. DME Command Dashboard — Live View
Below is a representative design of the real-time divisional dashboard accessible by Sr. DME, ADME, and Depot Incharges from any device.
Active Coaches
1,247
↑ 12 commissioned this week
WSP Faults This Month
38
↓ 22% vs last month
Checksheets Pending
7
⚠ 2 overdue D1 schedules
WSP Data Downloads
98%
✓ Compliance rate
Depot-Wise Shelling Incidents (FY 23–24 Baseline vs Current)
Top Fault Categories (Last 30 Days)
| Fault | Count | Severity |
|---|
| Dump Valve Connector Loose | 11 | HIGH |
| Speed Sensor Wiring Loose | 9 | HIGH |
| WSP Card Defect | 7 | MED |
| Grease in BC Flex Pipe | 6 | MED |
| Pressure Switch Issue | 5 | LOW |
Live Alerts — Action Required
LTT/0847 — WSP fault code 22 (WSP card defect). Download pending since 4h.
LTT/1123 — D2 checksheet overdue by 2 days. Speed sensor gap not recorded.
NCC/0341 — Dump valve operating sequence flagged. OEM verification needed.
LTT/0992 — K05 timer relay wiring not verified post SS-II schedule.
MZN/0156 — All checksheets current. WSP self-test: 9.9/99. Clear.
WSP Health by OEM
⬇ Download Compliance
98.2%
First-instance downloads this week
Platform Modules
The platform is designed against the 26 fault categories and 5 maintenance schedules (D1, D2, D3, SS-I/II/III, and Wheel Shelling Response) defined in RDSO Circular No. MC/LHB/Brake dated 10.10.2023.
📱
Digital Checksheet App (Mobile)
Android/PWA app for SSE/JE field staff. Schedule-wise checklists (D1, D2, D3, SS-I/II/III) with mandatory photo capture per parameter. Offline-capable — works in pit lines without connectivity.
📡
WSP Data Auto-Download Module
Triggers mandatory WSP CPU data download at first instance of wheel shelling detection. Logs timestamp, coach number, depot, OEM, and fault codes. Alerts Sr. DME office if download not completed within defined SLA.
🔍
Fault Pattern Intelligence
Analyses downloaded WSP data and cross-references with checksheet observations. Auto-identifies recurrence patterns per coach, depot, and OEM. Feeds into the RDSO recommended Google Sheet discrepancy column — now digital.
🚃
Coach Monitoring & Defect Log
Per-coach digital history: every shelling instance, subsequent defect noted, maintenance action taken, and sign-off by SSE/JE. Coaches with repeated shelling auto-flagged for enhanced monitoring per RDSO action plan point (d).
🏭
Workshop Commissioning Checklist
Digital checklist for all workshop turnouts. Every coach commissioning triggers mandatory verification of all check-sheet parameters. Discrepancies auto-highlighted to respective PU and Workshop as per Sr. DME instruction (e).
📊
Sr. DME Executive Dashboard
Unified web dashboard with depot-wise incident counts, OEM-wise fault distribution, WSP download compliance rate, checksheet adherence %, and coach-wise defect trends — accessible anytime, any device.
RDSO Action Plan → Platform Feature Map
| RDSO / Sr. DME Instruction |
Platform Feature |
User Role |
Covered |
| (a) Checksheet for brake system examination to be vigorously followed |
Digital Checksheet App — D1/D2/D3/SS-I/II/III schedules with mandatory fields |
SSE/JE (Maintenance) |
✓ |
| (b) WSP data to be invariably downloaded at first instance of wheel shelling |
Auto-download trigger module with SLA alert to Sr. DME if not completed |
SSE + System Auto-alert |
✓ |
| (c) One column added in wheel sheet monitoring for discrepancy remarks |
Digital discrepancy remarks field in WSP data download log — replaces manual Google Sheet |
SSE/JE |
✓ |
| (d) Coaches with wheel shelling to be closely monitored; defects recorded |
Per-coach defect log with enhanced monitoring flag and follow-up task assignment |
Depot Incharge + SSE |
✓ |
| (e) All workshop turnouts to be checked for check-sheet items at commissioning |
Workshop Commissioning Digital Checklist — auto-notifies PU and Workshop on discrepancy |
Workshop JE + PU Admin |
✓ |
| WSP fault codes (13 categories × 3 OEMs) identification and reset |
OEM-specific fault code matrix — Faiveley, Knorr/KBI, Escorts — with reset verification log |
SSE/JE |
✓ |
| Speed sensor gap measurement (0.9–1.4mm at each axle) |
Per-axle measurement entry with tolerance check — flags out-of-spec readings |
JE (Maintenance) |
✓ |
Implementation Roadmap — 8 Weeks to Go-Live
Our implementation methodology is built around zero disruption to maintenance operations. Pilot deployment at LTT (highest shelling incidence) before rolling out to MZN and NCC WB.
01
Week 1
Discovery & Requirement Alignment
On-site workshops at LTT, MZN, and NCC WB depots. Interviews with SSE/JE (Maintenance) and Depot Incharges. Mapping of existing paper checksheet workflows to digital equivalents. Capture of all 3 OEM-specific fault code logic (Faiveley, Knorr, Escorts). Stakeholder sign-off on feature scope.
On-site Workshop
Stakeholder Interviews
OEM Fault Code Mapping
Deliverable: BRS Document
02
Week 2
Solution Design & UI Prototyping
Design of mobile checksheet UX for SSE/JE (field-optimised, large touch targets, offline-first). Dashboard wireframes for Sr. DME and Depot Incharge roles. OEM-wise fault code decision trees. Data model design for coach history and WSP download log. Presentation and approval from Sr. DME office before build begins.
UI Wireframes
Role-based Access Design
Data Model
Deliverable: Approved Prototype
03
Weeks 3–5
Platform Build & Configuration
Development of all 6 platform modules. Configuration of D1/D2/D3/SS-I/SS-II/SS-III checksheet templates per RDSO check sheet format. WSP auto-download trigger logic per OEM. Coach master data loading from depot records. Integration of alert engine for Sr. DME notifications. OEM fault code matrix configuration (Faiveley 14/24/34/44; KBI 13/23/33/43; Escorts 1.x/2.x/3.x/4.x series).
Backend APIs
Android Mobile App
Web Dashboard
Alert Engine
Deliverable: Test Build
04
Week 6
Pilot at LTT Depot — UAT
Controlled pilot with 3–5 SSE/JE staff at LTT (highest incidence depot). Parallel running — paper + digital — for one maintenance cycle. Feedback collection on field usability (pit line conditions, lighting, gloves). WSP download trigger tested against live coach data. Bug fixes and UI refinement based on ground-level feedback. Final UAT sign-off by Depot Incharge and Sr. DME nominee.
LTT Pilot
Parallel Running
Field Feedback Loop
Milestone: UAT Sign-off
05
Week 7
Training & Rollout — All 3 Depots
Role-specific training sessions: SSE/JE mobile app (2-hour hands-on); Depot Incharge web dashboard (1-hour); Sr. DME office executive dashboard (30-minute overview). Printed quick-reference cards for field staff. On-site Extraaaz engineer present at each depot for first live maintenance cycle. Helpdesk WhatsApp group activated.
On-site Training
Quick Reference Cards
WhatsApp Helpdesk
Milestone: All Depots Live
06
Week 8 → Ongoing
Stabilisation, AMC & Continuous Improvement
30-day hypercare period with daily check-in with depot incharges. Monthly data review report to Sr. DME with shelling incidence trend, fault category heatmap, and WSP download compliance. Quarterly feature updates incorporating RDSO circular changes. Annual Maintenance Contract covering uptime SLA, upgrades, and priority support.
30-day Hypercare
Monthly MIS Reports
Quarterly Updates
AMC Support
Key Deliverables
01
Android Mobile App for SSE/JE
Offline-capable field application with all D1/D2/D3/SS schedule checksheets, mandatory photo capture, WSP self-test recording, and auto-submission on connectivity restore.
02
Sr. DME Web Dashboard
Real-time divisional overview: depot-wise incidents, fault heatmap, WSP download compliance tracker, coach defect history, and pending checksheet alerts.
03
WSP Data Download Log
Structured digital record of every WSP CPU download — coach no., date/time, downloaded by, fault codes extracted, discrepancy remarks — replacing the manual Google Sheet system.
04
Per-Coach Defect History
Complete lifecycle log per coach: all shelling instances, maintenance actions, schedule compliance, speed sensor gap readings, and phonic wheel condition — accessible by any authorised officer.
05
Monthly MIS Report to Sr. DME
Auto-generated PDF report covering shelling incidence trends, top fault categories, worst-performing coaches, OEM-wise health index, and checksheet compliance percentage.
06
Training & Documentation
Role-specific user manuals (Hindi + English), quick-reference laminated cards for pit-line use, and video walkthroughs for self-training of new staff joining depots.
Built for Indian Railways Field Conditions
📴
Offline-First Design
SSE/JE can fill checksheets and record WSP data in pit lines with zero connectivity. Data syncs automatically when the device connects to depot Wi-Fi or mobile data.
🛡️
Role-Based Access Control
Granular permissions: field JE sees only assigned coaches; Depot Incharge sees full depot; Sr. DME sees all depots. Tamper-proof audit trail for every entry.
⚡
4–6 Week Deployment
Unlike heavy ERP systems taking 6–18 months, our rapid-deploy model gets LTT depot live within 6 weeks. No disruption to ongoing maintenance schedules during rollout.