Page 67 - Sattva_2025

Optimizing Efficiency Through Innovation:

Rollingstock Maintenance at KMRL

Praveen C & Rajashekhara P
DGM (Rollingstock)

At KMRL, the Rolling Stock Department has adopted an innovative hybrid

maintenance model that balances operational efficiency with strategic resource
utilization. Preventive and non-critical maintenance tasks are judiciously outsourced,

freeing up the in-house team to focus on critical, high-skill interventions. This approach
enhances workforce effectiveness while reducing operational overheads.

Maintenance is carried out in a staggered and optimised manner, shifting from rigid
time-based intervals to a mileage-based schedule. This strategy reduces unnecessary

interventions, thereby minimising train downtime and boosting overall fleet availability.

KMRL’s maintenance philosophy resonates with the principles of Total Productive

Maintenance (TPM) a holistic approach aimed at achieving zero breakdowns, zero
defects, and zero accidents. By incorporating condition-based monitoring and

predictive maintenance practices, KMRL empowers operators and technicians alike.
These practices not only support proactive fault detection but also help the team align

with broader TPM goals, such as autonomous maintenance, focused improvement,
and systematic planning.

KMRL does not adhere blindly to OEM-prescribed schedules. Recognising the distinct

challenges posed by Kochi’s coastal, saline environment, the team evaluates
component health before initiating maintenance. This condition-based approach

enables the safe, full utilisation of components while conserving manpower and
reducing part replacement costs. A prime example of this success: even after an

average of 5.5 lakh kilometers of running, not a single brake block has required
replacement due to wear—an impressive testament to the effective use of

regenerative braking.

In fact, KMRL achieves a regeneration energy usage of 36%, ranking it among the
highest in Indian metro systems. This focus on sustainability, combined with a robust

maintenance ethos, continues to drive reliability, safety, and cost-efficiency across the
Kochi Metro fleet.