CASE STUDY · ENGINEERING, MANUFACTURING & INDUSTRIAL
How a railway Wheel Shop moved machine records from paper registers to one portal with live dashboards and complete wheel history
Wheel Shop & CTRB Shop, Pratapnagar (Indian Railways)
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The Wheel Shop at Pratapnagar repairs and rebuilds wheel sets for railway wagons and coaches. Every wheel and axle passes through boring, turning, burnishing, dismounting and mounting machines, and each step has precise measurements. We built a portal where railway and contractor staff record every machine entry, and officers see live dashboards, the complete history of any wheel or axle, and machine-wise reports they can export to Excel.
The Challenge
- 5 machines, each with its own set of readings: bore size, taper, surface finish, wheel seat, journal and shoulder sizes, wheel pressure, interference and more
- Thousands of wheel sets a year, recorded in paper registers
- Finding the full history of one wheel or axle meant searching many registers
- Both railway staff and contractor staff do the work, and officers need to see each side separately
- Monthly and yearly figures by wagon type (BOXN, BLC, ICF, VVN) were counted by hand
- Drawings, process documents and machine papers were kept in different places
Our Solution
- Machine-wise data entry for Wheel Boring, Axle Turning, Axle Journal Burnishing & Turning, Wheel Press Dismounting and Wheel Press Mounting
- Four user roles (Admin, Railway, Supervisor, Contractor), with a secure API (JWT) for the shop-floor app
- Live dashboard: total employees, total entries this year and entries per machine, filtered by Railway, Contractor or both
- Global Search: type a wheel number or axle number and see its complete history across all machines, with every reading
- Category-wise donut and month-wise stacked charts for every machine, by wagon type
- Drill-down: click a wagon type (e.g. BOXN) to list every entry behind the number, split into Railway and Contractor
- Before-and-after readings: initial and finished journal and shoulder sizes, left and right, for every axle burnished
- Data Report: choose a machine, date range and employee; the table shows the right columns for that machine (up to 25+ readings per wheel) and exports to Excel
- Chart Report: monthly or yearly, by year and source, switchable between donut/pie and column/bar
- Library for shop layout, machine information, machine process documents and drawing documents (PDF and images)
The Results
- Every wheel and axle has one digital record from dismounting to mounting
- Complete history of any wheel found in seconds with one search
- Officers see live machine-wise and wagon-type-wise figures without manual counting
- Railway and contractor work tracked separately and together
- Reports ready in Excel for any machine, date range or employee
- All drawings and process documents in one place
