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Journey towards Digital Transformation for Indian Railways workshops

10 minute read

Journey towards Digital Transformation for Indian Railways workshops

Indian Railways runs multiple overhaul workshops where coaches and wagons arrive for scheduled maintenance. These facilities are vast—often spread across hundreds of acres—and operate with a high daily movement of people, vehicles, and rolling stock. Despite their operational maturity, one problem remained persistent: limited real-time visibility of wagons and coaches inside the workshop. Location and status checks often relied on partial systems and manual effort, which slowed decision-making and created avoidable delays. In parallel, perimeter control and internal movement governance were also limited. With 4,000–5,000 workers moving daily through multiple gates and across designated zones, unmanaged movement created productivity loss and reduced operational control. Cidroy partnered with workshop stakeholders to deliver a practical, operations-first digital transformation—built around visibility, accountability, and execution discipline.

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The context

Indian Railways operates multiple large-scale overhaul workshops where coaches and wagons undergo scheduled maintenance. These facilities span hundreds of acres and see the daily movement of thousands of workers, vehicles, and rolling stock.

While operational processes were mature, workshop leadership faced a persistent gap: limited real-time visibility of wagons and coaches once they entered the workshop. Status checks depended on fragmented systems and manual follow-ups, slowing decisions and increasing turnaround time.

At the same time, movement governance inside the workshop—across gates, zones, and maintenance areas—was largely unmanaged. With 4,000–5,000 workers moving daily, this led to productivity loss and reduced operational control.

Cidroy partnered with workshop stakeholders to deliver an operations-first digital transformation focused on visibility, accountability, and execution discipline.

Indian Railways runs multiple overhaul workshops where coaches and wagons arrive for scheduled maintenance. These facilities are vast—often spread across hundreds of acres—and operate with a high daily movement of people, vehicles, and rolling stock. Despite their operational maturity, one problem remained persistent: limited real-time visibility of wagons and coaches inside the workshop. Location and status checks often relied on partial systems and manual effort, which slowed decision-making and created avoidable delays. In parallel, perimeter control and internal movement governance were also limited. With 4,000–5,000 workers moving daily through multiple gates and across designated zones, unmanaged movement created productivity loss and reduced operational control. Cidroy partnered with workshop stakeholders to deliver a practical, operations-first digital transformation—built around visibility, accountability, and execution discipline.
The challenge
  • Lack of real-time visibility of wagons and coaches inside large workshop premises
  • Heavy reliance on manual tracking, slowing decisions and increasing delays
  • Unstructured movement of workers and rolling stock across zones and gates
  • Limited entry/exit governance and delayed detection of workflow breaks
The CIDROY Solution

We implemented an operations-first digital system focused on automated visibility and control.

  • Digitized entry/exit and perimeter governance using CWMS, enabling centralized monitoring across multiple workshop gates
  • Automated wagon and coach tracking using RFID and industry-grade cameras, eliminating manual status updates
  • Custom software layer designed for Indian Railways workshop workflows, providing real-time visibility without adding operational burden

The solution was rolled out in phases, aligned with existing movement patterns and maintenance processes, ensuring zero disruption to daily workshop operations.

How We Delivered Value
  • Real-time visibility of wagons and coaches across the workshop, enabling faster and more confident operational decisions
  • Accurate time and movement tracking across maintenance stages, improving accountability and planning
  • Reduced workflow breaks through anomaly detection and alerts aligned to workshop process expectations
  • Centralized oversight for the Chief Workshop Manager, Deputy Chief Workshop Manager, and operational officers
  • Improved movement governance through digitized gate processes and perimeter surveillance using CWMS