Quality Department

Quality Review
Meeting
10.02.08
Rail Coach Factory,
Kapurthala

Dimensional accuracy of
shells
Length

Coach
No.

Specif Actua
ed
l

2T/3T10

21337
10

21335

2T/3T11

21337
10

2T/3T14

21337
10

Width

Specif
ed

Actu
al

Vari
ation

Nil

3245
05

3243

21336

Nil

3245
05

21340

Nil

21337
10

21336

SCN-1

21337
10

Averag
e

21337
10

2T/3T18

Specif
ed

Actu
al

Vari
ation

Nil

3111.5
05

3108

Nil

3242

Nil

3111.5
05

3108

Nil

3245
05

3240

Nil

3111.5
05

3109

Nil

Nil

3245
05

3242

Nil

3111.5
05

3108

Nil

21332

Nil

3245
05

3242

Nil

3111.5
05

3110

Nil

2133
5

Nil

3245
05

3241
.8

Nil

3111.5
05

3108
.6

Nil

08.03.08

Vari
ation

Height

Quality Department

Quality issues of LHB

coaches reported by
different Coaching
Depots
Agenda Item no. 1

Failure of Spring Domes

Description of failure : Top Plate

thickness found in range of 7.7 to
10.2 mm against nominal thickness
of 14 mm ( min 12.7 mm with
specified tolerances). In one single
case thickness was found 5.2 mm
also.
Coaches affected : Out of 111,
total 29 coaches 8 ER + 21 NR (48
bolsters 14 ER + 34 NR ) require
replacement.
Corrective Action :
38 nos. of bogie bolsters
despatched to Railways (22 ER +
16 NR). Now ER commitment is
over.
Balance NR supplies shall be
despatched by Mar 08.
Preventive Action :
Top Plate thickness introduced as
a stage
inspection by RITES
08.03.08
Quality Department

Top Plate

CRACKS IN SOLE BAR NEAR YAW

DAMPER BRACKET

Description of failure : Cracks

developed in sole bar at yaw damper
bracket location. On some of the
coaches, the cracks have recurred.
Corrective Measures :
Cracks to be welded as per
Welding Procedure issued by M&C
Area getting cracked
Dte RDSO.
on sole bar
Yaw-Damper - check for
replacement.
Yaw-Damper - in correct
installation position
Additional stiffening measures for
affected coaches
Preventive Measures :
RCF to ensure welding using jigs
& correct
welding sequence.
08.03.08
Quality Department

Failure of Anti Roll Bars

Description of failure : Central bar of Anti
Roll Bar Assembly broke into 2 pieces
between bar center and fork.
Analysis of failure : Initial Failed sample 2
nos - were investigated by RDSO. Fatigue
failure in one sample and sudden failure in
second sample found. Improper HeatTreatment at X1000 magnification detected
as against X100 prescribed.
Conclusion : Design of Anti-Roll Bar is
considered adequate. Above failures are
attributable to external hits. Improper HeatTreatment accelerated failure.
Corrective action :
So far 5 Anti Roll Bars have failed in 5
different coaches. All replaced by RCF.
10 nos Anti Roll bars supplied to WR as
assistance.
Preventive action : As a precaution,
assessment
of
all
the
vendors
was
undertaken by Design Deptt. Out of 3
vendors, 2 vendors were down graded to part
- II.
08.03.08
Quality Department

Control Arm Corrosion & Wear

Proper torqueing to be ensured.
FIAT had recommended to use Swiss made Blasol135 lubricating oil during fitment to minimize wear
on control arm and avoid corrosion. This needs to be
ensured by zonal railways also.
Due to non-availability of Blasol-135, alternative lubricant
Cortec was being used by RCF.
Source for Blasol-135 located, procurement under
process.

If wear observed beyond permissible

values during POH, re-machining can be
done with cut of 0.3 to 0.5 mm on the
bottom face of control arm.
Service limits to be set jointly by CAMTECH
& RDSO.
08.03.08

Quality Department

Machine cut

77

Disc Brake System

1. Knorr Brake Caliper Jammed
Caliper pins changed to Stainless
steel from MS
Bushes changed to polyamide.
Cleaning and re-greasing once in a
year recommended by the firm
User railways are getting the
regreasing done on quarterly basis
on AMC
2. Biased Wear of Brake Pads
Jamming of calipers leads to
misalignment of Brake pads
thereby producing to biased wear
3. At Cut Off angle cock BP/FP worked
out / Leaky
08.03.08
Quality Department

88

Wheel Shelling
Railways have reported low life of
wheels due to wheel shelling. This
problem is currently under study
with RDSO.
Following action has been taken/
suggested by RDSO to Rlys. :
Brake cylinder pressure reduced to 3
bar from 3.8 bar
Material of wheel upgraded as per
RDSO spec R-19 rev 3. Procurement
started with new specification.
1100 discs (ER 638, WR 116, RCF 306)
received as per revised chemistry.
Fitment in LHB coaches commenced.
549 wheel discs in pipeline (345 ECR,
204 ER).
08.03.08

Quality Department

Bearing Failures
Bearings of both the make SKF and Timken are giving
problem
Railways to detach coach based on bearing temperature as
per guidance issued by RDSO (800 C Max.)

08.03.08

Quality Department

10
10

Bearing Failures
o Timken
o The Steel cage is suspected reason for low bearing
life
o Timken has proposed changeover to polymer cage
o Firm seeking RDSO approval for the same

o SKF
o The non contact type seals were suspected reason for
water ingress and failure
o The firm is now supplying with contact type seal
o The firm is replacing seals even in refurbishment
08.03.08

Quality Department

11
11

En-route detachments - Bearing Failure

S
No

Coach No

TRAIN
NO. /
MAKE

Date of
Despatch
Brg Life

LACCZ,
NR 99151

2003

DEC 99 (7 07. 03. 2007 07.03. 06

yrs +)
BHOPAL
JUDW

Initial Report Failure due to

breakage of roller cage. Exact
cause could not be established
in Joint Inspection.

ERLACCW05061

2302

DEC 05 (1 29.04.07
yrs +)
ALD

Not
available

Dislocation of in board seal

from its seating area resulting
in leakage of grease. A small
end of cage pocket was
found worn out causing
damage to bearing.
Exact cause could not be
established
in
Joint
Inspection
but
bearing
replaced by Firm

LWACCN
ER
05105

2301
SKF

FEB 06
(1.5 yrs )

IOHWrong fitment during IOH

23.07.07 AT
LLH

TIMKE
N

TIMKE
N

08.03.08

D.O..F
PLACE OF
FAILURE

21.08.07
Kanpur

Last POH/
IOH

Quality Department

Cause

12

Marking on Springs
Copper
Band

Al. Tape

Stampin
g

Al Tape Indicates
positive direction of the
alignment deviation
Copper Band Gives
length of the spring
under test load and the
value of the alignment
deviation
Stamping on flat
portion Gives month &
year of manufacture and
running serial number.

Pair No.
08.03.08

Quality Department

13
13

 Description of Problem : ER and WR

reported the problem of pairing of springs
during POH
Method for Pairing : Each flexicoil spring
is provided with the following markings ( as
per international standard ) :
The positive directions of the alignment
deviations is indicated with an aluminium
coloured tape (secured tightly and
wound twice around the spring)
The length of the spring under test load
and the value of the alignment deviation
(in mm) are printed on a copper band.
Brazing of bands being recommended to
the firms by Design Office ( currently
mechanical locking )

08.03.08

Quality Department

Pairing
of
Springs

14

Alignment Deviation ( Spring

Pairing )
The difference between the alignment
deviations of the two outer springs not to
exceed 4mm and that of the inner springs
8mm.
A - B = 4 mm max, C - D = 8 mm max
In addition, the outer and inner springs with
the greater alignment deviations must be
situated in the same spring assembly, that is:
If A greater than B, C should be greater
than D
A

C
08.03.08

Quality Department

B
15
15

Rerouting speed
sensor cable
Problem of Frequent failures
of Speed Sensors
Design changed similar to
Delhi Metro type
arrangement

Revised cable
route with
clamps

08.03.08

Quality Department

16
16

Frames
o RCF Practice
Frames being shot blasted

Elastified High Build Paint being

applied

o Repair
Method
Railways

for

Zonal

Proper cleaning to remove dirt,

grease and loose scales
Use rust converter to IS:13515-92
(Rustcon of Kesanch Marketing, New Delhi and
Rustonil of Trimurti Manufacturing, Allahabad)

Primer paint with M&C/PCN/123

(addl)
Paint with Elastified High Build
Paint as per MDTS-94
o

FEA results
little stress
08.03.08 show veryQuality
Department

17
17

 Description of failure :
There are 4 type of pins in FIAT bogie
o Safety Rope pin
o Curve Roll Pin
o Body-bogie connection pin
o Primary
Suspension
movement
limiting pin

These pins are generally found

jammed and can be removed with
great difficulty. In ICF coaches,
these pins are chrome platted.
Corrective action :
o Material is alloy Cr-Ni steel with
high yield strength Material of
failed pins to be checked. WR to
send failed pins to RCF.
o Ensuring cleaning as per LHB
documents
08.03.08

Quality Department

BOGIE
PINS

18

WEAR OF BRACKET
HOLE
Description of failure :
Securing pin for the
restriction of primary
suspension dimensions at
control arm end is moving in
the bracket, resulting into
wear of the bracket hole.
Corrective action : Correct set
of drawings to be used. It
incorporates the use of antirolling rectangular piece which
will not permit any rolling and
hence pin will not elongate the
hole.
08.03.08

Quality Department

19

Failure of Dampers
Proper torqueing to be ensured
Use
proper
corrosion
resistant
chemicals on threads left open after
assembly
Cleaning/washing of bogie at regular
intervals as per FIAT Spec T.S.17.617
100
Dampers to be replaced after 6 years of
service life. (major issue)
08.03.08

Quality Department

20
20

Air Brake & Water Pipes

Ballast hitting

Description
of
failure :
Stainless
steel pipe use in Air
brake
system
and
water
system
are
found bent or cracked
due to ballast hitting.
Corrective/Preventiv
e action : Thickness
of
steel
pipes
increased by 0.5 mm
in sizes OD 10 mm, 18
mm, 22 mm & 28 mm.
08.03.08

Quality Department

21

Air Brake System (Ferrule

Description
of Fittings)
failure
:
Existing Single Ferrule Fittings
at the end connections of FP, BP
pipes start leaking or get
disconnected at the time of
testing of system.

Corrective/Preventive action :
Providing
Double
Ferrule
Fittings instead of Existing
Single Ferrule type Fittings
may eliminate it.
5 coach-sets of double-ferrule
tube-fittings under
procurement as trial
08.03.08

Quality Department

22

Honey Comb Partition Frames

Description of failure : Sometimes
top layer of LHB honeycomb
partition frames works out at
screwed locations. Such cases are
difficult to rectify.
Corrective action :
Maintenance procedure obtained
from Honey Comb International,
Bangalore circulated to all Z Rlys.
Thereafter, W Rly sent its
supervisors for training at firms
premises and developed skills in
maintenance of Honey Comb
partition-frames.
Other Rlys also have been
informed to follow suit
Preventive action : Rationalisation
of back-piece sizes in honeycomb
partition frames at RCF.
08.03.08

Quality Department

24

Jamming of Loading door

(Luggage Door)
o Design Review : Loading
Door design has been
reviewed
Top rollers changed to
imported linear bearings
Material of all recoil springs
changed to stainless steel
To control derailing, bottom
roller reprofiled with easy
curvatures
Locking mechanism
modified for trouble-free
operation
o Trial of modifed door : One
modified door under trial in
Delhi Division (Coach
PC2851)
08.03.08

Quality Department

25

Main Entrance Door

o Window design made similar to that of compartment window for ease in
replacement
o Door locking mechanism made similar to conventional type
o Door handle also made similar to conventional door
o Nylon stopper provided to prevent over travel
o First coach (FAC) fitted with such doors being furnished currently

08.03.08

Quality Department

26
26

Lavatory Door Related Issues

Lavatory Door mechanism
problems

08.03.08

Single flap Pivoted at top and

bottom. Being fitted since
2007

Quality Department

27
27

Industrial Locks not being ftted

as per drg
Four locations where industrial locks are
used are
Lavatory Ceiling
Diffuser Panels
Attachment Walls
Doorway/Gangway Panels
Areas where Problem resolved
Quarter Turn Fastener (Southco make)
switched over in Lavatory Ceiling
Cam Locks (Southco make) switched
over in Diffuser Panels and Attachment
Walls (CDTS Instrumentation Panel)
Areas where Problem yet not resolved
Cam Locks (Southco make) in
Doorway/Gangway Panels

08.03.08

Quality Department

28
28

Description of Problem : Longitudinal

jerks
Corrective/Preventive action :
Reduction in Pre-load : Pre-load of
draft gear reduced to 50 kN from 77
kN
Trial of Dellner couplers : 60
Dellner couplers are being tried out
Balanced draft gear
Muff coupling between coupler and
draft gear
Expected by Jun 08
Trial of soft side-buffers : 20 coach
set soft buffers are being fitted on trial
10 coach sets received. Rest by
beginning of Mar 08.
08.03.08

Quality Department

due to
CBC

FAIVELY CBC

ASF KEYSTONE
29
CBC

Lavatory Related Issues

Accumulation
of water

08.03.08

Additional drain hole As short

term measure
Raised portion of pan seat
eliminated Long term measure

Quality Department

30
30

Lavatory Related Issues

Space above
washbasin and at
entrance area

08.03.08

o Light fitting shifted above mirror

to release space above wash
basin short term
o Re-orientation of washbasin shelf
Long term

Quality Department

31
31

CDTS Related Issues

Chocking of toilets due to
top slide valve not
functioning

Flapper valve
introduced

Water dripping on PLC of

CDTS in both AIKON &
Vibhu make

PLC encased in box

since July 07

Spillage of water during

closing of flapper valve in
Vibhu make

Closing Speed
controller provided in
circuit

Working out of water filter

cap in AIKON

Y-type Brass filter

introduced

08.03.08

Quality Department

32
32

Process Audit at
Suppliers premises
Agenda Item no. 2

Process Audit (17 frms

o Gaurav
Associates,
since
Sep 07)
LHB fuel tanks,
Noida

Fabrication
components etc.
Spring Dome &
o Plasto Power
Wearing plate
Engineeer, Sangrur
Z Type carline
o Competent

Engineers,
End wall
Jalandhar
construction
o Neera Enterprises,
Chandigarh
Spring Dome, Single
o Alvind Industries,
piece Bracket
Chandigarh
Anti Roll Bar, Screw
o Emson Tools Mfg.
Coupling, BSS
Corp. Ltd, Ludhiana Hanger
08.03.08

Quality Department

34

Process
Audit
o Sarita
forging Pvt.

Anti Roll Bar

o
o

Anti Roll Bar

FRP Components

o
o
o
o

Ltd. , Ludhiana
VT Cottage, Goraya
Anurag Engineers,
Meerut
CRG Industries,
Baddi
Rubicon Steels,
Mohali
Rail Fab, Kapurthala
Kansal Industries,
Chandigarh
08.03.08

FRP Components
SS water tanks ,
Battery box
complete
Al Water Tank
Al Water Tank

Quality Department

35

Process
Audit
o Rail Master, Opposite

Seats & Berths

Seats & Berths

o
o
o

RCF, Kapurthala
Competent
Engineers, Jalandhar
Amit Engg, Mohali
Mohan Singh and
Company, Kartarpur
Mohan Rail
Component Pvt. Ltd,
Kapurthala.

08.03.08

Al Water Tank
Seats & Berths
Seats & Berths

Quality Department

36

Quality of Welding
especially in critical
load bearing areas
Agenda Item no. 3 (i)

QUALITY OF WELDING IN SHELL / MFG

SHOP
There has been improvement in welding quality in following
areas since last quality meeting held in :

S.
No

AREAS OF IMPROVEMENT

01

Trough floor welding in conventional coaches

02

Welding of side bearer conventional coaches

03

Welding of Yaw Damper Bracket of LHB coach.

04

Welding between end wall and head stock conventional coaches

05

Welding between back piece and body pillar conventional

coaches.

06

Welding of chair pillar supports and FL brackets with carlines

conventional coaches.
08.03.08

Quality Department

38

QUALITY OF WELDING IN SHELL / MFG

SHOP
There has been improvement in welding quality in following
areas since last quality meeting held :

AREAS

PROCESS IMPROVEMENT

Trough floor
welding in
conventional
coaches

oRegularised the use of Argon mixture

90 : 05 : 05 (Ar+CO2+O2)

Welding of side
bearer in
conventional
coaches

o Removal of paint & Grease from the area

to be welded
o Ensuring no gaps between side bearer
and body bolster
o Ensuring uniform weld size all around
the circular periphery
o 8-10 side bearers were welded in
presence of CMT

08.03.08

Quality Department

39

QUALITY OF WELDING IN SHELL / MFG

SHOP
AREAS

PROCESS IMPROVEMENT

Welding of Yaw o Grinding of edges of Yaw Damper

Damper Bracket Bracket for
of LHB coach.
flatness.

08.03.08

Grinding of sole bar joint to ensure flat

o
placement
of sole bar.
o
Centre to centre alignment of the set of
console
by calibrated jig.
o
Tack weld
o
Pre-heating of Yaw Damper Bracket
and sole bar
by gas flame at approx 150 deg C near
weld area.
Department
40
o
FullQuality
welding.

QUALITY OF WELDING IN SHELL / MFG

SHOP
AREAS

PROCESS IMPROVEMENT

Welding between end wall

and head stock
conventional coaches

o Regular interaction and

counselling with
welders for adopting correct
welding
parameters (voltage, current,
etc.) and
procedure.
o 8-10 head stocks were welded
in presence
of CMT

Welding between back

piece and body side pillar
conventional coaches.

o Welding process changed from

MMAW
to CO2 welding.

08.03.08

Welding of chair pillar

Quality Department

41

o Welding of chair pillar supports

QUALITY OF WELDING IN SHELL / MFG

SHOP
Areas still needing improvement in conventional coaches :
AREAS

IMPROVEMENT
REQUIRED

REMARKS

Welding of turn under,

sliding door sill, door
latches and window bars

CO2 welding
To improve the
process required
strength of weld
instead of MMAW joint and quality
process

Cant Rail welding

Calibrated jig
required

MMAW vs CO2

MMAW process to For better

be phased out
quality of weld

Cleaning of MMAW weld

joints

Removal of slag
and subsequent
rectification to be
done, if required

08.03.08

Quality Department

To control
distortion

For better
quality of weld
42

Shop Practices requiring

correction
Ammeter and
Volt meter
installed but not
working in
welding set
which is in use
Three leads are
connected to
single welding
set
08.03.08

Quality Department

43

Shop Practices requiring

correction
Welding set in
tilted position

Improper
posture of
welder
08.03.08

Quality Department

44

Poor quality of welding

Poor quality of
welding of foot
step

Irregular bead,
blow holes,
spatters of weld
joint of sole bar
and End
Stanchions
08.03.08

Quality Department

45

Poor quality of welding

Lack of fusion,
uneven weld joint,
missing areas of
welding, hanging
of metal along
with slag
Poor condition of
weld after removal
of slag in partition
frames
08.03.08

Quality Department

46

Improved Weld Joints

Good quality of
welding of foot step

Welding between
head stock and sole
bar improved by
personal
interaction of
quality wing
08.03.08

Quality Department

47

Improved Weld Joints

Perfect welding
of side bearer
with body
bolster.

Welding after
pre-heating

08.03.08

Quality Department

48

Improved Weld Joints

CO2 welding
introduced in
welding between
back piece and body
side pillar
CO2 welding
introduced in
welding between
light bracket and
carline
08.03.08

Quality Department

49

Improved Weld Joints

CO2 welding
introduced in
welding
between chair
pillar support
and car line

08.03.08

Quality Department

50

Missing back-pieces
in Partition Frames,
sidewalls & roof

Agenda Item no. 3 (ii)

MISSING BACK PIECES IN

SHELLS
Analysis of missing
back pieces in partition

frames, side wall, roof and end walls was done

for Feb08 production.
Summary
No case of back pieces missing in LHB , SCN
and GS coaches
A total of 27 coaches reported with missing/
wrongly located back pieces
Coach wise classification
GR coaches- 22 cases
Composite coaches02 cases
SLR coaches02 cases
ACCN
case
08.03.08 coach- 01
Quality
Department
52

MISSING BACK PIECES IN SHELLS

(contd)
Subassembly wise classification:
End wall 14 cases (trade item)
Side wall
09 cases (shop item)
Partition frame04 cases (trade item)
Action Plan : Special efforts in GR coaches
which is the major contributor as on date. This
will be done by :
Stricter inspection by shell QC
Educating the vendors (for trade items like
end wall and partition frame)
08.03.08

Quality Department

53

Undulations in
sidewalls &
endwalls
Agenda Item no. 3 (iii)

Undulation In End Wall

Assembly
o ECBT & Railtech process-audited so far
o Correct endwall manufactured at ECBT with the help of
RCF team of supervisors. Shram Shree awardee Sh.
Balwinder Singh, SSE, headed the team ( 1 coach-set)
o Meeting by Dy.CCMT with end wall vendors fixed on
12.03.08

Before process-audit
08.03.08

After process-audit
Quality Department

55

Undulations in Side Wall

Audit of Skin-Tensioning process introduced ( 2/month) CMT
Sources of Undulations
Raw material.
Stress developed during fabrication.
Deviations w.r.t prescribed WI PLW 0000 :

Cl.No.

Process

Deviation

11.4

o Pre- straightening in cold condition Not followed

11.4.2.1
11.4.2.2

o Segment wise heating above &

Not followed
below the window areas (4)
Not followed
o Heating from top to bottom of each Not followed
segment (25-30 mm)
o During heating the depressed
areas should be brought outside by
hitting from inside with the help of
bar.
08.03.08

Quality Department

56

Undulations in Side Wall

Cl.No
.

Process

Deviation

11.4.2 The area between body pillars is to Not followed

.3
be spot heated at a time
11.4.3 Dent removal after straightening
o After denting straightening shall
be carried out by feeling the
troughs and crest by hand.
o Entire coach body to be again
straightened after checking
with the help of a straight edge.
o The depressed spots where
hitting is not possible from
inside, an iron pull rod to be
used.
08.03.08

Quality Department

Attended
some times in
case of
unusually big
dent
Not followed

Not followed
57

Control Over Undulations By Skin

Tensioning
Data of skin tensioning of shell of audit Check in
Feb 08 (Flatness tolerance = 3 mm over 1200 mm)

Out of
Range
Readings

Within
Range
Readings

Total
Readings

31

110

141

08.03.08

Quality Department

58

Dimensional
accuracy of shells
Agenda Item no. 3 (iv)

Cabin Width Variation

08.03.08

Quality Department

60

Flaking of paint in
ICF coaches
Agenda Item no. 3 (v)

Problem of Peeling / Flaking Of

Paint

Quality wing (ACMT ) has studied the problem of

peeling/flaking of paint and advised process improvement

S
Stage
N
1 Surface
preparation
by shot
blasting

Shortcomings in
Action
Process
recommended
Unblasted areas
Adequate shot
such as turn under, blasting
end wall, isolated
locations of roof

2 Cleaning of
shell after
shot blasting

Dust remains on
the surface of shell

3 Application of Single coat applied

primer on roof
4 Application of Wet on wet
08.03.08
Quality Department
Putty
application of two

Air pressure to
be incorporated
in WI
Double coat as
per WI
Hard dry time
62
to be ensured

Problem of Peeling / Flaking Of

Paint
S
Stage
N
5 Application
of PU
surfacer

Short comings in
Action
Process
recommended
Applied on wet
Hard dry time
surface of NC putty should be ensured

6 Application
of PU top
coat

Satin blue top coat

is applied on not
fully hard dried PU
surfacer

Hard dry time

should be ensured

7 Application
of
Aluminium
paint

Cleaning of
overspray on the
roof not done.
Single coat applied

Cleaning to be
done for proper
adhesion.
Double coat as
per WI
63

08.03.08

Quality Department

Defciencies in Seats
& Berths like rexine,
stitching, SS fttings,
slot for catch in backrest, etc.
Agenda Item no. 3 (vi)

Finish of FRP
components & cutting
quality of their edges
e.g. attachment wall,
etc.
Agenda Item no. 3 (vii)

FRP COMPONENTS : LHB

COACHES

CEILING SHEETS

MODULAR
08.03.08
TOILETS

SIDE WALL
PANELS

ATTACHMENT
Quality Department WALL

66

FRP COMPONENTS : LHB COACH

FRP TREY FOR

BATTERY BOX

LAV MODULES

WINDOW HOLDING FRAME

08.03.08

Quality Department

67

Common Defects in FRP

Components

Cracks & delamination

Color variation & poor gloss
Poor Finish
Dimensional Variation
Paint Peeling off
Less Fibre
Less Tensile & Flexural strength
Tight movement of louvers and glass
shutters (windows)
08.03.08

Quality Department

68

Cracks & De-lamination

Cracks and De-lamination

08.03.08

Quality Department

69

Color variation , Poor gloss and

Poor Finish

Colour variation and Poor

finish
08.03.08

Quality Department

70

Paint Peeling off

Paint peeling of

08.03.08

Quality Department

71

Poor stacking of Window Holding

Frame and Ceiling Sheets

08.03.08

Quality Department

72

Storage of Side wall Panels

Desired
Packing

08.03.08

Quality Department

73

Packing and Storage of FRP

components
Poor handling and stacking

Desired packing

08.03.08

Quality Department

74

S.NO

FRP Lavatory Module (Firmwise

defects)
Supplier name

Supply in
last 3
years

Quality

Problems

1.

ANKUR FIBRES

1644

Delamination and
breathing effects
observed. Dimensional
variation

CRG INDUSTRIES

299

Delamination and
Cracks observed.
Dimensional variation

3.

JAGDAMBA
ENTERPRISES

2514

Delamination and
Cracks observed.
Dimensional variation

4.

ROTATORY
ELECTRICALS
08.03.08

2299

Breathing effects
observed. Dimensional
Quality Department
75
variation

FRP Window Cowl (Firmwise

S.No
Supplier name
Supply in
Quality Problems
last 3
defects)
years
years

GEE PEE
ENGINEERING
INDUSTRIES
KAE ENGINEERS PVT.
LTD.

30

Dimensional variation
observed

1504

De-lamination and
Dimensional variation
observed

3.

JAGDAMBA
ENTERPRISES

1461

De-lamination, Poor
finish and Dimensional
variation observed

4.

ROTATORY
ELECTRICALS

578

Crack and Dimensional

variation observed

1.

2.

08.03.08

Quality Department

76

S.N
o.

FRP WINDOWS (Firmwise

Supplier name defects)
Supply
Quality Problems
in last
3 years

1.

AG FIBROTECH (P) LTD,

HOWRAH

23122

Cracks, Continuous
burning and Dimensional
variation observed

CALSTAR STEEL LTD.

HOWRAH
A.B COMPOSITES
PRIVATE LIMITED,
HOWRAH
CENTURY POLYMER
INDUSTRIES, HOWRAH

670

Less bending strength

and fibre contents

399

Cracks and Dimensional

variation observed

16509

Cracks, Poor finish , color

variation and
Dimensional variation
observed

3.

4.

5.

6.

FIBRO PLASTICHEM
548
Less bending strength
(INDIA) PVT. LTD.
and fibre contents
HOWRAH
08.03.08
Quality Department
77
GENERAL INDUSTRIES,

S.N
o.

FRP WINDOWS (Firmwise

Supplier name
Supply
Quality Problems
defects)
in last
3 years

7.

HINDUSTAN FIBRE
1895
GLASS WORKS, HOWRAH

Cracks, Less bending

strength and fibre
contents
and Dimensional
variation observed

JKS FIBRE - GLASS (P)

LTD, HOWRAH

8,401

Cracks, Less bending

strength , Paint peeling
off , Less fibre contents
and Dimensional
variation observed

10

MOHAN RAIL
COMPONENTS (P) LTD,
KAPURTHALA
MACEDON VINIMAY
PVT.LTD HOWRAH

2699

Cracks and Dimensional

variation observed

12763

Cracks and Dimensional

variation observed

11

08.03.08

Quality Department

78

FRP WINDOWS (Firmwise

defects)
S.No.

Supplier name

Supply
Quality Problems
in last 3
years

13

URBANE
INDUSTRIES,
CHENNAI

1170

Cracks, less fibre and

Dimensional variation
observed

14.

RAIL MASTERS
KAPURTHALA

1589

Cracks, less fibre and

Dimensional variation
observed

15

RAIL TECH,
KAPURTHALA

14,192

Less bending strength ,

less fibre contents and
Dimensional variation
observed

08.03.08

Quality Department

79

FRP Ceiling Sheet (Firmwise

S.No. Supplier name defects)
Supply in Quality Problems
last 3
years

1.

KINECO

70

Cracks observed

2.

SIMBA

91.5

Paint peeling off and

Dimensional variations
observed

3.

Gee Pee Engg,

New Delhi

3.00

Colour variation and

Dimensional variations
observed

4.

Tech Force
14
Composite, Indore

De-lamination, Dimensional
variations and less TS
observed

5.

KAE Engg, New

Delhi

36.00

Dimensional variations
observed

6.

Hindustan Fibre,
Vadodara
08.03.08

39

Less fibre and Dimensional

variations observed
Quality Department
80

Material quality of
FRP Windows for
non-AC coaches

Agenda Item no. 3 (viii)

PACKING OF FRP WINDOW

IMPROPER

PROPER
HDPE FOLLOWED BY
CARDBOARD
PACKING
08.03.08

WITHOUT HDPE WITH

CARDBOARD ONLY

Quality Department

82

CRACKS ON LOUVER

08.03.08

Quality Department

83

CRACKS &POOR FINISH

08.03.08

Quality Department

84

Gaps & less fbre at

edges

GAPS
08.03.08

LESS FIBRE AT THE EDGES

Quality Department

85

Corrosion On Equalising
Mechanism

CORROSION

08.03.08

Quality Department

86

Proper slopes in
Lavatories
Agenda Item no. 3 (ix)

VARIATION IN LAV SLOPE

Following causes of variation in slope
have
been identifed

LHB
Variation in level of front part (from 05mm to
25mm). It should be flat
Vertical bulging above two pillow blocks just
below Indian style lavatory pan. After
lowering of the lavatory module on front
part. This results in raised level of SS
Lavatory pan with respect to lavatory floor
on fitment.
08.03.08

Quality Department

88

VARIATION IN LAV SLOPE

Following causes of variation in slope have
been identifed

CONVENTIONAL
Variation in level of head stock members up
to 20mm. This results in unwanted slope of
lavatory module base. It should be flat as
per drawing.
Heavy variation in slope of lavatory module
(inlay). Some of the inlays have been found
to have even negative slope at few
locations.
08.03.08

Quality Department

89

Quality of rubber
beadings & their
fxing
Agenda Item no. 3 (x)

SLIDING DOOR

DEGRADED RUBBER
08.03.08

Quality Department

91

ALUMINIUM WINDOW FOR RA COACHES

UPROOTING OF RUBBER TUBING

08.03.08

Quality Department

92

POOR PASTING OF RUBBER BEADING

08.03.08

Quality Department

93

Thanks
08.03.08

Quality Department

94