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KAY SONS ELECTRICALS PVT LTD

VARANASI INDIA

QUALITY ASSURANCE PLAN

FOR

CONTROLLER ASM DYNAMIC BRAKE WITH BEZEL ASM

MODEL NO. KSEL/R2/001

AN ISO 9001:2008 CERTIFIED ORGANAZATION


FOR CONTROLLER ASM DYNAMIC BRAKE WITH BEZEL ASM

Revision No. 03

Title Table Contents Date 04.12.2012 Section No. QAP : TC Page No. 2 of 45

Sl.No. Section No. Title Page No.

1 QAP: TC Table of Contents 2 2 QAP:CONF Confidentiality 3 3 QAP:CP Company profile 4-5 4 QAP:CC Certificate of conformity 6 5 QAP : QC Quality Control 7 6 QAP:ORG Organization Chart 8 7 QAP:QKP Qualification of Key Personal 9 8 QAP:PFC Process Flowchart 10-11 9 QAP- Section-D Detail of Su Assembly /Components manufactured in house and out sourced Items 12

10 QAP:01 Inward Inspection Test Format & Production Planning 13-16 11 QAP:SP Sampling Plan 17 12 QAP:02 Quality Assurance System – Inspection and Testing Plan Product Control 18-36 13 QAP:03(TR) Test Reports (Final Testing In House of Product ) 37-41 14 QAP: CC& WF Customer Complaints & Warranty Failure 42 15 QAP:WIS Work Instruction for Soldering 43 16 QAP:WIM Work Instruction for Mechanical assemblies 44 17 QAP:WIW Work instruction for wiring 45

KAYSONS ELECTRICALS PVT. LTD. Prepared & Reviewed by Approved by

QUALITY ASSURANCE PLAN FOR


Revision No. 03

Title Confidentially Date 04.12.2012 Section No. QAP : CONF Page No. 3 of 45

CONFIDENTIAL DOCUMENT

This document is the property of KAY SONS ELECTRICALS PVT. LTD. No. portion of this document can be copied without written permission of the Managing Director of Kay Sons Electricals Pvt. Ltd.

These documents are issued to RDSO for their reference Only.

Copy No. : Issued to : RDSO

01 (Research , Design & Standards Organization ) Manak Nagar, Lucknow

For : KAY SONS ELECTRICALS PVT. LTD., (RAVI GUPTA) (Managing Director ) Office Seal :

KAYSONS ELECTRICALS PVT. LTD.

Prepared & Reviewed by Approved by



Revision No. 03

Title Company Profile Date 04.12.2012 Section No. QAP : CP Page No. 4 of 45

INTRODUCTION

Ours is a small –scale industries engaged in design, development, manufacture and supply of sophisticated custom built Electrical, Electro Mechanical & Electronics Equipments at a very competitive price to Indian Railways for last 20 years. Company Registered with Resistor of Companies U.P. in 1991 vide registration no. 20-12984 Dt.02.04.1991. It started operations in 1992.

We have a strong technological base for designing and manufacturing of power electronics and control equipments.

Ours is an ISO 9001:2008 firm certified by Management System Certification Body vide Registration No. R91/108 when we are continues till date. (QSCert).

Kay Sons Electricals Pvt. Ltd. has strictly adhered to quality standards and years of trouble-free service our equipment have put in, can vouch for this fact. Stringent Inward component checks, in process inspection of drilling, Machining, Assembly and required checks are routine in our Quality Control Procedures.

With the transfer of EMD Locomotive Technology from USA to DLW Varanasi For manufacturing of WDG4/WDP4 Locomotives.

We got BIS Certification for use of ISI Mark on our Conduit pipes vide License No. CM/L-9283487 as per IS 9537 Part 2:1981.

Our Company Excise Registration No. AAACK9725D XM001

VAT Registration No. 09983800587 Dt. 03.06.1992

CST Registration No. VN-5236176 Dt. 03.06.1992

Import /Export License NO. 1592000444 Dt. 08.07.1992

All the items manufactured by us are conforming to relevant IS/ BS/ ASTM/ DLW/RDSO Specification and Drawing and serving to DLW/Indian Railway with excellent

reputation for quality and timely delivery for last many years.

We are having in house design and Development facilities for development of new products supported by engineers and consultants within the country and abroad.




Revision No. 03

Title QUALITY POLICY Date 04.12.2012 Section No. QAP : QP Page No. 5 of 45 Our Quality Policy: “To improve the quality of Products through continuous improvement in quality of raw material, manufacturing techniques and effective quality management system to enhance Customer satisfaction.” Our Objectives: The policy is developed through the following Quality Objectives:

1. Product design to meet customer specification and ease of production with technology up – gradation.

2. Adequate Vendor/Trader evaluation and monitoring the performance to ensure quality of incoming material.

3. Adherence to specification at different stages, product and assembly with aim of defect prevention.

4. Training and involvement of employees in development, implementation and improvement of quality system.

5. Continual reduction in customer complaints.

6. Monitor effectiveness of implementation of quality system.

7. Interaction with customers to increase order position.




Revision No. 03

Title Certificate of Conformity & Capacity Date 04.12.2012 Section No. QAP : CC Page No. 6 of 45

Product CONTROLLER ASM DYNAMIC BRAKE Manufactured By M/S KAY SONS ELECTRICALS PVT. LTD. Model No. KSEL/MC/R2/001 Brand KEPCO Specification No. DLW Specification No. WDG4/EL/PS/7 Dated 12.02.2002 DLW DRG.NO. DRG. No. 40055299 ALT. Ab P.L.No. 17050455 Application B.G. Main Line Diesel Electric Locomotives (WDG4 /WDP4 Locomotives ) Capacity of Monthly Production 60 Nos. Capacity of Yearly Production 720 Nos. to 750 Nos. The above product have been Inspected and Tested according to above specification and found meeting all the requirements. The Product is conformed to Specification and drawing as said above




Revision No. 03

Title Quality Control Date 04.12.2012 Section No. QAP : QC Page No. 7 of 45

The policy is developed through the following Quality Objectives:

1. Product design to meet customer specification and ease of production with technology up – gradation. 2. Adequate Vendor/Trader evaluation and monitoring the performance to ensure quality of incoming material. 3. Adherence to specification at different stages, product and assembly with aim of defect prevention. 4. Training and involvement of employees in development, implementation and improvement of quality system. 5. Continual reduction in customer complaints. 6. Monitor effectiveness of implementation of quality system. 7. Interaction with customers to increase order position.


SECTION -A QUALITY ASSURANCE PLAN


Revision No. 03

Title ORGANAZATION CHART Date 04.12.2012 Section No. QAP : ORG Page No. 8 of 45

MANAGING DIRECTOR

DIRECTOR

GENERAL MANAGER FA& C. A. O. Marketing Manager Quality Control R & D Head Material Production Manager

Account Officer-I Account Officer-II

Product Design Group In charge QC

Production Supervisor Production Supervisor

Marketing Ex.-I Marketing Ex.-II Marketing Ex.-III Marketing Ex.-IV In charge Store Purchase Supervisor

Inward Q.C. Inspector Testing Supervisor Final QC Inspector


SECTION -B



Revision No. 03

Title Qualification of Key Persona Date 04.12.2012 Section No. QAP : QKP Page No. 9 of 45 Pat I:

Sl.No. Requirement as per STR/Spec. Details of Personnel employed STR/Spec Para

No. Qualification Specified in Spec/STR

Experience Specified in Spec/STR

Name Designation Qualification Experience Brief Scope of Responsibilities

STR/ Spec.

Para

1 NIL NIL NIL NIL Uma Shankar Head R&D Head QC

Diploma 40 Year Design & QC

2 NIL NIL NIL NIL Rajesh Rao Incharge QC BE 12 Year QC Skill & Measurement & testing

3 NIL NIL NIL NIL Ramchandra Yadav

Final QC Inspection Diploma 6 Year Testing

4 NIL NIL NIL NIL Ajay Mishra Testing Supervisor Diploma 6 Year Testing 5 NIL NIL NIL NIL Kariyappa Testing Supervisor Diploma 12 Year Testing 6 NIL NIL NIL NIL Murgesh Testing Supervisor BE 10 Year Testing 7 NIL NIL NIL NIL Anand Testing Supervisor BE 4Year Testing

Part II: Not Applicable


SECTION –C PROCESS FLOW CHART


Revision No. 03

Part I: Process Flow Chart


Customer Specified PO Copy

Head R & D Head Materials Head Production

Reject

Mechanical Supplier

PO’s to Supplier s & Vendors

Electrical Supplier

Check according to Drawing by IE

Production Planning

In Process Q.C.

Re work

Store Inward Q.C

Final Integration of all sub Assembly

Final Testing With Test Report

OK

REWORK

Final Testing

Fitment of Bushes, ARM Assembly , Lower Shaft Assembly, Cam Shaft Assembly , Left Hand Gear & Right Hand Gear Assembly, Reverser Gear & Lock ASM , Read Out Drum Assembly , Fitment of Upper Shaft ASM , Partition Plate ASM, Switch Assembly , Brush Silver Graphite Assembly

Rheostat Plate Sub -ASM

Customer or Third Party Inspection

Electrical Sub –Assembly Mechanical Sub Assembly

Plug & Cable Sub -Assembly

Batch Rejection Finish Goods Packing & Forwarding

Dispatch to Customer

Reject

OK

In Process Q.C.

NC

OK

Re work

In Process Q.C.

NC

Re work NC

OK OK

OK

OK

OK

NC NC

ABBREVIATIONS NC- Non Conformity Rej.- Reject O.K. Accept TPI. Third Person Ins.



Revision No. 03

Title Section C Date 04.12.2012 Section No. Page No. 11 of 45 Part II : Brief Description of Different Manufacturing Process mentioned in flow Chart – OK Part III : Not Applicable


SECTION- D



Revision No. 03

Title Detail of Sub –Assemblies /components manufactured in house and outsourced Date 04.12.2012 Section No. D Page No. 12 of 45 Part –I :

Sl.No. Item Name Remark 1 Plug & Cable ASM

2 Read Out Drum ASM

3 ARM Assembly

4 Lower Shaft Assembly

5 Cam Shaft Assembly

6 LH Gear & RH Gear Assembly

7 Reverser Gear & Lock Assembly

8 Upper Shaft Assembly

9 Partition Plate Assembly

10 Brush Silver Graphite ASM

11 Bezel Assembly

12 Rheostat Plate Assembly

13 Rod Assembly

14 Sleeve & Slide assembly

Part –II : Not Applicable Part –III : Not Applicable


SECTION -E QUALITY ASSURANCE PLAN


Revision No. 03

Title Procedure for Inspection & Testing of Incoming material (Inward Inspection ) Date 04.12.2012 Section No. QAP : 01 Page No. 13 of 45

Part –I : Document No. KSEL/MC/R2/000 Date : Name of Material : EMD Part No. : KEPCO Pt. No. : Sample Plan :

Incoming No.____________ Date:__________ Batch No .__________ Date:__________ Vendor Details.___________________ Invoice/Challan No.__________ Date:__________ P.O.No. ___________________________ Date:___________ Qty Received : ____________ Sample Qty:----------------------------- Parameters Checked

Sl.No. Check Point Specified Observation Remarks 1. Visual Checking 2 Dimensional Checking 3 Material


Qty. Sample Size 1-10 5 11-25 15 26-50 35 51-100 75



Revision No. 03

Title Procedure for Production Date 04.12.2012 Section No. QAP : 01 Page No. 14 of 45

Step I

PRODUCTION MONTHLY PLAN

P.O.No. D.P. Product. Name Qty. for Month Consignee Remarks

Step II

Production Requisition Pleas Issue the Following Material For :-

Sl.No. Description of Material Qty. Required Material Required Issue Remarks




Revision No. 03

Title Procedure for Inspection & Testing of Incoming material Date 04.12.2012 Section No. QAP : 01 Page No. 15 of 45

Sr. No. Component Operation

Characteristic Classification Type of Check

Q.C. R.D. For Agency

1 Housing Visual Check Dimension check Material check

C C C

V V T

100% Sample

1Pec each Lot

KEPCO /R& D /Specification /Revision/Drg.

KEPCO /QC

QC

2 Gears Visual Checks No. of Teeth Dimension check Hardness

C C C B

V V V T

100% As per sampling

Plan


KEPCO /QC

QC

3 Shaft Visual Checks Dimension check Hardness

C C B

V V T


Plan


KEPCO /QC

QC

4 Switch Visual WTC

C B

V V

100% 100%


KEPCO /QC

QC

5 Heat Sinks Visual Check Dimensional Check

C V V

Sample KEPCO /R& D /Specification /Revision/Drg.

KEPCO /QC

QC

6 Bush Visual Checks Dimension Hardness

C C B

V V T


Plan


KEPCO /QC

QC

7 Pins Visual Checks Dimension Hardness

C C B

V V T


Plan


KEPCO /QC

QC

8 Connector and Accessories

Visual Check C V Sample KEPCO /R& D /Specification /Revision/Drg.

KEPCO /QC

QC

9 Hardware Visual Check Dimensional Check

C V

V V

Sample KEPCO /R& D /Specification /Revision/Drg.

KEPCO /QC

QC

10 Sub Assemblies Visual Check Dimensional Check

C V Sample KEPCO Drawings KEPCO Procedure

P.D.

11 Mechanical Sub Assembly

Visual & Dimensional Check

C V Sample KEPCO Drawings KEPCO Procedure

P.D.




Revision No. 03


The following are the list of tests conducted on Controller ASM Dynamic Brake

1. Visual Inspection 2. Tolerance & Dimension 3. Insulation Resistance Test 4. Di- electric test 5. Performance Test 6. Vibration shock & Bump Test 7. Endurance Test

TEST REFERENCE CODE NO

V : VISUAL I : INSSTRUMENT /MESURMENT T : TEST A : CRITICAL B : MAJOR C : MINOR TC : TEST CERTIFICATE SUPP TC : SUPPLIER TEST CERTIFICATE T& I SPEN : TEST AND INSPECTION SPECIFICATION PR SPN : PURCHER SPECIFICATION QCR : QUALITY CONTROL RECORDS WIP : WORK IN PROCESS




Revision No. 03

Title Sampling Plan Date 04.12.2012 Section No. QAP : SP Page No. 17 of 45

Sampling Plan as per Acceptance Norm

Lot Size Sample Size 01 to 5 3 6 to 10 5

11 to 15 8 16 to 20 12 21 to 25 15 26 to 30 20 31 to 35 22 36 to 40 25




Revision No. 03


Brand : KEPCO Model No.: KSEL/MC/R2/01 Manufactured By : KAY SONS ELECTRICALS PVT.LTD. -VARANASI Material Procurement Sl. No.

Component Operation

Machine/ Equipment used for Operation

Character-sticks to be Monitored

Classification of Criticality

Type /Method of Check

Quantum of Check

Reference Document

Acceptance Norms

Format of Records

Agency for Inspection

If Out source Address of Agency

Remark

1.1 Body Jigs, Gauges 1.Visual defects 2. Dimensional Check 3.Lab Test

Major Visual First off 100% for approval sampling for regular production as per sampling plan

EMD Drg. No. 10562868 & 10562867

As per Quality Procedure KSEL/MC/002

Inspection Register . Lab Test certificate

Internal Quality Control

Internal Goods Receiving Bay

1.2 Bush Bearing ½”, 3/8”,7/16”

1.Gauges 2.Vernier

1.Visual defects 2. Dimensional Check 3.LabTest Certificate

Major Visual First off 100% for approval sampling for regular production

EMD Drg. No.10563314, 10563387, 10563284, 10563317, 10563315, 10574188

As per Quality Procedure KSEL/MC/004 KSEL/MC/005 KSEL/MC/007 KSEL/MC/024 KSEL/MC/061 KSEL/MC/071




1.3 Rubber Grommet

1.Gauges 2.Vernier

1.Visual defects 2. Dimensional Check


EMD Drg.no. 10568052


Inspection Register . Manufacturer Test certificate



1.4 Rev. Gear ASM

N.A 1.Visual defects 2. Dimensional Check

Major Major Visual EMD Drg. No. 10563287








Revision No. 03

Title Procedure for Inspection & Testing of Incoming material Date 04.12.2012 Section No. QAP : 02 Page No. 19 of 45 Sl. No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.5 Retaining Ring

1.Gauges 2.Vernier



EMD Drg.No. 10568053, 9413182, 274612

As per Quality Procedure KSEL/MC/008,039,043




1.6 Roller Switches

1.Gauges 2.Vernier



EMD Drg. No.8296750,8298178,8299162

As per Quality Procedure KSEL/MC/108,109,110




1.7 Micro Bearing Roller Thrust

1.Gauges 2.Vernier



EMD Drg.No. 10563588





1.8 Plug ASM N.A 1.Visual defects 2. Dimensional Check


EMD Drg.no. 10611796





1.9 Aluminum Drum

Jigs Venire

1.Visual defects 2. Dimensional Check 3.Lab Test Certificate


EMD Drg. No. 10563319

As per Quality Procedure KSEL/MC/ 027




1.10 Gear Upper Shaft



EMD Drg. no. 10563305


Inspection Register . Manufacturer Lab Test certificate






Revision No. 03


Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.11 Gear Lower Shaft



EMD Drg. No. 10563309





1.12 Shaft ASM N.A 1.Visual defects 2. Dimensional Check


EMD Drg. No. 10563282





1.13 Lock ASM N.A 1.Visual defects 2. Dimensional Check







1.14 Rev. Roller ASM



EMD Drg. No.10563293





1.15 Gear Bevel ASM











Revision No. 03


Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.16 CAM ASM N.A 1.Visual defects 2. Dimensional Check


EMD No. 10563318





1.17 Lower Shaft N.A 1.Visual defects 2. Dimensional Check


EMD Drg. no.10563312





1.18 Clevis ASM N.A 1.Visual defects 2. Dimensional Check


EMD Drg. No. 10592349





1.19 Spring clives ASM








1.20 Knob TH N.A 1.Visual defects 2. Dimensional Check







1.21 Socket ASM N.A 1.Visual defects 2. Dimensional Check










Revision No. 03


Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.22 Bulb ASM 28 V








1.23 Shim N.A 1.Visual defects 2. Dimensional Check


EMD Drg.no. 10563589, 10564833, 10564776, 10564777

As per Quality Procedure KSEL/MC/033,111,125,126




1.24 Dowel Pin N.A 1.Visual defects 2. Dimensional Check 3.Lab Test Certificate


EMD Drg.No. 456652,453676,455481,4570089420389,454512,10622112

As per Quality Procedure KSEL/MC/016,020,030,034,071,084,091




1.25 Spring Detent Arm ASM



Drg. no. 10563303





1.26 Cable 12E &16E AWG



DLW Drg. No. 8475587 , 40019384

As per Quality Procedure KSEL/MC/115 KSEL/MC/116




1.27 Tie Cable N.A 1.Visual defects 2. Dimensional Check


EMDDrg.no. 8428099








Revision No. 03

Title Procedure for Inspection & Testing of Incoming material Date 04.12.2012 Section No. QAP : 02 Page No. 23 of 45 Brand : KEPCO Model No.: KSEL/MC/01 Manufactured By : KAY SONS ELECTRICALS PVT.LTD. -VARANASI Sl. No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records


If Outsource Address of Agency

Remark

1.28 Terminal Receptacle



EMD No. 8272337, 8380934

As per Quality Procedure KSEL/MC/118,119




1.29 Read Out Drum ASM



EMD Drg. No.10592089





1.30 Gear Lower Shaft








1.31 Wheel Assembly Detent








1.32 GEAR Bevel












Revision No. 03


Brand : KEPCO Model No.: KSEL/MC/01 Manufactured By : KAY SONS ELECTRICALS PVT.LTD. -VARANASI Sl. No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records


If Outsource Address of Agency

Remark

1.33 ARM ASM N.A 1.Visual defects 2. Dimensional Check







1.34 Plate Partition








1.35 Sleeve & Slide



EMD Drg.No. 10563269, 10563266

As per Quality Procedure KSEL/MC/062, KSEL/MC/064




1.36 Throttle Handle








1.37 Bezel Console












Revision No. 03

Title Procedure for Inspection & Testing of Incoming material Date 04.12.2012 Section No. QAP : 02 Page No. 25 of 45 Brand : KEPCO Model No.: KSEL/MC/01 Manufactured By : KAY SONS ELECTRICALS PVT.LTD. -VARANASI Sl.No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.38 Breaket Mounting








1.39 Handle Directional








1.40 Steel Plate N.A 1.Visual defects 2. Dimensional Check







1.41 Steel Rod N.A 1.Visual defects 2. Dimensional Check







1.42 Hardware 1.Gauges 2.Clamp Meter 3.Vernier


Major V/I/T As per sample plan



Inspection Register . Raw material test report

Internal Quality control






Revision No. 03

Title Procedure for Inspection & Testing of Incoming material Date 04.12.2012 Section No. QAP : 02 Page No. 26 of 45 Brand : KEPCO Model No.: KSEL/MC/01 Manufactured By : KAY SONS ELECTRICALS PVT.LTD. -VARANASI Sl.No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.43 Wires 1.Gauges 2.Clamp Meter 3.Vernier

1.Visual defects 2. Dimensional Check 3. Colour

Critical V As per sample plan



Inspection Register .



1.44 Packing Material

N. A. 1.Dimensional Checks 2.Printing 3.Gumming

Major V First of 100 % for approval



Internal Inspection Register .



1.45 Labels N. A. 1.Dimensional Checks 2.Printing 3.Gumming

Major V First of 100 % for approval









Revision No. 03

Title Procedure for Inspection & Testing of Incoming material Date 04.12.2012 Section No. QAP : 02 Page No. 27 of 45 In Process Inspection of Body Sl.No. Component

Operation Machine/ Equipment used for Operation




Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

2.1 Machining & Drilling

CNC Machine

1.Visual defects 2. Dimensional Check 3. Finish 4.Gauge

Critical V/I First off 100% for approval sampling for regular production






2.3 Cleaning Compressor /Air

Burs Removal Major V/I First off 100% for approval sampling for regular production






SHEET CUTTING 2.4 Sheet

Cutting Sheet Cutting Machine

Visual defects

Major V/I & Supplier TC

First off 100% for approval sampling for regular production






2.5 Sheet Bending

Sheet Bending Machine

Visual defects

Critical V/I 100% Testing /Checking




Internal Quality control Checks

Internal Goods Final Product Testing Bay

2.6 Welding Welding Machine

Welding Checks

Critical V/I As per sample Plan










Revision No. 03

Title Procedure for Inspection & Testing of Incoming material Date 04.12.2012 Section No. QAP : 02 Page No. 28 of 45 Sl.No. Component





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

2.7 Spot Welding

Spot Welding Machine.

Welding Checks







2.8 Cleaning Solvents. 1.Surface Finish 2 Dust. 3. Greece

Critical V/I/T 100 % Testing Checking






2.9 Painting Painting Machine

Colour etc

Major V 100%Testing/ Checkings

As per Manufacturer Instruction / Catalogue





2.10 Marking Marking Machine

Visual Defects


First of 100% for approval sampling for regular production

As per DLW Drg & Specification


Inspection Register . Raw material Test Report



2.11 ROD Cutting

Sheet Cutting Machine

Visual defects


First off 100% for approval sampling for regular production

As per Quality Procedure





2.12 Bending Sheet Bending Machine

Visual defects

Critical V/I 100% Testing /Checking









Revision No. 03


ROD ASM Sl.No. Component





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

2.13 Welding Welding Machine

Welding Checks

Critical V/I As per sample Plan






2.14 Spot Welding

Spot Welding Machine.

Welding Checks







2.15 Cleaning Solvents. 1.Surface Finish 2 Dust. 3. Greece

Critical V/I/T 100 % Testing Checking






2.16 Painting Painting Machine

Colour etc

Major V 100%Testing/ Checkings









Revision No. 03

Title Procedure for Inspection & Testing of Incoming material Date 04.12.2012 Section No. QAP : 02 Page No. 30 of 45 Part –II:

Equipment Sub Assembly Sl.No. Component





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

3.1 Partition Plate ASM

Remer Jigs Dies Fixtures Press Machine Riveting Machine

Visual Defects Dimensional Checks

Critical V/I First of 100% for approval sampling for regular production

EMD DRG. No. 10563590

As per DLW Drg & Specification As per Quality Procedure KSEL/MC/ 059




3.2 Slide ASM Remer Jigs Dies Fixtures Press Machine Riveting Machine



As per DLW Drg No.10563266 & Specification





3.3 Handle ASM




As per DLW Drg No. 10614092 & Specification









Revision No. 03






Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

3.4 Rod ASM Excursion Visual Defects Dimensional Checks







3.5 Plug and Cable ASM

Wire cutting Machine Sizing Machine Crimping machine



As per DLW Drg 40055297





3.6 Clevis ASM Remer Jigs Dies Fixtures Press Machine Riveting Machine








3.7 Detent ASM Remer Jigs Dies Fixtures Press Machine Riveting Machine



As per DLW Drg 10592838 & Specification





3.8 ARM ASM Remer Jigs Dies Fixtures Press Machine Riveting Machine











Revision No. 03






Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

3.9 Upper Shaft ASM




As per DLW Drg No. 10563282





3.10 Gear ASM Remer Jigs Dies Fixtures Press Machine Riveting Machine








3.11 Rheostat Plate ASM (D.B.)












Revision No. 03






Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

3.12 Read Out Drum ASM









3.13 CAM ASM Remer Jigs Dies Fixtures Press Machine Riveting Machine




As per Quality Procedure KSEL/MC/ 142,141




3.14 Switch ASM Remer Jigs Dies Fixtures Press Machine Riveting Machine




As per Quality Procedure KSEL/MC/ 108,109,110







Revision No. 03

Title Procedure for Inspection & Testing of Incoming material Date 04.12.2012 Section No. QAP : 02 Page No. 34 of 45 Equipment Final Assembly Sl.No. Component





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

4.1 Final Assembly

1.Bush ASM 2. Upper Shaft ASM 3.Partition Plate ASM 4.Slide ASM 5. Handle ASM 6. Clevis ASM 7.Detent ASM 8.ARM ASM 9. Lower Shaft ASM 10. Read Out Drum ASM 11.Gear ASM 12.Lock ASM 13. Cam Rod ASM 14 Switch ASM 15.Rheostat Plate ASM (D.B.) 16. Rod ASM 17.Plug and Cable ASM



EMD Drg.No. 40055299 And As per Quality Procedure KSEL/MC/ 001








Revision No. 03


PRODUCT FINAL TESTING AS PER DLW Specification No. WDG4/EL/PS/7 Dated 12.02.2002 Sl.No. Component





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

5.1 Visual Test Visual Visual Defect Critical V/I/T 100 % Testing Checking Routine Test





Internal/ Testing Agency

Goods Final Product Testing Bay

5.2 Preliminary Checking

General workmanship & Finish

General Operation

Critical V/I 100 % Testing Checking Routine Test







5.3 Dimensional Checks

Dimensional Checks


Critical 1.Digital Vernier. 2.Micromertr

100 % Testing Checking Routine Test







5.4 Insulation Resistance Test

Megger I.R.Level Critical V/I 100 % Testing Checking Routine Test







5.5 High Voltage test

High Voltage Tester

Should With Stand the Test








5.6 Sequence Test (Notch UP)

1.D.C. Source 2.Testing Panel

MC Should show correct sequence

Critical I 100 % Testing Checking Routine Test










Revision No. 03

Title Procedure for Inspection & Testing of Incoming material Date 04.12.2012 Section No. QAP : 02 Page No. 36 of 45 Sl.No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

5.7 Sequence Test (Notch Down )

1.D.C. Source 2.Testing Panel

MC Should show correct sequence








5.8 Wiring Check

Multi meter Continuity Critical I 100 % Testing Checking Routine Test







5.9 Functional Test (Forward )

Testing panel

MC Should Show correct function








5.10 Functional Test (Reveres)

Testing panel

MC Should Show correct function








5.11 Endurance Test

Endurance machine

No. of Operations

Critical Type test As per Quality Procedure










Revision No. 03

Title Final Internal Inspection of the Product by the Firm (Test Report) Date 04.12.2012 Section No. QAP : 03 (TR) Page No. 37 of 45 PART –III : (A) VISUAL EXAMINATION : (B) DIMENSIONAL CHECKS

Sl .No. Parameter Specified Value (in inches) Measured Value (in inches) REMARK’S 1 Upper Side Length 8.75 2 Upper Side Width 6.56 3 Bottom Side Length 7.35 4 Bottom Side Width 4.75 5 Height 11.91

(C ) REHOSTATE ASSEMBLY

Sl. No. Parameter Specified Value Measured Value REMARK’S 1 Continuity Should be OK 2 Contact Resistance 308 ±10% Ohm

(D ) Sequence Checks

Notch UP Position Position Switch should operate 1 2 3 4 5 6 7 8 Idle 6th 1st notch 1st 2nd notch 1st, 4th 3rd notch 1st, 3rd 4th notch 1st, 3rd, 4th 5th notch 1st, 2nd, 3rd, 5th 6thnotch 1st, 2nd, 3rd, 4th, 5th 7th notch 1st, 2nd, 3rd 8th notch 1st, 2nd, 3rd, 4th Setup 6th, 7th D B 6th, 7th, 8th (2) When Throttle handle operated from D.B to setup 8th switch should not operate




Revision No. 03

Title Test Report Date 04.12.2012 Section No. QAP : 03 (TR) Page No. 38 of 45

Notch Down Position

Position Switch should operate 1 2 3 4 5 6 7 8

D B 6th, 7th, 8th

Setup 6th, 7th 8th notch 1st, 2nd, 3rd, 4th 7th notch 1st, 2nd, 3rd

6thnotch 1st, 2nd, 3rd, 4th, 5th 5th notch 1st, 2nd, 3rd, 5th 4th notch 1st, 3rd, 4th 3rd notch 1st, 3rd 2nd notch 1st, 4th

1st notch 1st Idle 6th

Test Reverser in Forward direction Forward switch should operate

Reverser in reverse direction Reverser switch should operate

(E ) Rheostat plate:

Visual Check Remark (1) All Lugs should be insulated (2) Proper arrest of Brass plate it should be taper in copper terminal side (3) Nylon washer should be fixed in Brass plate





Revision No. 03

Title Test Report Date 04.12.2012 Section No. QAP : 03 (TR) Page No. 39 of 45 (F ) IR Value 500 V DC Specified Min 01 M ohm

Sl. No. Parameter Specified Value Observed REMARK’S 1 Insulation Resistance > 1 M Ohm

( G) HI-POT Check 1000 V DC One Min

Sl. No. Parameter Specified Value Observed REMARK’S 1 High Voltage Test Should be Stand at 1 KV For One Min.

(H) Operational Check

Sl. No. Parameter Observed 1 Th handle should not go beyond 8 notch 2 Proper crimping of pluck pins 3 Male & Female pluck should match 4 Switch should be in one line 5 Level of Reverser spring in one level 6 Reverser handle when taken out spring should be in little tension 7 Bezel should not rub with read out drum 8 Continuity of bulb to checked from holder capital (P) & capital (N) in holder 9 Proper locking of read out drum with washer &lock 10 Rheostat small shaft should rotate in bush 11 Rubber grommet 3 Nos. provided 12 Wiring of bulb is from clamp inside 13 Clamp out side have been provided





Revision No. 03


( I ) FUNCTIONAL CHECK :-( Drg No. 40055296)

(i) WITH DIRECTIONAL HANDLE IN NEUTRAL

(a) Throttle/Dynamic brake handle can only be moved to a position in the throttle sector. (b) Dynamic Brake Sector not accessible (c ) Directional handle can be removed from controller , if throttle/ Dynamic brake handle is in IDLE position of the throttle sector

(ii) WITH DIRECTIONAL HANDLE REMOVED FROM CONTROLLER :-

(a) Throttle/Dynamic Brake handle locked in IDLE position of the throttle Sector.

(b) Dynamic brake Sector not accessible

(iii) WITH DIRECTIONAL HANDLE IN FORWARD OR REVERSE

(a) Throttle / Dynamic brake handle can be moved to any position in the throttle or dynamic brake sectors. The design of the controller, However is such that only one sector can be engaged at a time.

(b) Throttle / Dynamic brake handle in Dynamic brake sector, Directional handle is locked in either FORWARD or REVERSE. (c ) Throttle/ Dynamic Brake handle in throttle sector, Directional handle is locked in either FORWARD or REVERSE.

(d) Throttle / Dynamic brake handle in IDLE position of throttle sector, Directional handle can be moved to FORWARD or REVERSE position, or if centered in the NEUTRAL position, handle can be removed which will lock throttle/Dynamic brake handle in IDLE position.

(J ) PLUG ASSLY – ( Drg No. 40055297)

Sl. No. Parameter Specified Value Observed REMARK’S 1 No of Pins 28 Pin 2 Wire Size 12 & 16 AW G





Revision No. 03


(K ) DIMENSIONAL CHECKS ( Drg No. 10611796 )

Sl. No.

Parameter Specified Value (in inches)

Measured Value (in inches)

REMARK’S

1 Length of Plug 4.74 2 Size of metallic portion 3.56 3 Dia of Plug 2.1 4 Dia of rubber sleeve 0.84 5 Size of Clamp 1.70



SECTION - G



Revision No. 03

Title System of Maintaining The Date of Customer Complaints/ Warranty Failures Date 04.12.2012 Section No. QAP : WF Page No. 42 of 45

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SECTION –H



Revision No. 03

Title Working Instruction for Soldering Date 04.12.2012 Section No. QAP : WIS Page No. 43 of 45

WORK INSTRUCTION FOR SOLDERING

1. Soldering will be done by qualified soldering Operators with appropriate tools. 2. Components are assembled in an order depending on their height and size 3. Solder joints are inspected 100% visually by operators in process control. 4. Inward Inspection cleared only is taken for soldering operators. 5. Soldering Iron Tip is wetted to achieve good solder flow and hens good joint. 6. Heating :-

a. Surface to be soldered is applied with sufficient heat by soldering iron. b. Heat should not be high as to cause damage to component

7. Optimum quantity of solder shall be applied to avoid Excess or under solder joints for especially for PTH border. 8. Solder Joints are inspected for the following.

a. Dry solder b. Excess and under solder c. Short and bridging effects d. Pin holes and blow holes e. Spikes and cavities

9. Goods contact between the soldering tip and the parts to be maintained. 10. Keep the contacts maintain between irons, the joint memers until good flow of solder occurs. 11. Proper tools must be used for bending, cutting and striping of wires and they should be kept clean and in order. 12. The high wattage soldering shall be used for soldering heavy components and wire joints. Like Brass contact, copper contacts. 13. After soldering the are cleaned with recommended solvents. 14. Visual inspection is done for good workmanship and sound and bright surface. 15. The soldering operator shall qualified for every 6-8 months as stated in KEPCO /Production department /F




Revision No. 03

Title Work Instruction for Mechanical Assembly Date 04.12.2012 Section No. QAP : WIM Page No. 44 of 45

Work Instruction for Assemblies

1. Conform the sub assemblies and their dimensions are as per drawing. By using measuring tools like, screw gauge and height gauge. Large dimensions. Are measured with steel rule.

2. Mechanical assemblies are carried out by approved samples or approved assembly drawings.

3. Rivet, Pins to with adequate strength.

4. Use proper tools and jigs for mechanical assemblies.

5. Check for loose fixing

6. Fixing of Each Nut, Bolt, Screw, spring pin, Retaining Ring, Pins and Dowel Pins at actual position shall be adequately tightened.

7. Fixing of handle and cover

8. Visual Inspection of Rheostat Plate Handle and Readout Drum alignment to base.

9. Visual Inspection of all Cable tie shall be adequately tightened.

10. Visual Inspection of Marking of all wires with wire marker.

11. Riveting of following anodized Aluminum Labels Manufacturers label, with Sl. No. , Label of Bezel ASM

12. Indentify the non –conforming and rejected products/components by means of tag and separately store in bins.




Revision No. 03

Title Work Instruction for Wiring Date 04.12.2012 Section No. QAP : WIW Page No. 45 of 45

WORK INSTRUCTION FOR WIRING

1. Master Controller wiring is done as per work instructions. 2. AWG Wire shall be used. 3. Proper wire and connect it to be Lugs and terminals with Crimping of Crimping Tools 4. Proper Crimping is done as per work instruction as below.

a. In additional appropriate insertion tool, extraction tool & guide /Pilot Pins are required b. Crimping Contacts.

i. Set the crimp tool with positioned pressed. ii. Select the position depending upon the type of contact used. iii. Place the contacts mating end first into tool. iv. Insert the stripped wire into the hollow end of the contact. v. Closed the tool completely to crimp vi. Check the contact thru the inspection hole to ensure that the wire is fully inserted.

c. Instruction of Contacts i. Before inserting the contacts, slide the coupling nut and the rear accessories over the wire bundle in proper sequence for reassembly. ii. Hold the contact in the insertion tool & dip in isopropyl Alcohol. iii. For socket contacts always use guide /pilot pins. iv. Hold Connector body firmly and apply a slow, even pressure perpendicular to the insulator face until the contact snap into position. v. Check from the mating end to ensure that the contacts are inserted to its proper depth.

d. Extraction of Contacts i. To remove the contacts, use the extraction tool, which contains tool tip for plug & socket contacts. ii. Apply a slow even pressure to push the contact out of the rear of the insulator.



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