Shop floor in loco manufacturing

Problem of fewer gaps between compressor bracket and compressor legs   analysed.

One should know about stamping schedule .

Stacking of HITACHI armature and 3-phase stator shown here

Problem of shortage of space and shortage of fixtures, should be sorted out.

Stamping work in progress.

Above picture shows the location of transformer mountingplate-central underframe gap. 

This problem can also been reduced by introduction of new quality check points.

Taking the measurement of axle. These axles are bought from RWF Bangalore. All Minus variation are rejected.

Wheel and gear pressing inspection. it may happen that, gear was pressed with 95 Tons, which is less than 100 Tons. 

What can go wrong while manufacturing a locomotive?

Material kept in open for months gets rusted and laden with dust. Check this out in  shell shop. Due to lots of corrosion in the bottom, some machining will again be required before fitment.

Rust ridden bottom.

Above is the photograph of one such cab.

Following shortcomings of TM to be looked into:-

• Less commutator slot depth.
• Slack insulators in TMs.

 It is to be seen that commutator slot depth in   TMs is not less than standarad.

Problem of slack insulators, need to be watched out.

Rocker rings of TM should be  inspected.

Regarding unsuitable Centre Pivot of Casnub bogies : problem of blow holes may be found.

Problem of Mica getting broken in commutator need to be  inspected in the shop.

It can be seen that due to Mica getting cracked in between slots( while fixing copper bars), the gap between two slots gets reduced which makes commutator unusable.

Commutator Spider is to be inspected as there can be blow holes/ spongy castings/less material while machining.  

Dynamic seasoning plant for commutator should be  inspected. Theres is a standard RPM (say 3050) at which all plants should be working  . Less than that

may result in less seasoning. 

Fixing up of welding defects in Locomotives

In the light of RDSO’s letter , support lugs of Aluminium gearcase in the WAP 5 loco were inspected in the shop .

Welding defects in the WAG7 loco #28243 were pointed out to production staff in the testing shed. This loco was  due to be dispatched tomorrow and wedling defects were rectified.

Another welding defect in the compressor of WAP 4 loco #31333 was asked to be attended by production staff. This loco has light passing from roof section and was being attended in the test shed as due for dispatch .

Roof fitment in locomotives

Underframe welding defects were observed in the loco# HH 1424 in testing shed inspection .

Inspection staff reported that piping hole defects in this loco pointed out earlier have been attended.

Roof fitment of TP-39 was being done in Assembly shop. Staff of Shop#12 were attending the roof since there were some issues in the fitment.

Status of NCs generated in the month of January-12 was analysed. In that month, total 7557 NCs were generated.

Number of NCs have increased by about 1000 that month.

Regarding problem of OCB equipments fouling with the roof of WAP5 ;TP-39 was inspected .

It was seen that dimensions of the OCB ( 4 parts ) needs to be checked.

It was told  that earlier OCB was imported and now it was being supplied locally, which might have led to dimensional variation leading to light passing through roof.

Locos due for dispatch today were inspected.

In The WAG9, following NCs were found:-

Unfilled holes in the OCB bottom frame will lead to dust ingress.

Baby compressor was mounted on three bolts only instead of four.

Reoprt sent by BZA shed was analysed in the TM shop. 

Satator MP coil over heated in one TM:- For this M/S Saini has been informed .

Armature Polyglass Banding given up in two TMs:- For this, commutators’ firms are being informed.

Stator MP connection open in one TM:- AS reported earlier, brazing workmanship has been found satisfactory. This TM failed after one year of service.

Armature coil damage in one TM:- This was a rewound armature, DyCEE TMM has been informed of the same as rewinding workmanship could not be checked in the shop.

BZA was informed of the above, and shed

asked for assistance regarding motors.