Shop Floor Inspection

Shop #12 and 26 were inspected  alongwith inspection staff.

Fitment of gearcase was inspected. Alternate tightening of the bolts was not being followed , same was emphasized.

Use of proper torque wrench was examined .

Torque wrenches are required to be calibrated. 

RTV 685 was being used as sealant between gear cases. It was checked for expiry.

Dimensional deviations in Raj-712 Underframe were checked.

Defects of welding undercut were examined. There were many such defects all over the shell all rectified..

Different thickness sheets were being used for same bellow duct in the underframe, shop supervisor revealed that they received material from shop #15 and applied what they received.

Matter was  discussed with Shop #15 supervisor.

It was observed that some dimensional deviation beyond permissible limits may be carried forward to shop #16.

TM inspection staff was made available the list of approved makes of bolts 9 of rocker ring assembly).

Oversized temperature Probe was being fitted in 3-phase TM, for which WI is to be checked.

TM shop was inspected for work instruction compliance of thread drilling in poles/compoles and SJ poles.

Head machining after making the drill under process.

Drilled pole shoes awaiting cleaning.

TP39 was inspected in the test shed. It was observed that CO2 pipe welding was done in the side wall after painting due to which surface cracks had appeared in the exterior paint.

This was in addition to the usual waviness in the surface giving the paint a blemish.

Crack-holes on the exterior surface of TP 39.

Though production staff assured that it will be touched up, inspection staff was instructed to advise assembly shop to do all inside welding work before painting only.

End Brazing and welding in Traction Motors

Brazing of the end rings and MIG welding  was inspected  in the TM shop.

In addition to MIG welding, Induction brazing and Zarconium welding ( stampings) are the other two types of end-ring preparation methods.

Almost 100 three phase Traction Motors are waiting for production for want of RTV622, which is applied in the terminal box as well as inside the winding.

Process of Pole terminal brazing was inspected in the shop.

Some bolts in the TM were found to be just punched of the make, unlike the standard practice of embossing. This was instructed to be recorded as Non-Conformity.



 

Provision of U Nomex paper at the ends of coils in three phase Traction Motor was inspected in the shop.

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.