3 phase loco quality checks

Work Instruction audit of W21.605 ( Main Pole and Compole lead terminal brazing) :

Process of silver foil melt filling  :

Underframe assembly should not have NC of camber deviation .

The NC of hanging CO2 emission pipe should be attended.

It was reported that in 3-phase loco traction-bar pang bead sealant is not being used since long.

A camber of 15 degree in the middle of the roof will be required with design section approval.

We should avoid stacking of roofs one over other continues, which may deform the profile.

With quality control pneumatic copper pipe failures can be controlled. (like disconnected copper pipes from TRIPLATE panel)

This problem was again analyzed in the shop.It was found that earlier design of TRIPLATE panel located on the wall was better as it was less vulnerable to vibrations.

Loco Depsatch and shell shop

Work flow of shell shop was discussed . It was told that Conventional shell takes 22 days cycle time and 3-phase   shell takes 31 days cycle time.

Problem of gap in roof of WAP5 was also discussed.

All quality officers were engaged in ISO internal audit meetings .

Steel foundry was inspected .

 

Mould hardness ( push button) measurement was observed.

 Core Hardness ( knife edged) measurement was observed.

Material Examiners of Shop#66 informed that they are chasing so that core was  being offered for inspection.

Wide opening found in one of the castings after knock down.

It was instructed to inspection staff that core and mould should be strictly inspected as rejection of final casting is wastage of resources.

However, staff reported that after their bookings on post-knock down castings, Fettling supervisor  signs on the mandatory register kept for this purpose.

Bogies are 100% undertaken for radiography test and other castings 20% , as reported by the steel foundry staff.

Three locos scheduled for dispatch ( HH- 1420,1421 & 1422) were inspected in the test shed today.

Traction Motor Cable fouling due to non provision of cleat was pointed out during inspection of HH-1422.

Another NC noticed during inspection of all three locos was that of use of PVC insulation cable in air dryer ( trade item). This was pointed out to the production staff also.

While measuring buffer height the measurements were prone to track error as not all tracks are fit for the measurement. 

Shop #12 was visited for WAP5 roof problem feedback again today. 

Though no changes have been made in the fixtures, it was assured by production staff that they will send the roof after surface matching only now onwards.

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.