How Hitachi Armature Coils are formed

Audit of 2  WIs was done today in TM Shop. Report is as follows:-

Hitachi Armature Coil Forming ( W 23.007):-

Points noticed:-

• WI needs modification since....
• Conductor being cut was of lesser length than mentioned in WI.

Conductor	Length in WI	Actual Length found during inspection
a-b	1691 mm	1689 mm
c-d	1682 mm	1680 mm
e-f	1666 mm	1664 mm
g-h	1654 mm	1652 mm
i-j	1642 mm	1640 mm

• Actual length being cut in shop is less than permitted tolerance in WI.
• Bending Jig INJ-017 was being sent for calibration.
• Clearance between jig and roller not as per para 3.2.3 of WI.
• Stopper location 810 mm instead of 812 mm mentioned in WI para 3.2.5

• Spacers used were not as per para 3.2.8 of WI.

• No GO guage for measuring dia of head also “goes” through.

Hitachi Armature Coil Forming ( W 23.008):-

Points noticed:-

• Tube KCTUN-1 was being used in place of KCTUN-CI -6 mentioned in WI.
• KCTUN was of 3 A make. This could not be located in the CLW approved list.
• KCTUN tube was being cut for 30 mm whereas mentioned 30mm in the WI. para 3.2.1

• 30 T press machine for doing Step Down was being sent for calibration.

• Jig for Step Down INJ-016 was being sent
  
  
  for calibration.

Hitachi Traction Motor Manufacturing

PE Side Deck Insulation of Equaliser Winding of Hitachi  ( W 23.020):-

Points noticed:-

• Grease KS707 for mould release treatment should not be of expiry date.

Equaliser  Coil Winding of Hitachi Armature  ( W 23.021):-

Points noticed:-

• Date of expiry of GUFZ 0.13 sheet should be established.

Equaliser Coil Earth Insualtion of Hitachi  ( W 23.022):

Points noticed:-

• P-200 powder and all M-60 mica sheets should be of expiry date.

Hitachi Armature Coil Earth Insulation  ( W 23.023):-

Points noticed:-

• Inter-Turn test machines were told to be calibrated but date of calibration was not marked.

Field Coil Manufacturing of Traction Motor

Audit of following WI was done in TM Shop. Report is as follows:-

Hitachi  Field Coils( W 23.024):-

Points noticed:-

• Punching jigs INJ-109 INJ-110 were being sent for calibration

• MP coil Baking jigs INJ -004 INJ-006 were being sent for calibration.

• CP coil Baking Jig INJ -012 was being sent for calibration

• Terminal corrector jigs INJ -210, INJ 211-A &B were being sent
  
  
  
  for calibration.
• Warnish/solvents WSY-285, HEW were checked for  expiry date.

Wheel Assembly Shop was visited with CEE ( P&I) for axle bearing bolts of WAP-4

FAG and NIE are using different sized bolts for same bearings.

Inspection staff has been asked to check tap drill depth.

Vacuum impregnation technology

Audit of following 2 WIs was done in TM Shop. Report is as follows:-

Hitachi  Field Coils( W 23.024):-

Points noticed (In continuation of audit done on this WI earlier):-

• Use of profile jigs ING-002 and ING-005 was not to be done on all coils.

• GUAT-CN-3 insulation sheet ( of M/S Perfect, Kolkata; approved make?) should not be provided AFTER layer baking as it was prescribed BEFORE layer baking as per WI para 3.2.8.

VPI of Hitachi  Field Coils( W 23.025):-

Points noticed:-

• Some of the varnish DER 332 (one of the three components of HEW-290 of HEW 290) used after vacuuming was checked for expiry date.
• Tank for making HEW-290 was got cleaned of dirt due to prolonged use.

• Baking jigs INJ-006 (MP) and INJ-013 (CP) were being sent for calibration.

• Cycle time as prescribed in the WI for initial 12 hours preheating of the job , then 3 hrs. pressure application, then 15 hrs rotary baking then 5 +15 hrs baking was being compared with actual
  
  
  
  in the interest of production.

Inductive Shunt in Locomotives

Audit of following Work Instruction was done in TM Shop. Report is as follows:-

Manufacture of Inductive shunt ( W 23.026):-

points noticed:-

• Coil working area got cleaned..

• Insulation tape GF being used should be of of size 0.09 x 25 mm instead of 0.08 x 25 mm.
• GMGS tape ( of M/S HATIM-this item featuring in master list of suppliers?) in the store was checked for expiry date..
• Insulating 4FTNA tape ( M/S Khandelwal) was checked for expiry date .
• Ruptam Foil make could be established?

• In the month of Feb-12, total 61 SJs were sent for HF/DE testing out of which 25 failed. This is too high rate of rejection. ( 40 %). Thus no compromise with quality.
  
  

Paint booth, Weigh Bridge and Assembly shop aslo seen GM inspection.