Quality Audit Report of Kharagpur Workshop, South Eastern Railway for POH of wagons

For official use only

Government of India
(Ministry of Railways)

Quality Audit Report of Kharagpur Workshop,

South Eastern Railway for POH of Wagons
Ref: Railway Board’s letter nos 2017/M(W)/814/32 dated 31.03.2017
Audit Date: 22.06.2017 to 24.06.2017

Report No. I&L/K/2017-10

June, 2017

Conducted by:

(P.K.Pandey) (Rakesh Kumar)

Director/Wagon/RDSO/LKO ARO/M&C/RDSO/LKO

(Yatish Kumar)
Director/I&L/Kol

RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW - 226011.
Quality Audit Report of Kharagpur Workshop, South Eastern Railway for POH of wagons

Quality audit report of Kharagpur Workshop,

South Eastern Railway for POH of Wagons

Introduction
As per Railway Board’s letter nos 2017/M(W)/814/32 dated 31.03.2017 &
10.04.2017, ED/QA(Mech.) vide letter no QAM/Quality Audit dated 17.05.2017 and
dated 19.05.2017 it was advised to carry out Quality audit of Kharagpur Workshop,
South Eastern Railway for all activities pertaining to POH of wagons.
S.E. Railway workshop, Kharagpur, West Bengal is one of the largest integrated
workshop on the Indian Railways dealing with POH of a wide variety of BG rolling
stock i.e. Coaches, EMUs, MEMUs, Diesel and Electric Locomotives, DEMUs,
SPART, SPARMEs, Tower Wagons, Diesel Cranes and various types of Wagons
like open wagon, covered wagon, hopper wagon, tank wagon etc. POH of Avg. 450
nos wagons is being carried out by the workshop.
RDSO team conducted quality audit of wagon POH activity as per the checksheet
(checksheet no. QAM/Quality Audit/May/02/2017 & QAM/Quality Audit/May/02/2017)
available at RDSO website on 05.06.2017 to 07.06.2017. Shri S.C.Behera,
Dy.CME/Wagon, Kharagpur Workshop and his team were with the RDSO audit team
throughout the audit. Filled up checksheets are attached in Annexure 1 & 2 of this
report.

Scope of audit:
Activities as mention below related to POH of wagon.
1. Attention of Underframe & superstructure
2. Attention of CTRB and Wheel set
3. Airbrake pipe and Air Brake Equipments
4. Bogie repair
5. Attention of Coupler and draft gear

Audit team:
1. Shri Yatish Kumar, Director/I&L/Kol
2. Shri P.K.Pandey, Director/Wagon/RDSO/LKO
3. Shri Rakesh Kumar, ARO/M&C/RDSO/LKO

Observations:

Strength:
1. DV overhauling section of the shop is well equipped well maintained and clean.
Separate arrangement for cleaning all components of DV is available with the
Quality Audit Report of Kharagpur Workshop, South Eastern Railway for POH of wagons

workshop. All cleaning plant has exhaust in built and they are using required
cleaning solvents giving quality cleaning. Models of various types of DV including
all spares are well displayed in DV assembly and testing area. Workers involved
in maintenance of DV are highly motivated and having adequate knowledge
regarding assembly and testing of DV.70% highly motivated female staff are
working in this section.

Cleaning plant for DV housing Model for reference Test Bench

Work instruction well displayed Staff of DV section with RDSO Ready DV storage
Audit team.

2. The shop had implemented laser marking by Laser Engraving Machine at grease
seal as per Wagon Dte/RDSO’s letter no MW/RB/General dated 14.12.2016.
Therefore marking is clear and bearing can be identified easily in situ position
Quality Audit Report of Kharagpur Workshop, South Eastern Railway for POH of wagons

3. Bogie maintenance shop is equipped with inspection table for spring with gauges
for grouping and colour coding of spring.

4. Cutting of RF-360 draft gear is being carried out by band saw which ensures
opening of draft gear without damaging housing and other components. The shop
is using in house developed fixture for checking of coupler operating handle.
Thus desired contour of coupler operating handle is being ensured. The shop
equipped with all necessary gauges for coupler and draft gear.This is indeed a
mandatory equipment for workshop handling POH of wagons.

5. SAB maintenance section of the

workshop and is well maintained. All
required tools and testing equipments
as specified in CAMTECH manual are
available as required.
Quality Audit Report of Kharagpur Workshop, South Eastern Railway for POH of wagons

6. The shop has developed very

important and useful devise using
electric motor driven for checking
bench lateral play of CTRB which
gives more accurate result than hand
operated device.

Weakness:

1. Latest CAMTECH maintenance manual is not available at relevant shop. The

workshop is following G maintenance manual in all shops which is not covering
latest instructions issued by Wagon Directorate. Latest CAMTECH manual and
maintenance instructions issued by Wagon Directorate should be available in
relevant shop.

2. The workshop is facing huge crisis of vital materials required for maintenance.
During audit stainless steel sheet, PU paint, zinc phosphate primer, CRF,
grease for Axle journal CTRB etc. was not available at shop.

3. Workshop’s pre inspection checksheet is not in line with G maintenance

manual and CAMTECH manual.

4. Lockbolting operation carried out by

the workshop required more
attention. Gauge should be used
after lockbolting to ensure proper
clamping.Gun should be kept at 900
Position while fitment operation.

5. PU painting is not being carried out in stainless steel wagon. Infrastructure for
painting stainless steel wagon as specified in clause 4.0 of RDSO document
no WD-02-BOXNHL/BCNHL/Paint-2016 is not available at shop

6. Cleaning of under frame, superstructure, bogie and coupler is not adequate.

No mechanised cleaning facilities available at workshop for cleaning of above
said components.
Quality Audit Report of Kharagpur Workshop, South Eastern Railway for POH of wagons

7. No facility like DPT/MPI is available for crack detection Knuckle pin , yoke pin
and other coupler components

8. Ovality and taper of axle wheel seat and axle journal were not being recorded.

9. Free Height and other parameters of brake cylinder spring not being
measured.

10. Critical dimensions of adapters as specified in G-95 is not being measured. No

records for checking of adapter are available at shop. Colour matching is not
being carried out. Gauges as per G-95 also not available.

Measurement of thrust shoulder as per fig.9 of G-95 not

being carried out.

11. No facility is available for cleaning of suspension coil springs. Springs are
manually cleaned but not at all to the requirment before painting which is not
adequate.Poor cleaning leads to poor inspection as well.

Springs ready for painting Painted Spring

Quality Audit Report of Kharagpur Workshop, South Eastern Railway for POH of wagons

12. Welding quality for general repair and welding of liner in bogie and coupler is
not up to the mark and down hand welding is not fully ensured. Preheating not
being done before building up surface by welding on bogie as per clause 5.3.6
of G-95. Electrodes to be used for welding is kept open in the shop floor which
may results absorption of moisture.pre inspection concept is absolutely
missing.over all bogie over hauling needs complete re orientation as per
prescribed procedures.

13. Air pressure of 10 kg/cm2 is not available at workshop for testing of air brake
pipe, air brake equipment and brake cylinder. Testing is being carried out 7
kg/cm2 instead of 10 kg/cm2 specified in para 3.1 of G-97.

14. Auxiliary reservoirs are not being attained as specified in para no 2.1 of G-97.
No separate section for repair and maintenance of Auxiliary reservoirs is
available. Hydraulic testing of auxiliary reservoirs not being carried out as per
clause 3.0 of G-97.seperate section for overhauling of auxiliary reservoir needs
to be developed.
Quality Audit Report of Kharagpur Workshop, South Eastern Railway for POH of wagons

Suggestion:

1. Adapter
All incoming adapter should be ckecked as per figure 9 to 16 of G-95. The
shop should be ensure that 3 nos full sets of gauges mentioned in G-95
should be available.
Blue matching should be carried out in all incoming adapter to ensure proper
matching with bearing. Procedure given below may be followed for this
purpose.
The adapter should be placed on the coloured CTRB outer ring & hand pressure
applied on the top of adapter. Then the adapter is removed from outer cup and the
adapter inner bore touching area with the CTRB outer cup to be inspected. At least
80% of the area must be coloured matched. Ideal photograph of colour matching are
given below.

2. Lockbolt
Lockbolt gauge as shown below must be used to ensure proper lockbolting.
Wagon Directorate’s report “Study Report on Field Reported Lock bolt
Failures in BCNHL Wagon at C.P. Top Location” circulated vide letter no
MW/Lockbolt dated 21.03.2014 must be followed for lockbolting.
Quality Audit Report of Kharagpur Workshop, South Eastern Railway for POH of wagons

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