ISO: 9001-2008 Doc. No.:CG-DM-4.2.2-1 Version No:3.0 Date

ISO: 9001-2008 Doc. No.:CG-DM-4.2.2-1 Version No:3.0 Date of effective: 12.06. 2013

Document Title: Directorate Manual of Carriage Directorate.

SSE/(M/Carriage) Director/E&S and Brakes Printed on : 12.06. 2013

Prepared by: Issued by: Page 1 of 17

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

RESEARCH DESIGNS & STANDARDS ORGANIZATION Manak Nagar, Lucknow – 226011

Document No: CG-DM-4.2.2-1


1.0 Amendment History:

S. No. Amend. Date Version Reasons for Amendment

1. 01.09.2010 1.0 First Issue under new documentation system for ISO 9001:2008.

Approved by EDSC on Noting page 05 of MC/ISO/Approval & Issue.

2. 05.04.2013 2.0 Document revised due to change in clause 2.3 b). Approved by EDSC on NP- 6 of file MC/ ISO/Issue Change Approval.

3 12.06. 2013 3.0 Document revised due to change in clause 2.3 b). Approved by EDSC on NP- 8 of file MC/ ISO/Issue Change Approval.





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

TABLE OF CONTENTS

Clasuse No Description Page No.

1.0 Amendment History 1

2.0 Purpose 3

2.1 Introduction & Brief Profile of Carriage Directorate 3

2.2 Organization Structure of the Directorate 3

2.3 Infrastructure & Resources 3

3.0 Scope of Application 4

4.0 Quality Management System 5

4.1 General Requirements 5

4.2 Documentation Requirement 5

4.3 Control of records 6

4.3.1 Issue 7

4.3.2 Re-issue 7

4.3.3 Change, review & approval 7

4.3.4 Personnel responsible of the records 8

5.0 Management Responsibility 9

5.1 Management commitment 9

5.2 Quality Policy 9

5.3 Quality Objectives 9

5.4 Responsibility, Authority And Communication 9

5.4.1 Responsibility 10

5.4.2 Authority & Communication 10

5.4.3 Management Representative 10

5.5 Management Review 10

6.0 Resource Management 10

6.1 Training 10

7.0 Product Realisation 10

7.1 Planning of product realization 10

7.2 Customer-related processes 11

7.3 Design And Development 11

7.4 Purchasing 14

7.5 Production and Service Provision 14

7.6 Control of Monitoring & Measuring Equipments 14

8.0 Measurment Analyses And Improvement 14

8.1 Customer Satisfaction 14

8.2 Customer Complaint 14

8.3 Continual Improvement 14

8.4 Corrective & Preventive Action 15

8.5 Customer’s of Carriage Directorate 15

9.0 References 15

10.0 Responsibility and Authority 16

11.0 Abbreviations 16





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

2.0 Purpose:

To laid down the operating procedure of the Carriage directorate.

2.1 Introduction & Brief Profile of Carriage Directorate:

Carriage Directorate of RDSO is actively engaged in design and development of all types of passenger coaches and their components including up-gradation and standardisation of existing designs. The directorate is also involved in human resource up gradation (In-house training). The main thrust areas for R&D activities are:

• Development of coaching stock with higher speed potential and having improved comfort level.

• Enhancing passenger capacity of coaches by way of more efficient use of moving dimensions.

• Improving reliability, maintainability and safety of coaching stock.

• Developing new materials having fire retardant properties and suitable for aesthetically pleasing interiors.

• Reduction in weight and cost of the coaches by new developments and modifications.

2.2 Organization Structure of the Directorate:

Carriage Directorate is headed by the Executive Director to look the works mentioned in clause No. 2.1 above. The whole Directorate has been divided into small units/sections, headed by the Director/Jt. Dir. to support EDSC. The complete organization set has been explained in a separate document (ref.1).

2.3 INFRASTRUCTURE & RESOURCES:

a) COMPUTER ROOM (Design hall): -Deals with preparation and modification of drawings, 3-D modeling of the components & Fire simulation etc.

b) COMPUTER WING:- i) It looks after System Administration of its in-house centralized hardware equipments, which

are being utilized for major Information Technology applications, its maintenance and AMC of PC’s and associated peripherals, of whole RDSO. It deals with technical vetting of all software/hardware proposals of RDSO. It works under the administrative control of Exe. Director/VDG/Carriage

ii) One HP ML-380 is used as Storage Server for CAD applications of users from Computer Wing, Carriage, Motive Power and Wagon Directorates.

One HP 9000 server is used as license server for UG-NX4, I-DEAS, and ANSYS CAD software, design work station, PCs, printer’s plotters, scanners.

One HP-ML350 with MS Windows Server 2003 is used as Web server, Oracle Database storage server, and for sending e-mails of Pay-particulars to RDSO officials.





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

One Dell Poweredge 2900 is used as Oracle Database server, Application server for Project Monitoring System (PMS).

NUCARS software for use of Vehicle Dynamics Group is installed on HP-UX workstation.

Train running Simulation application software for Electrical Directorate is installed on HP Compaq Desktop using Fedora 9 operating system. One Wipro Blade Server 2008 STD is being used as Document Management System Server (DMS Server). It is consists of two Blade servers one of them is meant for being used as license server and another as Database server.

One server make Dell Poweredge R900 is being utilised for maintaining the Licenses of CATS Application.

iii) Number of application software is being used in Computer Wing for design and simulation

purposes as following:

Adams-Rail Vehicle Dynamics Simulation Software on two numbers of HP- ZS600

Workstations with Windows 7 operating System.

Licenses of various CAD/CAE software such as ANSYS, UNIGRAPHICS,

NASTRAN and IDEAS are being maintained in Computer Wing for the use of

Engineers of RDSO.

c) CRASHWORTHNESS DESIGN CENTER: Crashworthiness Design Center has been equipped with high computing power Linux based Computer Cluster running LSDyna software for non-linear analysis. In addition to this, Center has been provided with two workstations for running pre-processor software True-Gride.

d) RECORD ROOM SSE/Stds. is assisted by other design and ministerial staff, heads the record room. Record room works under the administrative control of Director/Stds./Carriage.

e) CARRIAGE DIRECTORATE OFFICE

The Carriage Directorate office is headed by an OS supported by other ministerial staff. This office works under the administrative control of the senior most Director. The office provides support in terms of maintenance and upkeep of files, drafting and disposal of incoming and outgoing correspondence, preparation of periodical statements etc. The list of files maintained by the office is available in the master list of files (ref. 2). This document will be updated by OS /Carriage once every year in January.

3.0 Scope of Application:

This procedure is applicable to activities carried out with the authority of Carriage Directorate.




Prepared by: Issued by: Page 5 of 17 C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

4.0 Quality Management System:

4.1 General Requirements Carriage Dte. follows Para 4.0 of RDSO’s Quality Manual (ref-3 )

4.1.1 In addition Directorate manual is applicable.

4.1.2 Carriage Directorate

a) Has determined the processes needed for the quality management system and their application in the Directorate (Ref. 4)

b) Has determined the sequence and interaction of these processes,

c) Has determined criteria and methods needed to ensure that both the operation and control of these processes are effective,

d) ensures the availability of resources and information necessary to support the operation and monitoring of these processes,

e) Monitors, measures where applicable, and analyses these processes, and

f) Implements actions necessary to achieve planned results and continual improvement of these processes.

4.2 Documentation Requirement 4.2.1 General

The quality management system documentation of Carriage Dte. includes the following:

a) A Quality manual, (ref.3)

b) Documented statements of a quality policy (ref-4) and quality objectives (ref-5),

c) A Directorate manual, (CG-QM-4.2.2-1, this document)

d) Documented procedures and records required by this International Standard, and

e) Documents, including records, determined by the Directorate to be necessary to ensure the effective planning, operation and control of its processes.

The master list of quality documents (ref-6) lists all these documents maintained at RDSO apex level and applicable to the Directorate. The master list of quality records, ref-7 lists all QMS records maintained at the Carriage Dte.

4.2.1 The details of the various quality records and responsibility of maintaining & disposal of these records

have been tabulated as under:

S. No Records ISO Clause Ref.

Responsibility for record maintenance

1. Management Reviews 5.6 MR & EDSC

2. Education, Skills and experience 6.2 & Doc. No. QO-G-6.2.2-1

SO/Admn.

3. Training 6.2.2 (b) OS/Carr.





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

4. Evidence that the realization process and resulting product meet the requirements

7.1(d) Dir./concerned.

5. Results of the review of requirement related to the product and action arising from reviews.

7.2.2 Dir./concerned.

6. Designs and development inputs 7.3.2 Dir./concerned.

7. Results of design and development reviews and necessary action.


8. Results of design and development verification and necessary action.


9. Results of design and development validation and necessary action


10. Control of design and development changes 7.3.7 Dir./concerned.

11. Validation of processes for production and service provision

7.5.2 Not Applicable

12. Identification and traceability 7.5.3 Dir./concerned.

13. Customer property 7.5.4 Not Applicable

Preservation of product 7.5.5 Not Applicable

14. Control of Monitoring and measuring equipment. 7.6 Not Applicable

15. Results of calibration and verification equipment 7.6 Not Applicable

16. Validity of previous results , when measuring equipment is found not to confirm to requirements

7.6 Not Applicable

17. Internal Audit results 8.2.2 MR & OS/Carr. 18. Evidence of product conformity with the acceptance

criteria indicating the authority responsible for the release of product.

8.2.4 Not Applicable

19. Control of non-conforming products 8.3 Not Applicable

20. Results of corrective action 8.5.2 (e) MR & OS/Carr.

21. Results of preventive action 8.5.3 (d) MR & OS/Carr.

4.3 Control of records:

In addition to QM para 4.2.4 and (ref.8) for issue, re-issue, change, review and approval of controlled documents issued by Carriage Directorate, the following procedure shall be followed.

• OS/Incharge is responsible for issue of all documents under guidance of Director coordinating QS activities.

• 3rd tier documents shall be issued by the nominated supervisors in January each year, with the

approval of Director /E&S

a) Master list of 4th tier documents – US (Development).

b) Master list of drawings of All Type Coaching Stock, Specifications & Reports-US (Record).

c) Master list for distribution of QS documents –OS/Incharge.





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

• OS/Incharge shall be responsible to maintain issue & change registers for issue of master copies, and for recording changes made since previous master lists, to help in the next issue.

• Preparation of Master Copy:On approval of the draft, the document shall be printed after accepting all changes on the track changes feature. Only the master copy of the document shall be signed by the: Document preparing authority, Approving authority / Document issuing authority and shall be termed as the master copy.

• One copy of all the controlled documents issued by Carriage Dte. will be maintained by OS/Incharge. The document should be marked as “MASTER COPY” with red ink in file bearing No. MC/ISO/Master Copy.

• US of the assigned section for project shall ensure that the documents collected for carrying out the design project, quality records generated in course of project, and calculations etc. are kept in a project file in his personal custody.

• US of the assigned section shall ensure that all the design outputs are numbered in accordance with (ref. 9). For this purpose, he shall obtain a number from the Record Section, and furnish a master copy of the document to the Record Section along with soft copy.

• The assigned US is responsible for release of design output to the customer on completion of the project. He shall furnish master copies of all the design outputs to US (Recod) & all other documents in the project file to OS for merger in the subject file.

• Subsequent issue & record keeping shall be done by US (Record) & OS respectively, only with the specific approval of UO/EDSC. In case of issue of controlled documents to firms, the work instructions issued by Wagon Dte. (Ref. 10) shall be followed.

• OS will put up files every 3 years to all technical officers and nominated SE’s/Inspectors for weeding. The officers shall indicate the papers to be weeded out as per (ref.11). OS & his staff will remove the documents identified for destruction and recombine the files.

• UO (Record) will take similar action in respect of design outputs & other controlled documents in his custody but the documents retaining period shall be 30 yrs.

4.3.1 ISSUE All controlled documents shall be issued electronically to the registered users through intranet with proper security and in hard copy to other copy holders(Non-registered copy holders) by Dir/E&S. SE(IC) of each section shall maintain a folder for keeping `MASTER COPY’ marked in `RED' on first page of all such documents and a register to keep record of issue.

4.3.2 RE-ISSUE

Reissued copies shall bear a blue stamp containing copy number, copyholder with signature of re- issuing authority.

4.3.3 CHANGE, REVIEW & APPROVAL

• The authority for change, review & approval of 3rd tier documents of Carriage directorate is as under:





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Documents pertaining to Authority for change, review & approval

Coach design Dir/Jt. Dir/CD

E&S Stock Dir/Jt. Dir/E&S

STD/ICF/LHB Stock Dir/Jt. Dir/STD

Sub-systems Dir/Jt. Dir/SS

Vehicle dynamics Dir/Jt. Dir/VDG

Product Development Dir/Jt. Dir/PD

Computer Wing Dir/Jt. Dir/Comp.

• If any controlled document requires change/review, the same shall be carried out by authorities indicated in para 4.3.3. The change authority shall prepare background paper on format (ref. 12) covering the reasons for change and submit the same along with approved

copy of the new version to Dir/E&S/ISO for issue. After issue of new Version, SE (IC) keeps the background paper along with the obsolete copy for record in a folder.

• Controlled copy holders on receipt of his copy understands changes himself and, if required,

personnel working under him familiar with the document, maintains / updates the index, stores and preserves the document In such a way that the document is not damaged and is available for use.

4.3.4 Personnel responsible of the records

The following are the details of the records to be maintained personnel responsible for control and disposal:

S. No Record ISO Clause

No.

Generated/ Updated by

Indexed/filed/ accessed/

stored/ maintained/ disposed off

by

Location Record

retention period

1 Records for creation / change / issue and withdrawal of QMS documents.

Dir/Carr/ISO SE/JE/ISO MC/ISO/ GEN

Last 3 years

2 Records of Management Review 5.6.1 MR & EDSC SE/JE/ISO MC/MRM & MC/DRM

Last 3 years

3 Records of education / training / skill and experience of personnel.

6.2.2(e) EDSC OS/Carr. MC/Trg Till person in service

4 QAP’s for product realization. 7.1 (d) Director Concerned

SE/JE Concerned

DIC Concerned

Last 3 years

5 Records of review of customers’ requirements.

7.2.2 Director Concerned

SE/JE Concerned

DIC Last 3 years





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

6 Records for design and development inputs


SE/JE Concerned

DIC Last 10 years

7 Records for design and development outputs


SE/JE /Record In proper racks

Last 30 years

8 Records for design and development review.


SE/JE Concerned

DIC Last 10 Years

9 Records for design and development verification.


SE/JE Concerned

DIC Last 10 years

10 Records for design and development validation.


SE/JE Concerned

DIC Last 10 years

11 Records for design and development changes.


SE/JE Concerned

DIC Last 5 years

12 Records of product processing / service provision


SE/JE Concerned

DIC Last 5 years

13 Records for identification and traceability of product / service


SE/JE Concerned

DIC Last 5 years

14 Records of internal audit 8.2.2 Dir/Carr/ISO SE/JE/ISO MC/Audit Last 3 years

15 Records indicating conformity of the product / service.


SE/JE Concerned

DIC Last 3 years

16 Nature of the product non- conformities and any subsequent actions taken, including concessions obtained.

8.3 Director Concerned

SE/JE Concerned

DIC Last 3 years

17 Records of corrective action 8.5.2 (e) Dir/Carr/ISO SE/JE/ISO MC/ISO/C&P Currently Opened

18 Records of preventive action 8.5.3(d) Dir/Carr/ISO SE/JE/ISO MC/ISO/C&P Currently Opened

5.0 Management Responsibility

5.1 Management commitment

Carriage Directorate follows clause 5.0 of Quality Manual at ref-3. In addition, DM shall be applicable.

5.2 Quality Policy

Carriage Directorate follows RDSO Quality Policy (ref. 4)

5.3 Quality Objectives:

Quality objectives of Directorate are issued as a separate document at ref-5.

5.4 RESPONSIBILITY, AUTHORITY AND COMMUNICATION





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

5.4.1 RESPONSIBILITY:

In absence of EDSC, ED/VDG shall look after the duties of ED/Carriage. In case of all other officers, the responsibility shall shift to the next officer under their direct control, while the authority shifts to the nominated officer or (if no one is nominated) to the next higher rank.

5.4.2 AUTHORITY & COMMUNICATION:

Issuing Authority - Dir/Jt. Dir/ E&S Re-issuing Authority - Documents issued by MR shall be re-issued by Dir/E&S to

concerned copyholders of the Directorate. The issuing and re-issuing authority will be same.

5.4.3 Management Representative

Carriage Directorate has nominated Dir/E&S as a management representative for Co-coordinating activities related to quality system pertains to Carr. Dte.

5.5 Management Review:

Para 5.6 of QM (ref.3) will be followed.

6.0 RESOURCE MANAGEMENT:

QM para 6.0 shall be followed. In addition following shall apply: -

6.1 TRAINING:

Carr. Dte. maintains appropriate records of education, training, skills and experience as per guidelines specified in ref-11.

6.1.1 Trainings are organized by the Comp. Wing of the Carr. Dte. as and when requested by the various Directorates of the RDSO based on their requirements.

6.1.2 All the training information including training index register (Training record of course attended by the Officers / staff), Training needs formats ( ref.14), Performance Evaluation format No (ref. 15) and designer’s qualification log sheet formats No. (ref. 16) shall be maintained by OS/ Incharge

6.1.3 Procedure:

• Directorates of RDSO are to send nomination of staff /officers for particular quarter so as to reach Computer Wing at least one month in advance.

• On receipt of nominations, concerned SA-I will issue a Training-Calendar with the details of the nominees of each course, at least fifteen days before the start of the first course, so that trainees are advised of the dates well in advance.

7.0 PRODUCT REALISATION: -

7.1 Planning of product realization Carriage Directorate follows clause 7.0 of Quality Manual at ref-3. In addition, this DM is applicable.





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

7.2 Customer-related processes Carriage Directorate follows clause 7.2 of Quality Manual at ref-3

7.3 DESIGN AND DEVELOPMENT:

In addition to QO-G-7.3-1 (Design and Development), following shall apply:

• ED will specifically assign a project to Unit Officer(s), after completion of the contract review.

• The DIC for the project shall be prepared on standard format (ref. 17) by the concerned Unit Officer and approved by ED. The DIC shall indicate the nature of the project as per QO-F-7.3- 1.

• Project documentation as regards resource & output planning, preparation of Design activity plan (DAP) shall be initiated by the Unit Supervisor based on DIC and approved by the controlling officer of the Unit. While preparing the DAP the unit supervisor shall ensure that in the column for expected duration of each activity the man-hours required for that activity are clearly filled up.

• In case the project requires activities to be undertaken by other units within/outside the directorate, the Unit Officer should consult them through letter or telephone, and the planning be finalized only after this feedback has been factored in.

• The Unit Officer shall henceforth carry out all activities of co-ordination, planning & progress

monitoring for the project. He shall also report any constraints in achieving of the project output of his controlling officer & to ED when they arise.

• The SSE/JE preparing the design output shall obtain the relevant number from the Unit Supervisor – Record Section as per work instructions (ref.9).

• Design reviews may be carried out by a SSE/Officer as planned in the DAP. The US shall ensure that no project is completed without a design review. While carrying out design review in the last column of the DAP, in addition to filling up of actual date of completion of each activity he will also fill up the actual man-hours taken up for the activity. In order to keep track of the man-hours spent on each project the US shall fill up log sheet of man-hours spent on each activity project wise on PMS.

• Design verification may include activities such as:

• Undertaking tests (Simulations etc.) and demonstrations.

• Carrying out alternative calculations, wherever necessary.

• Comparing the new design with a similar proven deign.

• Review of documents before release.

• Validation of a design may be done by lab trials, instrumented field trials, service trials or customer feedback. In case validation is sought through customer feedback/extended service trials over a prolonged period, not in control of RDSO, the validation and subsequent design





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

changes may be planned as a follow-up project.

• All the project documentation such as contract review on format QO-F-7.3-1, DIC on format QO-F-7.3-1, DAP on format QO-F-7.3-2 , design review on format QO-F-7.3-3 , design verification on format QO-F-7.3-4 and design validation on format QO-F-7.3-5 shall be maintained on separate files. After completion of the projects all the documentation shall be merged with the project file on the noting side.

• ED will approve a new/substantial modification to a Specification/STR/CMI before issue.

7.3.1 Procedure for design of new stock:

• The Unit Officer shall prepare a concept design and put it up to ED for his acceptance. If found acceptable, ED shall inform the major design features to Railway Board.

• After acceptance, Unit Officer shall carry out further detailing. Parameters/dimensions of the layout, important sub-assemblies, shell, suspension etc. shall be identified, in consultation with the manufacturers/other R&D units, as required. Unit Officer shall ensure standardization & maintainability of the design.

• Design parameters arrived is submitted to the rolling stock manufacturer(s) for obtaining their views regarding manufacturability.

• Based on the discussion, the design parameters shall be finalised. The Unit Officer shall prepare the particular specification & necessary key drawings for the new stock. The Unit Officer shall obtain the specific approval of ED before sending them to the rolling stock manufacturer.

• Stage-wise monitoring meetings are held between manufacturer, RDSO & equipment suppliers as considered necessary. RDSO & manufacturers shall sort out any design/manufacturing problems jointly.

• The prototype stock shall be subjected to static tests, oscillation tests, and field trials as per the trial scheme prepared by RDSO.

• Speed certificates for trials, and final speed certificates shall be prepared by the Unit Officer and issued by ED/Motive Power to all Railways & Railway Board.

• Since RDSO does not control manufacture of prototype, the activity plan shall be in 2 phases; the second phase being planned only when the manufacture is complete.

7.3.2 Product development: 7.3.3 The Carriage Directorate develops new and improved products and materials for application on

coaches to improve safety, reliability, aesthetics and passenger comfort. Product development is also undertaken to promote environment friendly products.

7.3.4 To ensure consistency in quality of supply of various coach-furnishing materials the following procedure is proposed to be implemented.

i) For each inspected lot, the inspecting agency will seal two randomly selected samples duly

signed by the representative of manufacturer and inspector. The samples will be of sufficient





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

size so that all tests as per the specification can be done on them.

ii) The inspector will send these sealed samples to RDSO

iii) RDSO may send one of the samples for testing randomly at its discretion and in case of non conformity the punitive action as deemed fit will be taken against the firm.

iv) Sealed sample after coding will be sent to lab for testing as per the extent procedure. The records of sample will be maintained in a register.

v) In case of dispute, the second sample will be opened in the presence of firm’s representative and sent for testing in the concerned lab.

7.3.5 Procedure for conducting and monitoring the trials:

i) The trial scheme shall be made for every item to be put under trial. The scheme will have the

following details,

a. One official will be nominated from RDSO to monitor the trial.

b. The duration of trial and No. Of coaches on which trial has to be done.

c. The periodicity of feedback of trials by Railways.

d. The details of measurements and items to be monitored/observed.

ii) Trial scheme shall be issued along with instruction for trial.

iii) The nominated official of RDSO shall visit the field for monitoring and physical verification of trial results before closure of the trial.

iv) On closure of trial, closure report shall be made and put up to EDSC for approval and further necessary action.

v) A separate register for trials will be opened and each trial scheme will have a number in ISO format.

vi) The progress of each trial will be discussed in MRM meetings.

7.3.6 Product development is generally undertaken in collaboration with manufacturers. The following steps should be taken, as applicable to the particular development:

• Definition of end use requirements.

• Defining material requirements.

• Defining dimensional requirements.

• Defining manufacturing requirements.

• Framing of draft specifications.

• Inspection of items at various stages of manufacture, type test and prototype inspection.

• Prepare trial scheme for monitoring field performance, as required.





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

• Obtaining performance feedback by field visits wherever necessary.

• Modification in design based on feedback.

• Finalization of drawings and specifications. This is done only when the product has been found to be useful, parameters of the product have been established and a few vendors have been developed for supply of item.

7.3.7 The prospective vendors are asked to register with RDSO in accordance ref. No. 18.

7.3.8 Since the complete development of the product and finalization of the specification is time- consuming; for Railways benefit, tentative specifications along with the names of the manufacturers, successfully participating in the development may be circulated to Railways, as decided by the Director concerned.

7.3.9 In case a proprietary item is approved, which requires approval of some firms’ drawings, the same shall be approved by application of a rubber stamp as per CG-F-0006

7.4 PURCHASING: 7.4.1 Carriage Directorate follows clause 7.4 of Quality Manual at ref-2. In addition; this DM is applicable:

7.4.2 For the purpose of vendor registration, with reference to Directives, the Work Instructions at ref-18 shall apply.

7.5 Production and Service Provision: Carriage Directorate follows clause 7.5 of Quality Manual at ref-3.

7.6 Control of Monitoring & Measuring Equipments:

Carriage Directorate follows clause 7.5 of Quality Manual at ref-3.

8.0 MEASURMENT ANALYSES AND IMPROVEMENT:

QM para 8.0, ref.15 to ref. 19 shall be followed.

8.1 CUSTOMER SATISFACTION: QM para 8.2.1 shall be followed.

8.1.1 Improvement will be achieved in:-

• Customer satisfaction level by establishment of improved system for customer feedback & implementation of measures for customer satisfaction.

• Improvement in management information system through system up gradation.

8.2 A customer complaint Register is being maintained with SE/ISO to cater the customer complaints.

8.3 CONTINUAL IMPROVEMENT:

QM para 8.5.1 shall be followed. Improvement will be achieved in:-

• Design-development of coaches.





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

• Design, reliability & development of new products for coaches.

• Reviewing specifications, drawings and instruction manuals for coaches.

8.4 CORRECTIVE & PREVENTIVE ACTION:

QM para 8.5.2 & 8.5.3 shall be followed. Improvement will be achieved in addition to ref.19 following shall be applicable:

8.4.1 Any non-conformity pointed out by personnel of RDSO shall be addressed to the concerned Director. He will then take action as per ref. 19.

8.4.2 The identified customer complaints shall be entered into a Customer Complaint register by SO before further movement.

8.4.3 The complaints shall be analysed by concerned Unit Officer and reasons for the complaint, proposed corrective action, proposed preventive action & probable time frame recorded by him in a customer complaints register.

8.4.4 The implementation of corrective & preventive action shall be the responsibility of the UO concerned.

8.4.5 Any feed back, general reference, reference regarding manufacturing defects are not treated as complaints.

8.5 CUSTOMERS’ OF CARRIAGE DIRECTORATE a) Internal customers

All directorates of RDSO/Lucknow, The list of directorates of RDSO is as per para 2.2 of Quality Manual.

b) External customers All 16 zonal railways and production units viz. Integral Coach Factory/Chennai, Rail Coach Factory/Kapurthala, Rail Wheel Factory, Bangalore are the customers of the Carriage Directorate.

9.0 References:

Ref. No.

Document No. Description

1 CG-D-5.5.1-1 Organisation setup of Carriage Dte RDSO

2. CG-M-4.2.4-13 Master list of files dealt by Carriage Directorate.

3. QO-QM-4.2.2-1 RDSO Quality Manual

4. QO-QP-4.2.1-1 RDSO Quality Policy

5. CG-M-5.4.1-1 Quality objectives of Carriage Directorate

6. QO-C-4.2.1-1 Applicability of apex level documents in CG - Carriage Directorate

7. CG-M-4.2.4-1 Master list of quality records

8. QO-D-4.2.3-1 Control of Documents

9. CG-WI-4.2.3-1 Work instructions for numbering and control of design documents

10. WD-WI-4.2.1-4 Issue of controlled documents to firms

11. CG-F- 0005 Format for weeding of files.





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

12. CG-F- 0010 Format for job sheet

13. QO-G-6.2.2-1 Records of education, training, skill and experience

14. QO-F-6.2.2-1 Training needs format

15. QO-F-6.2.2-2 Performance Evaluation format

16. QO-F-7.3-6 Designer’s qualification log sheet 17. QO-F-7.3-1 Format for Design Input Catalogue

18. CG-W-0002 Work instructions for Vendor development & registration

19 QO-D-8.5-1 Corrective & preventive action

10.0 Responsibility and Authority

Activity Responsible Approver Supporting Consulted Informed

Compliance of Directives mentioned in this manual

Director/IC/

Carriage

EDSC Director E&S MR/ISO Cell All directorates through intranet

11.0 Abbreviations

EDSC Executive Director (Std)Carriage

MR Management Representative

Dir./Jt. Dir Director/Joint Director

DD/ADE Deputy Director/Asstt.Design Engineer

US Unit Supervisor

OS Office Superintendent (Carriage)

SSE/SE/JE Sr. Section Engineer/Section Engineer/Junior Engineer

Inspector Chief/Senior/Junior Inspector

RDSO Research Design & Standards Organisation

M&C Metallurgical & Chemical

PU Production Unit

QAP Quality Assurance Plan

SOP Schedule of Powers

DIC Design Input Catalogue

UO Unit Officer

QA Quality Assurance

SA System Analyst

AP Assistant Programmer

CO Console Operator

SCO Senior Console Operator

DPS Data Processing Superintendent

LIB Library (Computer Wing)

AMC Annual Maintenance Contract

PC Personal Computer





Copy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Webite

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

C

opy c

ontr

olle

d o

nly

when

vie

wed

on

the

RD

SO

IS

O C

ell

Website

. L

oca

l/P

rinte

d c

opie

s p

erm

itte

d, but

are

unco

ntr

olle

d. C

heck c

ontr

olle

d c

opie

s b

efo

re u

se

E&S EMU & Self Propelled Vehicles

SS Sub-System

CD Coach Design

CDC Crashworthy Design Centre

Std Standard

VDG Vehicle Dynamics Group

PD Product Development

Comp Computer