KAY SONS ELECTRICALS PVT LTD VARANASIdlwdesign.org/DLW_VA/DOCUMENTS/738/FUEL PUMP MOTOR... · Training and involvement of employees in development, ... 13 Wire Visual check Major

KAY SONS ELECTRICALS PVT LTD

VARANASI INDIA

QUALITY ASSURANCE PLAN

FOR

FUEL PUMP DIESEL LOCOMOTIVE –HHP Locos

AN ISO 9001:2008 CERTIFIED ORGANAZATION

QUALITY ASSURANCE PLAN FOR

FUEL PUMP FOR DIESEL LOCOMOTIVES

Revision No. Date Page No.

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KAYSONS ELECTRICALS PVT. LTD. Prepared & Reviewed by Approved by

Table Contents

Sl.No. Section No. Title Page No. 1 QAP: TC Table of Contents 2 QAP:CONF Confidentiality 3 QAP:CP Company profile 4 QAP:CC Certificate of conformity 5 QAP : QC Quality Control 6 QAP:ORG Organization Chart 7 QAP:QKP Qualification of Key Personal 8 QAP:PFC Process Flowchart 9 QAP- Section-D Detail of Su Assembly /Components manufactured in house and out sourced Items

10 QAP:01 Inward Inspection Test Format & Production Planning 11 QAP:SP Sampling Plan 12 QAP:02 Quality Assurance System – Inspection and Testing Plan Product Control 13 QAP:03(TR) Test Reports (Final Testing In House of Product ) 14 QAP: CC& WF Customer Complaints & Warranty Failure 15 QAP:WIS Work Instruction for Soldering 16 QAP:WIM Work Instruction for Mechanical assemblies 17 QAP:WIW Work instruction for wiring




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CONFIDENTIAL DOCUMENT

This document is the property of KAY SONS ELECTRICALS PVT. LTD. No. portion of this document can be copied without written permission of the Managing Director of Kay Sons Electricals Pvt. Ltd.

These documents are issued to DLW for their reference Only.

Copy No. : Issued to : DLW

01 Varanai

For : KAY SONS ELECTRICALS PVT. LTD., (RAVI GUPTA) (Managing Director ) Office Seal :




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QAP : CP (Company Profile )

INTRODUCTION

Ours is a small –scale industries engaged in design, development, manufacture and supply of sophisticated custom built Electrical, Electro Mechanical & Electronics Equipments at a very competitive price to Indian Railways for last 20 years. Company Registered with Resistor of Companies U.P. in 1991 vide registration no. 20-12984 Dt.02.04.1991. It started operations in 1992.

We have a strong technological base for designing and manufacturing of power electronics and control equipments.

Ours is an ISO 9001:2008 firm certified by Management System Certification Body vide Registration No. R91/108 when we are continues till date. (QSCert).

Kay Sons Electricals Pvt. Ltd. has strictly adhered to quality standards and years of trouble-free service our equipment have put in, can vouch for this fact. Stringent Inward component checks, in process inspection of drilling, Machining, Assembly and required checks are routine in our Quality Control Procedures.

We got BIS Certification for use of ISI Mark on our Conduit pipes vide License No. CM/L-9283487 as per IS 9537 Part 2:1981.

Our Company Excise Registration No. AAACK9725D XM001

VAT Registration No. 09983800587 Dt. 03.06.1992

CST Registration No. VN-5236176 Dt. 03.06.1992

Import /Export License NO. 1592000444 Dt. 08.07.1992

All the items manufactured by us are conforming to relevant IS/ BS/ ASTM/ CLW/RDSO Specification and Drawing and serving to CLW/Indian Railway with excellent

reputation for quality and timely delivery for last many years.

We are having in house design and Development facilities for development of new products supported by engineers and consultants within the country and abroad.




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QUALITY POLICY

Our Quality Policy: “To improve the quality of Products through continuous improvement in quality of raw material, manufacturing techniques and effective quality management system to enhance Customer satisfaction.” Our Objectives: The policy is developed through the following Quality Objectives:

1. Product design to meet customer specification and ease of production with technology up – gradation.

2. Adequate Vendor/Trader evaluation and monitoring the performance to ensure quality of incoming material.

3. Adherence to specification at different stages, product and assembly with aim of defect prevention.

4. Training and involvement of employees in development, implementation and improvement of quality system.

5. Continual reduction in customer complaints.

6. Monitor effectiveness of implementation of quality system.

7. Interaction with customers to increase order position.




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QAP : CC (Certificate of Conformity & Capacity )

Product FUEL PUMP Manufactured By M/S KAY SONS ELECTRICALS PVT. LTD. Model No. KSEL/FP/000 Brand KEPCO DLW DRG.NO. DRG. No. 40122943 ALT b P.L.No. 17454633 Application HHP LOCOS Capacity of Monthly Production 50 Nos. Capacity of Yearly Production 400 Nos.- 600 Nos. The above product have been Inspected and Tested according to above specification and found meeting all the requirements. The Product is conformed to Specification and drawing as said above




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Technical Detail

Maximum Outlet Pressure

120 PSI at 74 VDC

FUEL FLOW RATE 7GPM @90PSI and 74 VDC 0 GPM @120 PSI and 74V (Relief Valve FULL Bypass )

Max Continous Current At 120 PSI 20 AMPS Input Voltage 45-87 VDC Nominal With Short Duration Drops to 25VDC Weight 85 LBS Max Dry

QAP : QC (Quality Control )

The policy is developed through the following Quality Objectives:

1. Product design to meet customer specification and ease of production with technology up – gradation. 2. Adequate Vendor/Trader evaluation and monitoring the performance to ensure quality of incoming material. 3. Adherence to specification at different stages, product and assembly with aim of defect prevention. 4. Training and involvement of employees in development, implementation and improvement of quality system. 5. Continual reduction in customer complaints. 6. Monitor effectiveness of implementation of quality system. 7. Interaction with customers to increase order position.




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QAP : ORG (ORGANAZATION CHART ) MANAGING DIRECTOR

DIRECTOR

GENERAL MANAGER FA& C. A. O. Marketing Manager Quality Control R & D Head Material Production Manager

Account Officer-I Account Officer-II

Product Design Group In charge QC

Production Supervisor Production Supervisor

Marketing Ex.-I Marketing Ex.-II Marketing Ex.-III Marketing Ex.-IV In charge Store Purchase Supervisor

Inward Q.C. Inspector Testing Supervisor Final QC Inspector




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QAP : QKP (Qualification of Key Personal )

Pat I:

Sl.No. Requirement as per STR/Spec. Details of Personnel employed STR/Spec Para

No. Qualification Specified in Spec/STR

Experience Specified in Spec/STR

Name Designation Qualific. Experience Brief Scope of Responsibilities

STR/ Spec.

Para

1 NIL NIL NIL NIL Sir Uma Shankar Head R&D & Q.C.

BE Mechanical

40 Year Design & Development

2 NIL NIL NIL NIL Mr. Anjani Tiwari Production Head BE 12 Year Production 3 NIL NIL NIL NIL Mr.Ajay Mishra Final QC Inspection Diploma 6 Year Testing 4 NIL NIL NIL NIL Mr.Gopal Incoming QC BE 6 Year Testing 5 NIL NIL NIL NIL Mr.Rajesh Mishra Testing Supervisor Diploma 12 Year Testing 6 NIL NIL NIL NIL Mr.Akhilesh Design Engineer BE 10 Year Design 7 NIL NIL NIL NIL Mr. Biredra CNC Programmer Diploma 4Year Programmer 8 NIL NIL NL NIL Mr. Avinash Sr. Manager (Co-

ordination ) BE 6 Year Material procurement

Part II: Not Applicable




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Part I: Process Flow Chart

Customer Specified PO Copy

Head R & D Head Materials Head Production

Reject

Mechanical Supplier

PO’s to Supplier s & Vendors

Electrical Supplier

Check according to Drawing by IE

Production Planning

In Process Q.C. (wiring)

Sock & Burn Test

Store

Inward Q.C

System Assembly in Cabinet

Final Testing With Test Report

OK

Wave Soldering OF PCB Wire harness prep, cabinet wiring

Component lid cutting and shaping

Customer or Third Party Inspection

Winding of chock Cabinet Printing

In Process Inspection (Chok /Transf)

Finish Goods Packing & Forwarding

Dispatch to Customer

Reject OK

In Process Q.C. of Soldering

In process Inspection /Testing of PCB

In Process Q.C. Inspection /Testing of

equipment

Re work

NC

OK

OK

ABBREVIATIONS NC- Non Conformity Rej.- Reject O.K. Accept TPI. Third Person Ins.




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Sl.No. Item Characteristic Classification Type of Check

Quantum Check

Reference Document

Acceptance Norm

Agency

1 Electrical Cover Plate , Body and Base

Visual , Dimensional

Major Measurement & Observation

As per sampling Plan

DLW Drg. & Specification

Inspection Report Q.C. Depot

2 Bare PCB Thickness ,Grade, Solder ability, BBT (for PTH ) visual

check

Major Observation As per sampling Plan



3 Lifting Eye Grade &, Dimensional




4 Relief valve Grade &, Dimensional




5 Factory set Relief Valve

Grade &, Dimensional




6 Electrical Conduit Interface Female





7 CL Of INLET Outlet & Relief Valve Vent





8 INLET Port Grade &, Dimensional




9 Component Assembly


Major Observation 100% Check DLW Drg. & Specification

Test report Quality Inspector

10 Populated PCB Visual Check of Soldering



11 Positive negative Terminals

Visual & Dimensional

Major Measurement 100% Check DLW Drg. & Specification

Test report Production supervisor

12 Outlet Port Grade &, Dimensional



13 Wire Visual check Major Observation 100% Check DLW Drg. & Specification





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Sl.No. Item Characteristic Classification Type of Check Quantum Check

Reference Document

Acceptance Norm

Agency

14 Condenser 250V Visual Check & Electrical Checking



15 PF Condenser Visual Check & Electrical Checking



16 Transistor Visual Check & Electrical Checking



17 Terminal Lug Visual Measurement &

testing

Major Observation Measurement

100% Check DLW Drg. & Specification

Test report Production supervisor/ Q.C.

18 Hardware Visual Performance

Testing


100% Check DLW Drg. & Specification

Final Test report Production supervisor/Q.C

19 Sub Assembly Visual Measurement &

testing


100% Check Inspection for Subassembly /final

product

Test report Production supervisor/ Q.C.

20 Product Assembly Visual Performance

Testing


100% Check Inspection for Subassembly /final product & W.I. &

Product Specification

Final Test report Production supervisor/Q.C




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In Process Su Assembly Sl.No.

Component Operation

Machine/ Equipment used for Operation

Character-sticks to be Monitored

Classification of Criticality

Type /Method of Check

Quantum of Check Reference Document

Acceptance Norms

Format of Records

Agency for Inspection

If Out source Address of Agency

Remark

21 Wire Cutting Cutting Machine

Visual defects 2. Dimensional Check 3. Finish

Major V/I First off 100% for approval sampling for regular production

As per Quality Procedure


Inspection Register .

Internal Quality control Checks

Internal Goods Receiving Bay

22 Sizing Sizing Machine








23 Machining CNC Machine








24 Grinding Grinder Machine








25 Buffing Buff Machine








26 Crimping Crimping Tool

Visual ,Crimping of wire

Critical V/I First off 100% for approval sampling for regular production






27 Soldering Soldering Equipment

Visual ,Crimping of wire

Critical V/I First off 100% for approval sampling for regular production









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Equipment Sub Assembly Sl.No.

Component Operation






Acceptance Norms

Format of Records



Remark

28 Electrical Cover Plate ASM

Screw Driver ,Riveting Machine

Visual Defects Dimensional Checks

Critical V/I First of 100% for approval sampling for regular production

As per DLW Drg & Specification

As per DLW Drg & Specn.

Inspection Register . Raw material Test Report

Internal Quality control


29 Mechanical Assembly

Wire cutting tools Crimping tools








30 Out Let ASM Visual Defects Dimensional Checks







31 LIFTING EYE ASM

Screw Driver ,Riveting Machine











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Equipment Final Assembly AS PER DRG.NO. 40122943

Sl.No.

Component Operation






Acceptance Norms

Format of Records



Remark

32 Electrical Cover Plate Assembly

Visual Defects Dimensional Checks ,Performance check

Critical, Major V/I First of 100% for approval sampling for regular production

DLW Drg. & As per Quality Procedure KSEL/FP





33 Relief Valve Port Assembly








34 Factory Set ASM








35 Electrical Conduit Interface Female ASM








36 Positive Negative Terminal Posts Polarity











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PRODUCT FINAL TESTING AS PER DLW DRG. Sl.No. Component

Operation Machine/ Equipment used for Operation





Acceptance Norms

Format of Records



Remark

1 Visual Test Visual Visual Defect Critical V/I/T 100 % Testing Checking Routine Test

As per DLW Drg

As perDLW Drg



Internal/ Testing Agency

Goods Final Product Testing Bay

2 Preliminary Checking

General workmanship & Finish

General Operation

Critical V/I 100 % Testing Checking Routine Test

As per DLW Drg

As perDLW Drg





3 Dimensional Checks

Dimensional Checks


Critical 1.Digital Vernier. 2.Micromertr

100 % Testing Checking Routine Test

As perDLW Drg

As perDLW Drg

Inspection Register




4 Insulation Resistance Test

Megger I.R.Level Critical V/I 100 % Testing Checking Routine Test

As perDLW Drg

As perDLW Drg

Inspection Register




5 High Voltage test

High Voltage Tester

Should With Stand the Test

Critical V/I 100 % Testing Checking Routine Test

As perDLW Drg

As perDLW Drg





37 CL Of Inlet Out Let & Relief Valve vent asm








38 Main Assembly (Consisting of Electrical ASM and Mechanical ASM











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Procedure for Inspection & Testing of Incoming material (Inward Inspection ) QAP : 01

Part –I : Document No. KSEL/FP/000 Date : Name of Material : EMD Part No. : KEPCO Pt. No. : Sample Plan :

Incoming No.____________ Date:__________ Batch No .__________ Date:__________ Vendor Details.___________________ Invoice/Challan No.__________ Date:__________ P.O.No. ___________________________ Date:___________ Qty Received : ____________ Sample Qty:----------------------------- Parameters Checked

Sl.No. Check Point Specified Observation Remarks 1. Visual Checking 2 Dimensional Checking 3 Material

Qty. Sample Size 1-10 5 11-25 15 26-50 35 51-100 75




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Step I

PRODUCTION MONTHLY PLAN

P.O.No. D.P. Product. Name Qty. for Month Consignee Remarks

Step II

Production Requisition Pleas Issue the Following Material For :-

Sl.No. Description of Material Qty. Required Material Required Issue Remarks




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INCOMING MATERIALS Item Sample size and frequency of

insp. Parameter for insp.

Equipment Used Acceptance limit/criteria/ specified value

Rejection details

IGBT 100% INSPECTION As per work instruction

Multi Meter As per characteristic Returned to vendor

Enclosure & Heat Sink

100% inspection Ss per SIPL Scale, Vernier As per Drawing -do-

Discrete Electronic Components

Sampling Plan as per IS- 2500 Part- I:L 2000 Insp. Level S-1

As per Multi Meter, LCR Bridge, Voltage Source

As per their characteristic -do-

Discrete Mechanical Items

-do- -do- Scale, Vernier As per items characteristic -do-

Discrete Electrical Components

-do- -do- Multi Meters, voltage Source, Current Source

As Per items characteristic -d0-

PROCESS CONTROL

Item Sample size and frequency of insp.

Parameter for insp. Equipment Used Acceptance limit/criteria/specified value

Rejection details

Populated PCB 100% Visual checking of soldering & burn in test

Magnifier As per Work Instructions for Soldering

Reworked or scrapped as per Product Nonconformity Report

Populated PCB 100% Burn in Test at 70°C Environmental chamber and Power supply

Test for functionality -do-

Sub- assembly 100% Visual, Measurement & Testing

Multi Meter, Oscilloscope

As per Work Instruction for Sub- Assembly Inspection

-do-




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PRODUCT CONTROL Item Sample size and

frequency of insp. Parameter for insp. Equipment Used Acceptance

limit/criteria/specified Rejection details

Complete product assembly of Fuel PUMP

100% Visual, Performance as per DLW DRG. & spec. No. 40122943

Oscilloscope, Multi Meter, Voltage Source, Testing ZIG

As per WINS for inspection of FUEL PUMP

Reworked or scrapped as per Product Nonconformity Report




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Title System of Maintaining The Date of Customer Complaints/ Warranty Failures Date 04.12.2012 Section No. QAP : WF Page No. 42 of 45

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QAP : WIS (WORK INSTRUCTION FOR SOLDERING )

1. Soldering will be done by qualified soldering Operators with appropriate tools. 2. Components are assembled in an order depending on their height and size 3. Solder joints are inspected 100% visually by operators in process control. 4. Inward Inspection cleared only is taken for soldering operators. 5. Soldering Iron Tip is wetted to achieve good solder flow and hens good joint. 6. Heating :-

a. Surface to be soldered is applied with sufficient heat by soldering iron. b. Heat should not be high as to cause damage to component

7. Optimum quantity of solder shall be applied to avoid Excess or under solder joints for especially for PTH border. 8. Solder Joints are inspected for the following.

a. Dry solder b. Excess and under solder c. Short and bridging effects d. Pin holes and blow holes e. Spikes and cavities

9. Goods contact between the soldering tip and the parts to be maintained. 10. Keep the contacts maintain between irons, the joint memers until good flow of solder occurs. 11. Proper tools must be used for bending, cutting and striping of wires and they should be kept clean and in order. 12. The high wattage soldering shall be used for soldering heavy components and wire joints. Like Brass contact, copper contacts. 13. After soldering the are cleaned with recommended solvents. 14. Visual inspection is done for good workmanship and sound and bright surface. 15. The soldering operator shall qualified for every 6-8 months as stated in KEPCO /Production department /F




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Work Instruction for Assemblies

1. Conform the sub assemblies and their dimensions are as per drawing. By using measuring tools like, screw gauge and height gauge. Large dimensions. Are

measured with steel rule.

2. Mechanical assemblies are carried out by approved samples or approved assembly drawings.

3. Rivet, Screw to with adequate strength.

4. Use proper tools and jigs for mechanical assemblies.

5. Check for loose fixing

6. Fixing of Each Nut, Bolt, Screw, spring pin, Retaining Ring, Pins and Dowel Pins at actual position shall be adequately tightened.

7. Fixing of handle and cover

8. Visual Inspection of Rheostat Plate Handle and Readout Drum alignment to base.

9. Visual Inspection of all Cable tie shall be adequately tightened.

10. Visual Inspection of Marking of all wires with wire marker.

11. Indentify the non –conforming and rejected products/components by means of tag and separately store in bins.




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SOM PHOTOGRAPH OF FUEL PUMP TO DRG.NO. 40122943

Documents

KAY SONS ELECTRICALS PVT LTD VARANASIdlwdesign.org/DLW_VA/DOCUMENTS/738/FUEL PUMP MOTOR... · Training and involvement of employees in development, ... 13 Wire Visual check Major