TEST REFERENCE CODE NO - DLW, Varanasidlwdesign.org/DLW_VA/DOCUMENTS/738/QAP Control Console 1... · Web viewAll the items manufactured by us are conforming to relevant IS/ BS/ ASTM

KAY SONS ELECTRICALS PVT LTDVARANASI

INDIA

QUALITY ASSURANCE PLAN

FOR

CONTROL CONSOLE #1 & #2(P.L.No. 18000060 & 18000071 )

MODEL NO. KSEL/CC#1 & CC# 2 /01

AN ISO 9001:2008 CERTIFIED ORGANAZATION

QUALITY ASSURANCE PLAN FOR

CONTROL ONSOLE #1 & CONTROL CONSOLE #2

Revision No. 00

Title Date 04.12.2012Section No. Page No. Page 2 of 31

Sl.No. Section No. Title Page No. 1 QAP: TC Table of Contents 22 QAP:CONF Confidentiality 33 QAP:CP Company profile 4-54 QAP:CC Certificate of conformity 65 QAP : QC Quality Control 76 QAP:ORG Organization Chart 87 QAP:QKP Qualification of Key Personal 98 QAP:PFC Process Flowchart 109 QAP- TRC Test Reference Code 1110 QAP:01 Incoming Material Inspection 12-2111 QAP:02 In Process Inspection 22-2412 QAP:03 Equipment Sub Assembly 25-2713 QAP:04 Final Assembly 2814 QAP: 05 Product Final Testing 29-30

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



Revision No. 00


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 (Diesel Locomotive Works ) VARANASI

For : KAY SONS ELECTRICALS PVT. LTD.,

(RAVI GUPTA)(Managing Director )

Office Seal :




Revision No. 00


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.

With the transfer of EMD Locomotive Technology from USA to DLW Varanasi For manufacturing of WDG4/WDP4 Locomotives.

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/ DLW/RDSO Specification and Drawing and serving to DLW/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.




Revision No. 00


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.




Revision No. 00


Product CONTROL CONSOLE #1 & CONTROL CONSOLE #2 Manufactured By M/S KAY SONS ELECTRICALS PVT. LTD.Model No. KSEL/CC #1/001 & KSEL/CC#2/001Brand KEPCOSpecification No. DLW Specification No. WDG4/EL/PS/22 DLW DRG.NO. DRG. No. 10630977 ALT –F & 10633575 ALT –HP.L.No. 18000060 & 18000071Application B.G. Main Line Diesel Electric Locomotives (WDG4 /WDP4 Locomotives )

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




Revision No. 00


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.




Revision No. 00


ORGGANAZATION 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




Revision No. 00


Sl.No. Details of Personnel employedName Designation Qualification Experience Brief Scope of Responsibilities

1 Uma Shankar Head R&DHead QC

Diploma 40 Year Design & QC

2 Rajesh Rao Incharge QC BE 12 Year QC Skill & Measurement & testing

3 Ramchandra Yadav

Final QC Inspection Diploma 6 Year Testing

4 Ajay Mishra Testing Supervisor Diploma 6 Year Testing

5 Kariyappa Testing Supervisor Diploma 12 Year Testing

6 Murgesh Testing Supervisor BE 10 Year Testing

7 Anand Testing Supervisor BE 4Year Testing




Revision No. 00


Process Flow Chart

Not OK

OK


Incoming Material

Incoming Inspection Rejected Material

Accepted Material

Supplier

Sub Assembly of Panel Assembly

Cable Crimping

Cable Cutting As per Doc. KEPCO /WL/CC & CC2

Wiring & Termination As per Doc: KEPCO /WL/CC1 & CC2

Final Assembly

Tube Pipe /Valve Assembly

Assembly Inspection

Functional Test

Continuity Test

Store



Revision No. 00


TEST REFERENCE CODE NO

V : VISUALI : INSSTRUMENT /MESURMENTT : TESTA : CRITICALB : MAJORC : MINORTC : TEST CERTIFICATESUPP TC : SUPPLIER TEST CERTIFICATET& I SPEN : TEST AND INSPECTION SPECIFICATIONPR SPN : PURCHER SPECIFICATIONQCR : QUALITY CONTROL RECORDSWIP : WORK IN PROCESS


Packing Dispatch Final Testing



Revision No. 00


Material Prequirement 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

1.1 Speed Indicator (WDG4)

40071195(OEM)

1.Visual defects2. Dimensional Check

Major Visual First off 100% for approval sampling for regular production

DLW Drg. No. 40071195 As per Quality Procedure KSEL/CC/001

As per Quality Procedure KSEL/CC/001

Inspection Register . Manufacturer Test certificate

WTC Internal Goods Receiving Bay

1.2 Speed Indicator (WDP4)

40087769(OEM)







1.3 Meter TE/TB (WDG4)

40068798(OEM)







1.4 Meter TE/TB (WDP4)

40088591(OEM)



DLW Drg. No. 40088591As per Quality Procedure KSEL/CC/001

As per Quality Procedure KSEL/ CC /001



1.5 Control Valve ASM

10635322(OEM)










Revision No. 00


Sl.No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.6 Control Valve ASM

40044050(OEM)







1.7 Valve Emergency Brake

8136987(OEM)







1.8 Push Button Horn

10562203(OEM)

N.A 1.Visual defects2. Dimensional Check

Major Visual DLW Drg. No. 10562203 As per Quality Procedure KSEL/CC/001




1.9 Push Button Sand

10562201 (OEM)







1.10 Head Light Switch

8213092(OEM)







1.11 Switch Toggle 102529(OEM)


Major Visual First off 100% for approval sampling for

DLW Drg. No 102529 As per Quality Procedure

As per Quality Procedure KSEL/MC/001

Inspection Register . Manufacturer Test





Revision No. 00


regular production

KSEL/CC/001 certificate

Sl.No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.12 Rheostate with knob

8481573(OEM)







1.13 Attend call Push button

8481267(OEM)







1.14 Receipt Asm 28 Pos.

10611797(OEM)







1.15 Air Gauge Complex

10631881(OEM)







1.16 Slide Switches 8481164(OEM)







1.17 Slide Switches 8481166(OEM)

1.Visual defects2. Dimensional

Major Visual First off 100% for approval

DLW Drg. No. 8481166 As per Quality


Inspection Register . Manufactu





Revision No. 00


Check sampling for regular production

Procedure KSEL/CC/001

rer Test certificate

Sl.No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.18 Plug 40073090(OEM)







1.19 Plug CPC 23-9 40026394(OEM)







1.20 Plug CPC 23-16 M

40019314(OEM)







1.21 Ind. Lt. Push Button Sw.

8482812(OEM)







1.22 Engine Run /Stop Sw.

40090876(OEM)










Revision No. 00


Sl.No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.23 Bell 80045762(OEM)







1.24 Latch Asm 10649115(OEM)







1.25 Circuit Breaker 10A

9322826(OEM)







1.26 Strain Relief 40026395(OEM)







1.27 Cir Connector Receipt

40019320(OEM)








40019313(OEM)

1.Visual defects

Major Visual First off 100% for

DLW Drg. No. 40019320

As per Quality Procedure

Inspection Register .

WTC Internal Goods Receiving




Revision No. 00


2. Dimensional Check

approval sampling for regular production


KSEL/CC/001 Manufacturer Test certificate

Bay

Sl.No. Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark


40019315(OEM)








40034541(OEM)







1.32 Cir Connector Receipt 23-22

40019316(OEM)







1.33 Lug Terminals N.A(OEM)










Revision No. 00


1.34 Faston Terminal

N.A(OEM)












Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.39 Hardware 1.Gauges 2.Clamp Meter3.Vernier4. Thread Gauges


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



Inspection Register . Raw material test report

Internal Quality control

Internal Goods Receiving Bay

1.40 Wires 1.Gauges 2.Clamp Meter3.Vernier

1.Visual defects2. Dimensional Check 3. Colour

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





1.41 Lugs N.A. 1.Visual defects2. Dimensional Check

Major V/I 100% Checking



Internal Inspection Register .


1.42 Packing Material

N. A. 1.Dimensional Checks2.Printing3.Gumming

Major V First of 100 % for approval

As per Customer Requirement & As per Quality Procedure KSEL/CC/001





1.43 Labels N. A. 1.Dimensional Checks

Major V First of 100 % for

As per Customer

As per Quality Procedure

Internal Inspection

Internal Quality

Internal Goods Receiving




Revision No. 00


2.Printing3.Gumming

approval Requirement & As per Quality Procedure KSEL/CC/001

KSEL/CC/001 Register . control Bay






Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.44 Chemicals N. A Visual Major V First of 100 % for approval






1.45 Sheets 1.Gauges 2.Clamp Meter3.Vernier








1.46 Copper Tubes 1.Gauges 2.Clamp Meter3.Vernier








1.47 Tubes Assembly

Drg.No. 106335021.Gauges 2.Clamp Meter3.Vernier


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



Inspection Register . Raw material test report






Revision No. 00


4. Thread Gauges

1.48 Pipe Fittings 1.Gauges 2.Clamp Meter3.Vernier

1.Visual defects2. Dimensional Check 3. Colour












Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

1.49 TAPE N.A. 1.Visual defects2. Dimensional Check

Major V/I 100% Checking






1.50 Switch Toggle N.A. 1.Dimensional Checks2.Printing3.Gumming







1.51 Copper Brazed Tubes

Drg. No. 80985941.Gauges 2.Clamp Meter3.Vernier4. Thread Gauges

1.Dimensional Checks2.Printing3.Gumming










Revision No. 00


In Process Inspection of CONSOLE #1 & CONTROLE CONSOLE #2

Sl.No.

Component Operation





Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

2.1 Cutting Cutting Machine

Visual defects2. Dimensional Check 3. Finish

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




Internal Quality control Checks


2.2 Sizing Sizing Machine Visual defects2. Dimensional Check 3. Finish







2.3 Bending Bending Machine

Visual defects2. Dimensional Check 3. Finish







2.4 Drilling Drill Machine Visual defects Major V/I First off 100% for approval sampling for regular









Revision No. 00


production2.5 Cleaning Compressor

/AirBurs Removal Major V/I First off

100% for approval sampling for regular production











Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

2.6 Machining Milling Machine

1.Visual defects2. Dimensional Check 3. Finish

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






2.7 Grinding Automatic Grinder Machine


Critical V100 % Testing Checking




Internal Quality controlChecks


2.8 Spot Welding Spot Welding Machine








2.9 Butt Welding Butt Welding Machine



As per Customer Requirement & As per Quality

As per Customer Requirement & As per Quality Procedure







Revision No. 00



KSEL/CC/001

2.10 Grinding Automatic Grinder Machine













Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

2.11 Varnishing N.A. 1.Visual2.Uniformaty.3. Dry

Major V/I 100 % Checking






2.12 Sheet Cutting Sheet Cutting Machine

Visual defects Major V/I & Supplier TC

First off 100% for approval sampling for regular production






2.13 Sheet Bending Sheet Bending Machine

Visual defects Critical V/I 100% Testing /Checking





Internal Goods Final Product Testing Bay

2.14 Welding Welding Machine

Welding Checks

Critical V/I As per sample Plan






2.15 Spot Welding Spot Welding Machine.

Welding Checks

Critical V As per sample plan






2.16 Cleaning Solvents. 1.Surface Critical V/I/T 100 % As per Quality As per Quality Internal Internal Internal Goods Final




Revision No. 00


Finish2 Dust.3. Greece

Testing Checking




Quality control

Product Testing Bay

2.17 Painting PaintingMachine

Colour etc Major V 100%Testing/ Checkings

As per Manufacturer Instruction / Catalogue

As per Manufacturer Instruction / Catalogue









Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

2.18 Marking Marking Machine

Visual Defects Major V/I & Supplier TC

First of 100% for approval sampling for regular production

As per DLW Drg & Specification


Inspection Register . Raw material Test Report






Revision No. 00


Equipment Sub Assembly of CONTROLE CONSOLE #1 & CONTROLE CONSOLE #2Sl.No. Component

OperationMachine/Equipment used for Operation




Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

3.1 Frame Assembly

Remer JigsDiesFixturesPress MachineRiveting Machine

Visual Defects Dimensional Checks

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

As per DLW Drg 10630978 As per Quality Procedure KSEL/CC/001





3.2 LWR CON PANEL ASM APL









3.3 PANEL ASM Remer JigsDiesFixturesPress MachineRiveting





Inspection Register . Raw material Test






Revision No. 00


Machine Report 3.4 PANEL ASM Excursion Visual Defects

Dimensional Checks







3.5 PANEL ASM Crimping Machine



As per DLW Drg 10643843 s per Quality Procedure KSEL/CC/001










Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

3.6 LATCH ASM Wire cutting Machine Sizing Machine Crimping machine








3.7 COVER ASM Remer JigsDiesFixturesPress MachineRiveting Machine








3.8 PANEL ASM Remer JigsDiesFixtures


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

As per DLW Drg 10632908 As per Quality Procedure








Revision No. 00


Press MachineRiveting Machine

regular production

KSEL/CC/001 Raw material Test Report

3.9 PANEL ASM Remer JigsDiesFixturesPress MachineRiveting Machine








3.10 TUBE CLAMP ASM














Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

3.11 CABLE ASM Remer JigsDiesFixturesPress MachineRiveting Machine



As per DLW Drg 8140357, 10634587, 10634586 As per Quality Procedure KSEL/CC/001




Internal

3.12 CLAMP ASM Remer , JigsDies, FixturesPress MachineRiveting Machine











Revision No. 00


3.13 VALVE ASM Remer ,JigsDiesFixturesPress MachineRiveting Machine



As per DLW Drg 10632578 & 10635890 As per Quality Procedure KSEL/CC/001





3.14 TUBE ASM Remer JigsDiesFixturesPress MachineRiveting Machine



As per DLW Drg 10632779 & 10632780, 10632781, 10632782, 10633510, 10633511, 10633512, 10633504 , 10633503 , 10633502, 10633505, 10633675, 10633676, 10633677& Specification




Equipment Final AssemblySl.No. Component

OperationMachine/Equipment used for Operation




Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

4.1 Body Assembly Frame Assembly

LWR CON PANEL ASM

APLPANEL ASM











Revision No. 00


PANEL ASM

LATCH ASM

COVER ASM

PANEL ASM

TUBE CLAMP ASM

CABLE ASM

CLAMP ASM

VALVE ASM

TUBE ASM

PRODUCT FINAL TESTING AS PER DLW Specification No. WDG4/EL/PS/22 July ,2008






Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

5.1 Visual Test Visual Visual Defect Critical V/I/T 100 % Testing CheckingRoutine Test

As perDLW Drg & Specification




Internal/ Testing Agency

Goods Final Product Testing Bay

5.2 Preliminary Checking

General workmanship & Finish

General Operation

Critical V/I 100 % Testing CheckingRoutine Test










Revision No. 00


5.3 DimensionalChecks

DimensionalChecks


Critical 1.Digital Vernier.2.Micromertr

100 % Testing CheckingRoutine Test







5.4 Insulation ResistanceTest

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







5.6 High Voltage test

High Voltage Tester

Should With Stand the Test








5.7 Continuity Multimeter Continuity Critical I 100 % Testing CheckingRoutine Test







5.8 Functional Test 1.D.C. Source 2.Testing Panel

Equipment should glow

Critical I 100 % Testing CheckingRoutine Test







5.9 Functional Test (Air Pressure Leakage Test

Compressor 2.Testing Panel

There should be no leakage













Quantum of Check

Reference Document

Acceptance Norms

Format of Records



Remark

5.10 Corrosive Atmosphere Test

Oven, Chemicals

CC-1 &CC-2 should withstand the test

Critical I Type test As perDLW Drg & Specification






5.11 Vibration Shock & Bump Test

Vibration Test Bench

CC-1 &CC-2 should withstand the test

Critical I Type test As perDLW Drg & Specification






5.12 Wiring Check Multimeter Continuity Critical I 100 % Testing

As perDLW Drg &

As perDLW Drg &


Internal Quality

Internal/ Testing

Goods Final Product




Revision No. 00


CheckingRoutine Test

Specification Specification controlChecks

Agency Testing Bay

5.13 Functional Test CC1

Testing panel CC-1 Should Show correct function








5.14 Functional Test CC2

Testing panel CC-2 Should Show correct function








5.15 Endurance Test Endurance machine

No. of Operations

Critical Type test As perDLW Drg & Specification







Documents

TEST REFERENCE CODE NO - DLW, Varanasidlwdesign.org/DLW_VA/DOCUMENTS/738/QAP Control Console 1... · Web viewAll the items manufactured by us are conforming to relevant IS/ BS/ ASTM