QUALITY ASSURANCE PLAN FOR SPRING SETTING DEVICE

QAP FOR SPRING SETTING DEVICE

SPRING SETTING DEVICE                                         INSPECTION/TESTING AND FINAL    DIFFERENT COMPONENT/ITEMS                                   ASSEMBLY SCHEDULE FOR                                                                         SPECIFICATION NO:IRS:T-10-2000
Sr NoDescription of item of Component/ OperationCharacteristicsInspection & Test Equipment (Type or method of check)Quantum of check (Sample size)Ref Drg.Accepted Norms   Responsibilities
ManufacturerInspection AgencyRejection details/Re-processed/scraped
Base Plate Lever Holder Block Stopper Block Cover Stopper With BoltsALengthBy measuring Tape & Vernier Caliper100%DrgAs per Drg No RDSO/T-6216,RDSO/T-6217 to RDSO/T-6217/32                Internal Test Report                  Random sampling & testing for confirmation of materials as per relevant specification One sample per lot          Corrected/ Reprocessed, Scraped  
Lever Arm Bush(Central) Lever Arm Bush (End)BWidth  By measuring Tape & Vernier Caliper100%Drg…do…
Lever ArmCThicknessVernier Caliper100%Drg…do…
Spring Spring Nest(Female) Spring Nest(Male)  DCentre to Centre DistanceMeasuring Tape100%Drg…do…
Connecting Rod Lever MouthESize of oval HoleVernier Caliper100%Drg…do…
M.S PlateFHeightMeasuring Tape100%Drg…do…
Hexagonal Socket Head Cap ScrewGSize of Holes 100%Drg…do…
Split PinHSlot SizeVernier Caliper100%Drg…do…
Lever Arm Pin 65mmIInner DiaVernier Caliper100%Drg…do…
Lever Arm Pin 80mmJOuter DiaVernier Caliper100%Drg…do…
Nut & Bolts for StopperKWire DiaVernier Caliper100%Drg…do…
Tee Head Nut & Bolts for Base PlateLNumber of CoilAs per Drawing100%Drg…do…
SSD Cover Tongue Mouth Insulating Bush Insulating Washer Rail PinMHole PositionMeasuring Tape & Vernier Caliper100%Drg…do…

QUALITY ASSURANCE PLANE FOR SPRING SETTING DEVICE

INSPECTION/ TESTING AND FINAL ASSEMBLY SCHEDULE FOR DIFFERENT COMPONENTS/ITEMS       Spring Setting Device                                                                                     SPECIFICATION NO-10-2000
Sl NoDescription of item of Component/ OperationName & Address of SupplierCharacteristicsInspection & Test Equipment (Type or method of check)Quantum of check (Sample size)Ref Drg.Accepted NormsResponsibilities
ManufacturerInspection AgencyRejection details/Re-processed/scraped
Base Plate Cover Stopper With Bolts Lever Arm Spring Nest(Male & Female) Connecting Rod M.S Plate SSD Cover Tongue MouthChemicalChemical Lab                  2%              IS:2062/2011 Gd.E250 Quality BRChemical C%=0.22max Mn%=1.50 max Si%=0.40 max S%=0.45 max P%=0.045 max Physical Tensile Strength=410 Mpa(Min) Yield Stress(<20mm-250Mpa,20-40mm-240Mpa,>40mm-230Mpa)Min Percentage Elongation 23%(Min) Charpy  V  Notch =27J(min) Bend Test=2t(<25mmThick) & 3t(>25mm Thick) (No Crack)              Format – A & Format-B    Random sampling & testing for confirmation of materials as per relevant specification One sample per lot                  Corrected/ Reprocessed, Scraped  
Physical test Tensile Yield Stress Percentage ElongationUTM
Impact testChirpy test m/c
Bend testUTM
Lever Holder Block Stopper Block Lever Mouth Lever Arm Pin Rail Pin  ChemicalChemical Lab          2%    IS:2062/2011 Gd.E250 Quality BRChemical C%=0.22max Mn%=1.50 max Si%=0.40 max S%=0.45 max P%=0.045 max Physical Charpy  V  Notch =27J(min    Format – A & Format-B  Random sampling & testing for confirmation of materials as per relevant specification One sample per lot
Physical test Impact testCharpy test m/c
Lever Arm Bush Central & End split pinChemicalChemical Lab        2%    IS:2062/2011 Gd.E250 Quality BRChemical C%=0.22max Mn%=1.50 max Si%=0.40 max S%=0.45 max P%=0.045 max Physical 130-180BHNFormat – A & Format-B 
Physical test Micro Examination HardnessMicroscope Brinell Hardness Tester
Hexagonal Socket Head Cap ScrewChemicalChemical Lab  2%As per CL 12.9 (IS 1367 Part- 3 2002)   Format – A & Format-B  Random sampling & testing for confirmation of materials as per relevant specification One sample per lot
PhysicalBrinell Hardness Tester  2%As per CL 12.9 (IS 1367 Part- 3 2002) 

QUALITY ASSURANCE PLAN FOR SPRING SETTING DEVICE

INSPECTION / TESTING AND FINAL ASSEMBLY SCHEDULE FOR DIFFERENT COMPONENTS / ITEMS               Spring Setting Device                                                                       SPECIFICATION NO.IRS-T-10-2000
Sl. No.Description of item of Component/ OperationName & Address of SupplierCharacteristicsInspection & Test Equipment (Type or method of check)Quantum of check (Sample size)Ref. Doc.Accepted NormsResponsibilities
ManufacturerInspection AgencyRejection details/Re-processed/scraped
Bolts & Nuts  Chemical            Chemical Lab                      2%      IRS/T-23/67 & IS:1875/92 Cl.3 (for Bolts) Cl. 2A (for Nuts)Chemical C%=0.25-0.35 (for Bolt) C%=0.20-0.30 (for Nut) Mn%=0.60-0.90 Si%=0.15-0.35 S%=0.40 Max P%=0.40 Max     Physical UTS (for Bolt)= 55-68 Kg/mm² Head Soundness (for Bolt) = 30º (No Crack) Drifting Test (for Nut) – 1.5 times of hole Ø (No Crack) Screwing & Unscrewing Test for Bolt & Nut =              Format – A & Format-B          Random sampling and testing for confirmation of materials as per relevant specification One sample per lot                      Scraped  
TensileUTM
Unscrewing Head soundness Drifting testFixture
 Fixture as shown in T-23-67
Mandrel as per T-23-67
Ø25mmØ18mm  
2 Kg. (Screwing) 12 Kg. (Unscrewing)  1.2 Kg. (Screwing) 6 Kg. (Unscrewing)    

QUALITY ASSURANCE PLAN FOR SPRING SETTING DEVICE

INSPECTION / TESTING AND FINAL ASSEMBLY SCHEDULE FOR DIFFERENT COMPONENTS / ITEMS               Spring Setting Device                                                                       SPECIFICATION NO.IRS-T-10-2000
Sl. No.Description of item of Component/ OperationName & Address of SupplierCharacteristicsInspection & Test Equipment (Type or method of check)Quantum of check (Sample size)Ref. Doc.Accepted NormsResponsibilities
ManufacturerInspection AgencyRejection details/Re-processed/scraped
SSD SpringInternational spring, MumbaiChemical        Chemical Lab            2%IS:3195 Gd. 55 Si 7Chemical C% 0.50-0.60 Mn% 0.80-1.00 Si% 1.50-2.00 S% 0.030 Max P% 0.030 Max   Physical Hardness = 245 Max (BHN) as per IRS:R-2 Depth & Decarburization = 0.15mm + 1% of  bar dia. Inclusion Rate = 2.5 Max for ABCD for both Thick & Thin Series            Format – A  & Format-B        Random sampling and testing for confirmation of materials as per relevant specification One sample per lot    Corrected/ Reprocessed, Scraped  
Depth of DecarburizationMicroscope
MetallurgicalMicroscope
Physical test 
Hardness        Brinell Hardness Machine
Insulating Bush & Insulating WasherG.G Industries, mumbai  IRS S-40-84.   Manufacturer invoice shall be provided    Scraped

QUALITY ASSURANCE PLAN FOR SPRING SETTING DEVICE

INSPECTION / TESTING AND FINAL ASSEMBLY SCHEDULE FOR DIFFERENT COMPONENTS / ITEMS               Spring Setting Device                                                                       SPECIFICATION NO.IRS-T-10-2000
Sl. No.Description of item of Component/ OperationCharacteristicsInspection & Test Equipment (Type or method of check)Quantum of check (Sample size)Ref. Doc.Accepted NormsResponsibilities
ManufacturerInspection AgencyRejection details/Re-processed/scraped
Assembly of Spring Setting DeviceAs per Drg.By Measuring Tape, Scale & Vernier, Caliper100%As per Drg. No. RDSO/T-6216 & RDSO/T-6217 to RDSO/T-6217/32As per Drg. No.RDSO/T-6216 & RDSO/T-6217 to RDSO/T-6217/32        Format – C    Random sampling and testing for confirmation of materials as per relevant specification One sample per lot    Corrected/ Reprocessed, Scraped  
Assembly of Spring Setting Device with Thick Web SwitchA)  Main line (mm) Gap at      JOH/Throw at ATS B)  Turnout (mm) Gap at      JOH/Throw at ATS C)  Matching of Stock &       Tongue Rail D)  Versine of Curved Stock  Rail E)  Straightness of Straight      Stock Rail F)  Versine of Curved Tongue Rail G)  Straightness of Straight      Tongue Rail H)  Track Gauge for main line  and turnout    By Measuring fishing cord, steel scale, filler gauge & Track gauge100%As per Drg.No. RDSO/T-6216 & RDSO/T-6217 to RDSO/T-6217/32, RDSO/T-6280, RDSO/T-6155As per Drg. No.RDSO/T-6216 & RDSO/T-6217 to RDSO/T-6217/32, RDSO/T-6280, RDSO/T-6155            Format – ERandom sampling and testing for confirmation of materials as per relevant specification 100%  Corrected/ Reprocessed, Scraped  
PunchingPunching on spring setting device 10125mm, 60 Kg. TWS Last 3 digit of P.O. Sl. No. onwards.
Painting1.    1st Primer coat within 4 hours from cleaning. 2.    2nd Primer coat after first coat dried. 3.    Final paint coat after drying 2nd primer coat.
DispatchDispatching with copy of Bill / Copy of PO, IC

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