SCHEDULE OF TECHNICAL REQUIREMENTSFOR ELECTRONICS USED IN COACHING STOCK
APPLICATION OF INDIAN RAILWAYS
3TR_tT_~_31T_/1fr_t/~_ it 3TR_/~/ 0034-2012 (~q;r_o)
STR No. RDSO/PE/STR/AC/0034-2012 (Rev'O'),-- -
Details of Revision PageAmendment Numb
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File no. EL/6.4.6w.e.f. June 2012
SCHEDULE OF TECHNICAL REQUIREMENTS
FOR ELECTRONICS USED IN COACHING STOCK APPLICATION
OF INDIAN RAILWAYS
1. FOREWORD:
1.1 There has been an increase in electronics based applications on coaching stock ofIndian Railways in last few years. The environmental stress on electronics used incoaching stock is very high. Reliability and quality assurance requirements have tobe fulfilled to ensure high reliability under the heavily adverse working conditions.The Schedule of Technical Requirements (STR) are essential guidelines to theconcerned device manufacturers (hereafter called "the firm") and shall be read inconjunction with the specification of the concerned devices.
1.2 The firms applying for vendor registration should satisfy themselves about havingcomplied with the technical requirements of the specification and otherinfrastructures & testing facilities requirement as per STR. Firm shall haveminimum experience of 03 years in designing & manufacturing of controller basedsystems.
1.3 The firm should have currently valid ISO-9001-2008 certification covering its workaddress and including the subject item under its range of manufacture.
1.4 Existing firm shall comply this Schedule of technical requirements within six monthsfrom the date of issue of this STR. Compliance of this STR shall be mandatorybefore renewal of firm.
1.5 The firm is advised to regularly visit RDSO website and get them updated onchange being made from time to time in vendor approval procedure.
2.1 All the required testing facilities shall be available at firm's premises In the event ofnon-availability of Shock, Vibration, EMI/EMC testing facility at the works of thefirm, the tests may be conducted at any NABL approved laboratory, test results ofwhich in original shall be submitted to RDSO.
2.2 The accuracy and capacity of the testing & measuring equipments shall beadequate to meet the requirements of the specification. The testing and measuringequipments/instruments shall be duly calibrated at regular intervals and the validcalibration certificate shall be produced on demand.
2.3 Electronic component/LED used in unit shall be purchased from manufacturer ortheir accredited agents. The copy of original invoice having proof of componentspurchased from them and lot certificate should be kept in record for every batch.
2.4 Detailed records of in-house /preliminary testing of each unit shall be maintained.This shall be produced to Inspecting Agency at the time of inspection.
prepare~
!-DE/(LI-~Ch Elcctronics)
File no. ELl6.4.6w.e.f. June 2012
RDSO/PE/STR/AC/0034 -2012 (Rev 0')
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3.1 Information shall be furnished as per the details required in the following AnnexureI, II & III. The documentary evidence of requirements shall be submitted with theapplication. Ownership of Equipment shall be evidenced by invoices in the name ofthe firm and physical verification at the premises of the firm. During capacityassessment firm shall also submit photograph of all the machine plant and testingfacilities for record.
3.1.1 Essential machinery and plants required for production and designing(Annexure-I). It contains essential M&P infrastructure required formanufacturing /assembly of unit. It, however, does not specify the capacity andquantity of the various items of equipment/components, the quantity/capacity ofthe M&P dependent upon the manufacturing requirement. The firm should alsohave the requisite facility for storing the raw material as per the guidelines ofstoring the specific product viz insulating material, varnish, battery, LED etc.and the finished product so as to maintain them in a healthy condition.
3.1.2 Essential test facilities required for quality assurance (Annexure-II): Itcontains all testing facilities required. The firm should have up-to-datecalibration record of testing and measuring instruments required for testing ofunit and should be produced on demand of inspecting agency. All the abovefacilities are considered essential at the developmental and production stageand shall be verified by Indian Railways before considering the firm as adevelopmental source / renewal of approval.
3.1.3 Format for Quality Assurance Plan (Annexure-III): It contains QualityAssurance Plan for implementation by the firm. It will also be a prerequisite fora firm to submit QAP for according approval for supply of unit. The majorpoints, which are essentially required to be covered, are included therein.
3.2 Any changes made to the plant and machinery / testing facilities etc. includingits non-availability due to repairs shall be informed to ROSa.
All design documents / instruction manual / QAP / test reports / photograph etcshall be submitted in Hard copy & Soft copy. The soft copy shall be in non-editable format but should have properly indexed search facilities for ease inlocating requisite information.
P"pmd By ~
ADE/(LHB System & Coach Electronics)
LP_age4 of 9 ~File no. EL/6.4.6
w.e.f. June 2012------ -- --
RDSO/PE/STRI AC/0034 _-2_0_1_2_(R_e_V_O_')__ .J
Annexure-IEssential machinery and plants required for manufacturing of Electronic items.
2. Wave soldering line for purpose of ensuring high reliability and qualitysoldering of PCBs.
3. Ultrasonic cleaner (suitable for volume production cleaning) for assembledPCB's to prevent field failure of assemblies due to PCB surface impurities inhigh moisture / humidity environments
4. Visual inspection system (with magnifying lens/CCO camera) or Automaticoptical inspection unit.
5. Burn-in chamber / Ory heat test chamber (0- 85 deg C) to test reliability andharvest infancy failures.
6. Component forming Machines for radial and axial components and lC's forcorrect handling of components and prevent mechanical stress oncomponents and failure thereof.
7. Oust free environment for assembly of electronic modules. Assembly areashould have electro static discharge protection in line with IS: 10087-1981 (Antistatic mat in assembly area and wrist band earthed with anti static mat).
10. Microcomputer based and computer aided design system with workstationsfor R&O which will be, needed for failure investigation and future up-gradation.
11. IC programmer/flash programmer/universal programmer required for burn inembedded software.
Note: - SN 1, 2 & 3 can be outsourced to ISO certified firm. MOU with sub vendoralong with QAP and M& P shall be submitted to ROSO for prior approval.ROSO official may visit to the premises of sub vendor for physicalverification.
Prepared By ~
ADE/(LHB System & Coach Electronics)
File no. EL/6.4.6w.e.f. June 2012
True R.M.S Digital multi - meters - 4 Y2 digits display. Nos. of metersshall be as per requirement of item.
Complete test bench for measuring the different parameters asmentioned in concerned specification.
[8] Essential test facilities required for quality assurance of solid state temperaturecontroller for AC coaches in addition to mentioned in clause [A] of this annexure:
1. Test set up (Calibration bath) for calibration of temperature as per figure 6 ofIS 6274 Liquid Glass thermostat comparator bath propeller type.
3. Endurance test jig with 3 A inductive load equipped with digital counter andtimer.
[C] Essential test facilities required for quality assurance of Microprocessorbased controller unit for all types AC coaches in addition to mentioned inclause [A] of this annexure :
1. Test set up (Calibration bath) for calibration of temperature as per figure 6 ofIS 6274 Liquid Glass thermostat comparator bath propeller type.
2. Energy meter and wattmeter for measuring energy and power.
6. Endurance test jig with 3 A inductive loads equipped with digital counter andtimer.
[D] Essential test facilities required for quality assurance of Electronic time delayrelay AC coaches in addition to mentioned in clause [A] of this annexure:
1. Stop watch timer of adequate rating/ resolution2. Endurance test jig with 3 A inductive load equipped with digital counter and
timer.
[E] Essential test facilities required for quality assurance of Emergency lightunit for all types of coaches in addition to mentioned in clause [A] of thisannexure:
1. Vertical test fixtures in Dark room as per requirement of specification.2. Rheostat for battery discharge test.3. Lux meter for measuring lux output of lighting equipment.
Prepared By
~ADE/(LHB System & Coach Electronics)
File no. EL/6.4.6w.e.f. June 2012
The firm shall submit the organizational chart, along with the qualification andexperience of key persons in management involved in quality assurance program.
The manufacturer shall maintain all necessary documents and data that willhelp him to have consistency in producing quality product. All documentation shall bee-documents with back up for at least 6 Years.
Raw material/equipments shall be procured from manufacturer or theiraccredited agents. If support is not available from the accredited source for low volumeof production, the same may be procured from resellers after due verification ofgenuineness for a limited period of time or while volumes are low. For LED basedproducts, material shall be procured from manufacturer or their accredited agents onlyconforming to relevant standards.
Screening of critical electronic component/devises shall be carried out as a partof in-process quality control. Method adopted should be clearly explained.
(i) Receiving Material: The manufacturer shall ensure that incomingmaterial is not used for processing until it has been inspected or otherwise verified asconforming to specified requirements. Verification shall be in accordance with qualityplan or laid down documented procedures.
(ii) In process inspection and testing: Inspect, test and identify product asrequired by the quality plan or documented procedures evolved on the basis of Rosaspecification and other relevant specification/standard.
(iii) The supplier shall carryout all final tests and inspection in accordancewith the quality plan or documented procedures evolved on the basis of ROSaspecification and specified standard to complete the evidence of conformances of thefinished product.
The instrument and equipment used for testing and inspection shall be of therequired accuracy. The calibration record should be maintained and shall be produceat the time of inspection& shall be included in QAP documentlTest reports.
~_~DE/(LHB System & Coach Electronics)
File no. ELl6.4.6w.e.f. June 2012
The firm shall indicate the organizational structure of their R&D wing along withqualification of the personnel. Firm should have at least one EngineeringGraduate design engineer with experience of more than 3 years in the field ofdesign, development ,fault diagnostic of electronic item. Experience profile shallbe suitable to the complexity of item. Firm shall submit documentary evidencein support of quafification and experience d employee.
8. Laboratory Test House: The manufacture shall have a well equippedLaboratorylTest House to carry out various tests on the raw material, stageinspection and inspection of the finished product.
9. Traceability of components used, test carried out on the each PCB/unit forcoaching stocks. Manufacturers shall elaborate the procedure being followedfor ensuring traceability of critical components used, in house test performedon each critical components, sub assembly & complete equipmentsindividually.
10. Handling /Storage/Delivery: The manufacture shall have proper facilities forhandling and storage of raw material and finish product. The supplier shallcontrol packing presentation and marking process so as to ensure conformityto the railway requirement.
~ADE/(LHB System & ~Cs)
File no. EL/6.4.6w.e.f. June 2012
CHIEF ELECTRICAL ENGINEER
1 Northern Railway, Baroda House, New Delhi - 110 001.
2 Central Railway, II Floor, Parcel office, CST Mumbai - 400001.
