1

Proposal

AN ISO-9001-2000 WORKSHOP

Presented by:

Mr. Anand Shekhar

INTRODUCTION

Spring Karkhana is the Largest and dedicated plant for helical hot

coiled Spring for IR Rolling Stock.

Manufactures 75000 springs (3000MT) per annum.

Renovates in under…………………………..

Purpose -To cater the increasing need of quality Coil springs for

switchover from Laminated Springs.

2

PROPOSED LAYOUT OF PLANT

3

4

Manpower:- 460 sanctioned.

Initial Investment:- Rs. 120 Crores.

Connected Load:- 3000 KW

Furnaces:- LPG fired

Certification:- ISO-9001:2000

Machinery & Plant:- Semi-automatic CNC &

PLC based Machines.

Total land area for the project:- 30 hectares

Shop covered area:- 6400 sq. m

Administrative building area:- 1800 sq. m

Nos. of Quarters:- 90

Associated infrastructure facilities:- 03 Nos. of Sub-Stations

SALIENT FEATURES OF RSK

5

QUALITY OBJECTIVES

• Compliance to production and dispatch target

of 75000 springs for the year 2018.

• Minimize the “in house rejection” of springs to

6.5%.

• Improve skill and knowledge of the

employees.

6

QUALITY POLICIES

Commitment to supply springs according

to customer requirement.

Help in safe and comfortable rail travel.

To make continual improvement in the

Quality Management System.

To comply with all legal and other

statutory requirements.

7

Staff Position Required

Category Sanctioned

Supervisors 80

Other Group “C” 279

Group “D” 103

TOTAL 460

BUDGET AT A GLANCEReference Taken From Existing Plant (Rsk)

(Estimated price in lakhs of INR.)Civil :400

Electrical :500

Mechanical:7000

Meslenious:10008

9

MACHINERY & PLANT

Walking Beam Bar End heating Furnace

End tapering machine

Walking Beam Bar heating furnace

Coiling machine

Quenching machine

Tempering furnace

Hardness testing machine

End face grinding machine

contd.

MACHINERY & PLANT (CONT.)

Shot peening machine

Magnaflux crack detection machine-2

Scragging hydraulic press

Load testing hydraulic press

Re-pitching machines 2 no:s

Primary paint plant

Black paint plant

Packing machine

Eot Crane 5 ton10

STEPS TO MANUFACTURE SPRINGS

• Secure firm orders.

• Purchase Raw Material.

• Inspect Raw Material.

• Processing.

• Inspection of springs.

• Packing.

• Dispatch.

11

PROCESS FLOW CHART

12

Raw Material

End Tapering

Peeled bar

Walking Beam Bar end heating furnace

PROCESS FLOW CHART (CONT)

13

Bar Heating

Coiling

Quenching

Tempering

Dispatch

Colour Coding

Painting/Phosfeting

Load Testing

End Grinding

Scragging

Shot Peening

Crack Testing

Resizing

Under/over

Height

14

END TAPERING OPERATION 15

END TAPERED BARS16

17

Walking Beam Bar End Heating Furnace

End Tapering Machine

18

Walking Beam Bar Heating Furnace 19

SPRING COILING IN OPERATION20

Quenching Machine21

Automatic End Grinding Machine22

END GRINDING Process (Manual)23

END GROUND SPRING24

Shot Peening Machine

25

26

MAGNA FLUX CRACK DETECTION OF SPRING

27

SPRING DEFLECTION TESTING MACHINE

28

REPITCHING MACHINE

29

RED OXIDE PAINT PLANT

30

SPRINGS ON BLACK PAINT PLANT

31

UNLOADING FROM BLACK PAINT & CODING OF SPRINGS 32

PACKING CARTON OF SPRING33

PACKING OF SPRING34

35

TYPES OF SPRINGS

36

From To From To From To From To From To From To From To

1 001 01 006 001 00 BG/ AXLE A 01 33.5 4230 6.75 5.25 175 360 30.2 2038 281 289 281 283.7 >283.72 286.3 >286.3 289 2832 251 261 3400 229 242 3954 213 216

2 001 05 002 001 00 BG/BOLSTER B 01 42 4457 5.75 4.25 218 385 49.8 3330 304 312 304 306.7 >306.7 309.3 >309.3 312 5292 255 268 6350 229 244 6794 225 228

3 013 01 202 001 00 WTAC/AXLE A 03 33.5 4230 6.75 5.25 175 375 30.2 2694 271 281 271 274.3 >274.3 277.7 >277.7 281 3053 257 269 3664 234 247 4370 213 216

4 013 05 202 001 00 WTAC/BOLSTER B 03 42 4529 6.25 4.75 200 400 50.5 4815 294 304 294 297.3 >297.3 300.7 >300.7 304 5534 278 290 6641 253 267 7271 246 249

5 083 01 002 001 00 DC/E/T/AXLE H 25 38 3567 5.75 4.25 170 304 32.7 1575 275 278 275 276 >276 277 >277 278 3280 243 249 3936 230 237 5598 203 206

6 087 01 203 001 00 DC/EMU/M 2/AXLE H 07 40 2977 4.7 3.2 175 250 28.5 3005 212 216 212 213.3 >213.3 214.7 >214.7 216 4199 197 202 5249 183 190 6399 172 175

7 089 01 024 001 00 AC/E/M/AXLE K 10 40 3350 5.25 3.75 175 284 33.9 3009 239 244 239 240.7 >240.7 242.3 >242.3 244 4303 220 226 5164 207 215 6303 194 197

8 180 05 001 001 00 DE/TC/B/INN G 87 27 4227 9.5 8 119 400 19 1832 313 321 313 315.7 >315.7 318.3 >318.3 321 1979 305 314 2375 287 298 3351 246 249

9 180 05 001 002 00 DE/TC/B/OUT G 88 41.5 4515 6.5 5 190 400 47.9 4105 313 321 313 315.7 >315.7 318.3 >318.3 321 4433 305 314 5319 287 298 7165 253 256

10 1269513 Fiat secondary inner F19 34 6230 8.3 6.8 212 663 44.4 2576 463 468 3104 3275

11 1269514 Fiat secondary Outer F18 50 7410 6.6 5.1 318 707 114.22 4798 507 512 5783 6101

12 1268836 Fiat Gen2 secondary Outer F16 55 7870 7 5.5 317 702 146.79 6043 510 515 7098 8337

13 1268837 Fiat Gen2(2) secondary F17 37 6280 8.5 7 206 658 53.01 3489 466 471 4098 4813

14 1277145 Fiat Gen1 secondary Inner F15 38 6425 8.7 7.2 205 664 57.2 3948 463.5 468.5 4029 4062

15 1277146 Fiat Gen2 secondary Outer F14 57 7855 7 5.5 315 708 157.36 7294 507.5 512.5 7443 7503

16 1267412 FIAT Chair Car Pri. Inner F02 26 3175 7.6 6.1 112 324.5 13.23 1737 260 264 1902 2177

17 1267411 FIAT Chair Car Pri. Outer F03 38 3640 5.6 4.1 181 324.5 32.4 2950 260 264 3231 3696

18 1277143 FIAT Generator car Pri. Inner F04 27 3300 7.9 6.4 111 337 14.83 2692 248 252 2967 3021

19 1277142 FIAT Generator car Pri. Outer F05 40 3800 5.8 4.3 179 337 37.48 4829 248 252 5322 5419

20 LG01101 FIAT GS Pri. Inner F06 27 4240 7.7 6.2 111 313 14.5

21 LG01100 FIAT GS Pri. Outer F07 40 3690 5.6 4.1 179 313 36.4

22 LG05100 FIAT GS Sec. Inner F08 36 6530 8.75 7.25 209 593 52.18

23 LG05101 FIAT GS Sec. Outer F09 55 7365 6.5 5 321 637 137.37

Inner. DIA

TARE

LOAD (in

Kgs)

Permissible Height

at Tare Load

Springs for FIAT design Bogies

Springs for ICF design Bogies

GRD. BAR

DIA (MM )

(without

scaling

allowance)

DRG. No. DESCRIPTION CODE 2 Wire 3 Wire

428

SPRING

WEIGHT

CUT

LENGTH OF

BAR

Total No.

OF

COIL

No. OF

Effective

COIL

Permissible Height at Tare Load

SPRING DATA (Revised Dtd: 09.10.14)

Sl.

No.

Shock Load

(in kgs)

Gross Load

(in kgs)

Home Load (in

kgs)

FREE

HEIGHT

Permissible

Height at

Shock Load

Permissible Height

at Home Load

Permissible

Height at Gross

Load1 Wire

248.6

472

482.5

438.5

508.5

464.5

258.2 189.8

258.2

243.3

243.3

415

459

444.2

400

462.9

506.9

268.6

310

316.2

300

315.4

376.2

201.4

205.2

220

NOTE: The above data are indicative only. The respective Spring drawings shall be referred for authenticity.

248.6

241.6

241.6

RANGE OF SPRINGS & RAW MATERIAL

1. Major Parameters

1.1 Bar diameter 20 to 65 mm

1.2 Bar

length

2500 to 10,200 mm

1.3 Outer diameter of

spring

100 to 450 mm

1.4 Free height of

spring

200 to 950 mm

1.5 Number of

coils

3 to 12

1.6 Weight of

spring

200 Kg (Maximum)

1.7 Productivity Shall be tested on B01

type springs

37

52Cr4Mo2V For larger dia above 33 mm.

60Si7 For smaller dia below 33 mm up to

16 mm

MATERIAL

QUALITY ASSURANCE

Needs ISO-9001: 2000, certification.

Arrangement available for testing of raw

material.

Stage wise in process quality assurance system

during production.

Well equipped LAB for assessing & assuring

the quality of springs at each stage of

production.

Having proper system for customer feedback

& continual improvement in quality. 38

THESE ARE ALSO REQUIRED FOR THE PLANT

Installation of fire fighting arrangement at LPGYard.

Developments of indigenous substitute forimported spares.

Installation of Air Dryer & Moisture Separators incompressed air circuit.

Installation of isolation transformers and voltagestabilizers for control panels.

Installation of Effluent Water Treatment Plant.

Contd39

Provision of air-conditioners for controlpanels.

Provision of new water-cooling towers forimproving efficiency of water-cooling circuit.

Provision of DM plant to prevent choking ofwater-cooling circuit due to hard water.

Compliance of mandatory requirements suchas public liability insurance and approval ofdisaster management plan etc.

Installation of DG set (1000 KVA) to ease outthe power problem.

40

NEED S PRODUCTION AS PER CONTRACT

About 75,000 springs produced per year

covering all types of springs as listed

above.

Set-up of Phosphating plant to reduce

corrosion.

Re-conditioning of important machines.

Spring production cost is less than

market.

41

INVESTMENT PLANS

Additional infrastructure for manufacture of springs-

sanctioned.

Replacement of old and obsolete machines of existing

production line sanctioned.

Planning of new Bolster (B01) wagon spring production Line.

42

BOTTLENECKS

•Shortage of officers and staff.

• Inadequate local market.

•Poor communication.

•Old & obsolete machines.

43

ASSISTANCE REQUIRED

•Communication: more and better Rlyphones.

•Mobile phones.

•Security.

•More delegation for machine repairs.

•Approach road without railwaycrossing.

44

RECOMMENDATIONS TO IMPROVE

•Balance engineering officers to be

placed under workshop .

•Enhancement of procurement powers.

45

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