ISO9001:2008 Document No: QM-F-7.

1-17/A Document Title: Wagon Quality Score Sheet(Open Wagon BOXN Type)

Version No: 1.0

Date Effective: 01.02.2012

RESEARCH DESIGNS & STANDARDS ORGANIZATION

Manak Nagar, Lucknow 226011 QM-F-7.1-17/A
Wagon Quality Score Sheet (Open Wagon BOXN Type)

1. Amendment History:
S. No. 1 Amendment Date 01.02.2012 Version 1.0 Reasons for Amendment Fresh issue

SIO/QA(Mech) Prepared By:

Director/ QA(Mech) Issued By:

Printed: 01/02./2012 Page 1 of 2

ISO9001:2008 Document No: QM-F-7.1-17/A Document Title: Wagon Quality Score Sheet(Open Wagon BOXN Type)

Version No: 1.0

Date Effective: 01.02.2012

2. Purpose:
To calculate wagon quality score to be prepared as per the the requirement of the Railway Boards Wagon contract.

3. Scope of Application:
Applicable for open wagon- BOXN Type.

4. Procedure / Details:
Wagon Quality Score (Format QM-F-7.17/A) for open wagon Type BOXNHL is annexed. While using the form print and use only the Format/Annexure pages.

5. Referenced Documents
None

6. Referenced Documents of External Origin

None

7. Associated Records
None

8. Responsibility and Authority

Activity Creation, maintenance of this document Requirement of deviation from this form template. Responsible AIE/SIO, I&L/LKO Approver Supporting Director/I&L/ SE/SSE, LKO QA (Mech) Director/I&L/ LKO AIE/SIO, I&L Consulted Informed ED/QA(Mech) All Zonal office of QA (Mech) Dte.

AIE/SIO, I&L/LKO

ED/QA(Mech

All Zonal office of QA (Mech) Dte.

9. Abbreviations:
QA(Mech) RDSO I&L ED/QA (Mech) AIE SIO MR QMS STR M&P/T&P Quality Assurance(Mechanical) Directorate Research Designs & Standards Organization Inspection and Lisening Executive Director/ Quality Assurance (Mechanical) Assistant Inspecting Officer Senior inspecting Office Management Representative QA Mech. Schedule of Tech. requirements Schedule of Tech. requirements Machinery and Plant/ testing and Plant

SIO/QA(Mech) Prepared By:

Director/ QA(Mech) Issued By:

Printed: 01/02./2012 Page 2 of 2

ISO9001:2008 Document No: QM-F-7.1-17/A Document Title: Wagon Quality Score Sheet (BOXN Type)

Version No: 1.0

Date Effective: 01/02.2012

Wagon Quality Score Sheet

(Open Wagon BOXN Type)
Name of Wagon Builder & location Type of wagon and wagon no. Date of assessment Total score Score obtained 100

QM-F-7.1-17/A

Score sheets
S.N. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Items Cambering of under frame in final wagon Distance between bolster bogie centre Overall width Overall height Coupler height from RL Dimension of doors Air brake testing Welding of under-slung brackets/Clamp/safety strap/cross members i) Very good 4 ii) Acceptable 3 Welding of under-frame and its sub-assemblies. i) Very good 4 ii) Acceptable 3 Welding of end wall/side wall i) Very good 4 ii) Acceptable 3 Floor plate welding i) Very good 4 (With use of hydraulic press arrangement) ii) Acceptable 3 Use of MIG welding in maximum locations i) Above 90% 3 ii) Less than 90 % 2 Overall welding quality i) Very Good 4 ii) Acceptable 3 Edge preparation i) Very Good 4 ii) Acceptable 3 Provision of APD as stipulated for brake system and bogie assembly. i) Very Good 3 ii) Acceptable 2 Centre Pivot assembled height from bolster Side bearer set up height from bolster Painting as stipulated and paint thickness Lettering and marking as stipulated Total score 3 3 3 3 3 3 3 4 4 4 Actual obtained

11.

12. 13. 14.

3 4 4

15. 16. 17. 18. 19.

3 3 3 3 3

Quality Assurance (Mechanical) Directorate/RDSO

Format/Annexure Page 1 of 3

ISO9001:2008 Document No: QM-F-7.1-17/A Document Title: Wagon Quality Score Sheet(Open Wagon BOXN Type)

Version No: 1.0

Date Effective: 01.02.2012

S.N. 20.

21.

22.

23.

24.

25. 26. 27. 28. 29.

30.

31.

32.

33.

34.

Items Overall finish of wagon i) Very Good 4 ii) Acceptable 3 Lock bolting of CP top i) Very Good (With Use of hydraulic press) 4 ii) Acceptable 3 Lock bolting of side wall/end wall/stanchion i) Very Good 3 ii) Acceptable 2 Lock bolting of striker casting, Anchor plates, YPSP, YSP, back stop and other components i) Very Good 3 ii) Acceptable 2 Internal inspections and their records i) Fully available 3 ii) Not fully available 2 Tare weight of wagon i) With printing facility 2 ii) Without printing facility 1 Proper door locking arrangement Operation of knuckle with operating handle and Articulation of coupler body Hand brake operation Deployment of qualified welders and certification through 3rd Party i) System for regular certification and training exist 2 ii) Partially available 1 Validation of jigs and fixtures/other tools as specified in QAP i) System for regular validation is available 2 ii) System for regular validation is partially available 1 Use of hydraulic/Pneumatic clamp in fixtures i) Available for under-frame & other major subassemblies 2 ii) Partially available/Conventional clamping available 1 Use of CNC plasma machine i) Used for all application 2 ii) Not used for all application 1 Use of inverter based/pulse synergic MIG welding machine i) Available for all application 2 ii) Not available for all application 1 Automatic/auto grit recovery semi-automatic shot blasting machine i) Auto recovery of grit available 2 ii) Auto recovery of grit is not available 1

Total score 4

Actual obtained

2 2 2 2 2

Signature of Inspecting Official with name and date

Quality Assurance (Mechanical) Directorate/RDSO

Format/Annexure Page 2 of 3

ISO9001:2008 Document No: QM-F-7.1-17/A Document Title: Wagon Quality Score Sheet(Open Wagon BOXN Type)

Version No: 1.0

Date Effective: 01.02.2012

Annexure

Name of Wagon Builder: Date of Inspection: Check-sheet for inspection of lock Bolting i) ii) iii) iv) v) vi) 1 2 3 4 5 6 7

Works: Wagon No.

Location of Lock Bolt (As applicable) Remarks (defects observed, if any, to be mentioned) Centre pivot top Side stanchion End stanchion Corner stanchion Backstop Striker casting Lock bolting to be checked for following defects, as applicable Swaging of collar done properly or not(min. collar dia, max. collar length and profile as prescribed or not) Any scoring marks on collar Swaging done properly or not(collar diameter and length to be as prescribed) Projection of shank form collar(to be as prescribed) Pin tail cut off or not Collar straight or not Any sign of enlargement of hole

Check-sheet for inspection of welding joints Location of Joint Remarks (defects observed, if any, to be mentioned) i) Two Side Stanchions ii) One end stanchion iii) Two cross bars iv) One bolster v) One side top coping vi One floor plate joint Welding joints to be checked for following defects, as applicable Non-uniformity, Blowholes/Porosity, Cracks, Spatter, Sealing of ends of joints done or not, Undercut, Overlap, Scalloping proper or not, Proper gap maintained or not, Convexity within specified limits, Ground flush done or not(if specified in WPS), Leg length within specified limits, Throat within specified limits, Excessive convexity

Signature of Inspecting Official with name and date

Quality Assurance (Mechanical) Directorate/RDSO

Format/Annexure Page 3 of 3