General Requirements

Interface Activities
Quality Assurance
Reliability
Availability
Maintainability
System Safety Assurance
Hazard Analysis
Fail safe Design
Electromagnetic Compatibility
Noise and Vibration
Fire and Toxicity Standards
Life Cycle Costing
Energy consumption & carbon credits
Maintenance management system

Interface management requirements between rolling stock and:

Signaling and Train Control system

Train Born Radio System
Overhead and Electric Traction System
Track Work
Depot Maintenance Equipment
Depot Civil Work
Operation and Maintenance Contractor
Independent Safety assessor
Independent RAM assessor

Interface requirements
All interface issues between two contractors are satisfactory resolved.
Supply, installation, testing and commissioning of equipment and software are fully
coordinated.
All equipment supplied in the contracts are fully compatible with each other.
It Contains
A) Lead versus Match (Following)Contractor
B) Division of Responsibility between the contractors
C) System Description of the lead and other contractor.
D) Details to be furnished by one contractor to other
E) Interface Tests

Rolling Stock and S&TC

ATC equipment, Antenna
Drivers display
Speedometer

 Train description& next station information

Power & Earthing requirements of S&TC equipment
Message/Data exchange to TIMS

Rolling Stock & Train Born Radio System

Train borne equipment to be supplied by radio contractor
Functional Interface

Rolling Stock & Over Head Electric Traction System

Photographs
Earthing arrangement
Harmonics
Energy consumption

Rolling Stock & Track

Track geometry & tolerances

Wheel/Rail dynamic behavior
Buffer stops
Neutral section detection

Rolling Stock & Depot Maintenance Equipment

Underfloor Wheel Lathe

Automatic train wash plant
Mobile Jacking System
Bogie wash plant
Bogie preloaded machine
Bogie Drop

Rolling Stock & Depot civil works

Inspection facility
Repair facility
Wash facility

QUALITY ASSURANCE PLAN

What is Quality ?

The ability to make the same thing the same way, over and over again.
Customer buys today is same as what they bought last week or will buy next week.
Product meets customers expectations 100% of the time.
Governing standard is ISO:9001-2008 of ISO(International Standards Organization)

PROCESS APPROACH FOR QUALITY MANAGEMENT SYSTEM

(As Per ISO 9001-2008)

(a) Understanding and meeting requirements,

(b) The need to consider processes in terms of added value,
(c) Obtaining results of process performance and effectiveness, and
(d) Continual improvement of processes based on objective measurement.

Model of a process-based quality management system

DOCUMENTATION REQUIREMENTS
Documented statements of a quality policy and quality objectives
Quality manual
Documented procedures and records required by ISO 9001

 Documents and records determined by the organization to be necessary for the

effective planning, operation, and control of its processes.

Documented procedure
Documented procedure means that the procedure is established, documented,
implemented, and maintained.
A single document may address the requirements for one or more procedures.

CONTROL OF DOCUMENTS & RECORDS

Documents required by the quality management system. (Policy Procedures)
Records are a special type of document and must be controlled as required
(document relating to a particular product produced).
Control of document means identification, numbering, retrieval, modification
procedure.
Establish and control records as evidence of conformity to requirements and to
demonstrate the effective operation of the quality management system.

Quality Assurance

Written definition or policy(Quality Manual)

Procedures to maintain quality
Reporting Methodology
Authority to take decisions
Product standards
Complete documentation regarding a product sent to customer

Management Support to QA
Top management must buy into what QA is doing
QA manager must report to CEO or direct link
Corporate support does not always make one popular with local managers but is
critical for maintaining high quality standards

Customer expectations

This is where quality programs begin.

Marketing has defined the customer expectations.
Product development has created a product that meets those expectations.
Engineering has designed a process to make the desired product.
Now, all QA must do is design a control system that verifies that everything is
working as designed.

PROCESSES IN DELIVERY OF PRODUCT TO CUSTOMER

(As per ISO 9001)
1.
2.
3.

Planning
Design & Development
Purchasing

4.
5.
6.

Production & Service Provision

Control of Measuring & Monitoring Equipment
Measurement ,analysis and Improvement

1.Planning

Planning of Product Realization

Customer related Process
Review of requirements related process
Review of requirements related to product
Customer communications

2.Design & Development

Planning
Inputs
Outputs
Review
Verification
Validation & Control of changes

3.Purchasing
Purchasing process
Purchasing information
Verification of purchased product

4.Production & Service Provision

Validation
Identification & trace ability
Customer property
Preservation of product

5.Control of Measuring & Monitoring Equipment

Calibration
Instruments not to be calibrated

6.Measurement, Analysis and Improvement

Monitoring measurement
Customer satisfaction
Internal audit
Monitoring and measurement of processes
Monitoring and measurement of product
Control of non conforming product
Analysis of data
Improvement

 Continual improvement
Corrective action
Preventive action

Quality Assurance by RS Contractor

Quality Policy
The objective of quality control is to provide rolling stock requirements and expectations
of customer, and in order to achieve this objective, it establishes its quality system for a
series of activities through product design, development ,production, and after-sales
service to meet all the requirements of ISO 9001 and make all organization members to
observe and execute this.

Design Control
Relevant procedures
Procedure for design process
Instruction of design input and output process
Instruction of design review and validation process
Design Plan
Design inputs(contractual requirements, applicable laws, and standards, drawings,
calculations and supporting data, instructions, supporting documents)
Design Review
Design verification & validation(Alt. calc., approved design , design qual. tests and
demo)
Design Output
Design change control & configuration control

Document And Data Control

Relevant procedures
Quality system document control procedure
Engineering document control procedure
Procedure for quality record control

Purchasing

Subcontractor Evaluation & Selection

Subcontractor control
Purchasing data
Verification of purchased product

Product Identification And Traceability

Product identification and traceability control instruction
Traveller sheet
Traceability
Part Number and unique serial no.

Process Control
Reference Procedures
Procedure for production planning
Procedure for process control
Process for production engineering
All work should be done as per
Process diagrams
Work instructions(quality assurance requirements are specified in these)

Inspection And Test

Design Qualification Testing (Type testing )
Acceptance testing (Routine tests)
First Article configuration inspection (prototype test)
Inspection and Test Plan(issued by design team)
Defines inspection and test activities
Witness points and hold points
Final inspection and testing and commissioning
Inspection and test records

Control Of Nonconforming Product

Reference Procedures
Procedure for non conformity control
Non conforming product is classified as follows
Waiver
Use as is
Repair/rework
Scrap
Claim
Holding of decision
Conditionally used

Corrective And Preventive Action

Procedure for corrective and preventive action
Non conformance received during inspection/test, internal /external quality audit or
after- sales service
Preventive action to detect, analyze, and remove potential cause of non conformance

Others
Car history book to be submitted at time of delivery
Internal quality audit
External quality audit of sub contractors

 External audit performed by the client

Training for the client
After sales service