MCF Inspection
Best practices observed
• LHB wheel line produces quality wheelset with data integration between all machines
helps exact tolerances & easy data traceability.
• Bogie assembly is on the concept of line production with proper tooling, calibrated
torques wrenches, torque testers which maximize the bogie production
• Separate lines are available for different variants of LHB like LSCN, LACCN & GS etc
reduces shunting work
• Proper Lifting tackles for underframe, Sidewall are available and being used
• Automated plug weld at top of underframe trough sheet is being done
which is reducing heat input
• Proper clamping arrangement for sidewall framework fixture are available
Sidewall sheet stretching arrangement is available
• Mechanism to be made to ensure same torque to be available throughout sidewall manufacturing
Following points may be consider for enhancement of quality
IN LCW ( laser cutting & welding machine ) only chisel test is being followed
currently.
• LCW test samples may sent to CMT periodically for tensile test, root
test, face bend test to check machine condition
• Daily production test in RSW (robotic spot welding ) for Shear
strength, indentation measurement (nugget dia & surface
indentation) is not being done.
• Templates for various critical dimension of sidewall like room dimension
pitch, perpendicularity of framework members to be used
• Spot welding at certain location are not inline.
• Stacking of underframe to be • Underframe to be intermittently
improved. supported to avoid sagging
• Welding lumps and spatter observed in Manual MIG welding used for
sidewall & endwall integration
• Unusual dent marks observed in furnished coach near sidewall &
underframe integration
• Torque marking not done in fastening arrangement of draft gear &
CBC coupler
• Painting of LHB wheelsets is not being done. Painting of wheelset of min DFT 180
microns to be ensured with HPAC ( PCN123) as primer & MDTS -094 Epoxy
elastified paint as top coat
• In bogie frame, painting to be followed as per MDTS-213. PCN 123 is not being applied
and entire DFT is maintain with MDTS-094. Already material has been planned and
material is under procurement stage
• Air bubbles on PVC sheet observed.
During pasting care should be taken to avoid entrapment of Air
Sheet can be unrolled and dried in sunlight for 45 to 60 mins to remove moisture before
pasting.
Rollers can be used while pasting the PVC which ensures No air entrapment
• Additional securing pins with washer to be added in ceiling for fixing of
Insulation.
• At duct flange joints EPDM rubber shall be used for prevention of Air
leakage
• LACCN berth supporting pillars are provided with shims at top side to make up the Gap.
Adequate care should be taken at body shell stage to control the height at every body
pillar.
Template can be used to ensure
cross brace bracket location
• Precut contours partially available in FRP sidewall panel. To be extended for
other cutaways, otherwise templates should be used for cutting
Pre cutouts not available
• Door Corner moulding on the floor to be extended for full profile length.
SS chequered sheet to be extended for full door way length for ease of maintenance as PVC
is subjected to more wear & tear
• Stacking of prelaminated seat is not properly stacked
Thank you
