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SITHAULI, GWALIOR

AN ISO-9001-2000 WORKSHOP

Presented by:

Ms. Rachna Marcus

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Rail Spring Karkhana is the Largest and dedicated plant for helical hot coiled Spring for IR Rolling Stock.

Manufactures 90000 springs (3100MT) per annum.

Set-Up in 1989 under TOT agreement with M/s Ernst Komroski & Co.& Grueber, Germany.

Purpose -To cater the increasing need of quality Coil springs for switchover from Laminated Springs.

INTRODUCTION

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The Plant has state-of-the-art facilities for manufacturing hot coiled springs.

Annual turnover of RSK is Rs. 49 Crores.

INTRODUCTION

Major Customers Nos. of Springs supplied during 2007-2008

RCF, Kapurthala 25000

Zonal Railways 65000

Total 90000

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Manpower:- 460 sanctioned.

Initial Investment:- Rs. 54.04 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:- 22 hectares

Shop covered area:- 6400 sq. m

Administrative building area:- 1800 sq. m

Nos. of Quarters:- 60

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

SALIENT FEATURES OF RSK

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QUALITY OBJECTIVESQUALITY OBJECTIVES

• Compliance to production and dispatch target Compliance to production and dispatch target of 90000 springs for the year 2008-2009.of 90000 springs for the year 2008-2009.

• Minimize the “in house rejection” of springs to Minimize the “in house rejection” of springs to 6.5%.6.5%.

• Improve skill and knowledge of the Improve skill and knowledge of the employees.employees.

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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.

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ORGANISATIONORGANISATION

DyCME

ACMT

WM(F) WM(Pl) WM(Mfg)

AWM/Pl WAAO

SEE

ASC APO

SrDMO

CWM

AMMM

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STAFF POSITION

Category Sanctioned On-Roll

Supervisors 78 72

Other Group “C” 279 262

Group “D” 103 103

TOTAL 460 437

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BUDGET AT A GLANCE

Figures of 2008-2009 in lakhs of Rs.

Staff Wages:- 903Material Stock :- 2300Direct Purchase (Material) :- 700Miscellaneous Charges:- 230

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MACHINERY & PLANT

END TAPERING MACHINEBAR HEATING FURNACECOILING MACHINEQUENCHING MACHINETEMPERING FURNACEHARDNESS TESTING MACHINEEND FACE GRINDING MACHINE

contd.

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MACHINERY & PLANT (Cont.)

SHOT PEENING MACHINEMAGNAFLUX CRACK DETECTION

MACHINESCRAGGING HYDRAULIC PRESSLOAD TESTING HYDRAULIC PRESSRE-PITCHING MACHINES 2 No:sPRIMARY PAINT PLANT BLACK PAINT PLANTPACKING MACHINE

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STEPS TO MANUFACTURE STEPS TO MANUFACTURE SPRINGSSPRINGS

Secure firm orders.Secure firm orders. Purchase Raw Material.Purchase Raw Material. Inspect Raw Material.Inspect Raw Material. Processing.Processing. Inspection of springs.Inspection of springs. Packing.Packing. Dispatch.Dispatch.

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PROCESS FLOW CHARTRaw Material

End Tapering

Peeled bar

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PROCESS FLOW CHART (Cont)Bar Heating

Coiling

Quenching

Tempering

Dispatch

Colour Coding

Black Painting

Load Testing

End Grinding

Scragging

Primary Painting

Shot Peening

Crack Testing

Resizing

Under/over Height

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16END TAPERING OPERATION

17END TAPERED BARS

18SPRING COILING IN OPERATION

19QUENCHING MACHINE

20END GRINDING MACHINE

21END GROUND SPRING

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23MAGNA FLUX CRACK DETECTION OF SPRING

24SPRING DEFLECTION TESTING MACHINE

25REPITCHING MACHINE

26RED OXIDE PAINT PLANT

27SPRINGS ON BLACK PAINT PLANT

28UNLOADING FROM BLACK PAINT & CODING

OF SPRINGS

29PACKING CARTON OF SPRING

30PACKING OF SPRING

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TYPES OF SPRINGSRSK is manufacturing springs for:-

Coaching:- Axle & Bolster springs for AC & Non-AC, 4 types.

Loco Springs:- Inner & Outer for BG locomotives. 2 types.

High CapacityParcel Van:- Axle box & Bolster 3 types

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RANGE OF SPRINGS & RAW MATERIAL

PARAMETER Minimum Maximum

Wire Dia (mm) 16.0 53.5

Free Height (mm) 123.0 877.0

Spring Outer Dia. (mm) 86.0 450.0

Weight (Kg./spring) 3.8 171.2

52Cr4Mo2V For larger dia above 33 mm.

60Si7 For smaller dia below 33 mm up to 16 mm

MATERIAL

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QUALITY ASSURANCE RSK has got 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.

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MAJOR JOBS DONE DURING

LAST 4 YEARS New heat exchanger system for cooling of quenching

oil. Installation of fire fighting arrangement at LPG Yard. Developments of indigenous substitute for imported

spares. Installation of Air Dryer & Moisture Separators in

compressed air circuit. Installation of isolation transformers and voltage

stabilizers for control panels. Installation of Effluent Water Treatment Plant. Contd

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Provision of air-conditioners for control panels.

Provision of new water-cooling towers for improving efficiency of water-cooling circuit.

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

Compliance of mandatory requirements such as public liability insurance and approval of disaster management plan etc.

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

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PRODUCTION AND ITS VALUE

S. S. No:No:

YearYear TargetTarget

No:No:

ProductionProduction

No:No:

Value inValue incrorescrores

11 2002-032002-03 7271172711 6816168161 23.823.8

22 2003-042003-04 9000090000 9000090000 29.429.4

33 2004-052004-05 9000090000 7900079000 34.834.8

44 2005-062005-06 9000090000 9270592705 42.542.5

55 2006-072006-07 9000090000 9215092150 42.442.4

66 2007-082007-08 9000090000 8100081000 41.041.0

77 2008-092008-09 9000090000 9275092750 49.049.0

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ACHIEVEMENTSAbout 90,000 springs produced per year

covering 9 types of coaching and loco springs.

Set-up of Phosphating plant to reduce corrosion.

Re-conditioning of important machines.Spring production cost is less than

market.

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INVESTMENT PLANSINVESTMENT PLANS

Additional infrastructure for manufacture of Additional infrastructure for manufacture of FIAT springs- sanctioned. FIAT springs- sanctioned.

Replacement of old and obsolete machines of Replacement of old and obsolete machines of existing production line sanctioned.existing production line sanctioned.

Planning of new BOXN wagon spring Planning of new BOXN wagon spring production Line.production Line.

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BOTTLENECKS

• Remote geographical location of plant.

• Shortage of officers and staff.

• Inadequate local market.

• Poor communication.

• Old & obsolete machines.

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ASSISTANCE REQUIREDASSISTANCE REQUIRED

Communication: more and better Rly Communication: more and better Rly phones.phones.Mobile phones.Mobile phones.Security.Security.More delegation for machine repairs.More delegation for machine repairs.Approach road without railway Approach road without railway crossingcrossing..

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RECOMMENDATIONS TO RECOMMENDATIONS TO IMPROVEIMPROVE

Civil engineering officers to be Civil engineering officers to be placed under workshop in charge.placed under workshop in charge.

Enhancement of procurement Enhancement of procurement powers.powers.

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