CUSTOMER INTERACTION MEETING HELD AT ICF ... OF THE CUSTOMER INTERACTION MEETING HELD AT ICF ON 21ST AND 22ND OF MAY 2015 Members Present ICF S/Shri. 1 Ashok K Agarwal - GM 2 Pankaj

Integral Coach Factory, Chennai.38

MINUTES OF THE

CUSTOMER INTERACTION MEETING HELD AT ICF

ON 21ST AND 22ND OF MAY 2015

Quality Assurance Department

MINUTES OF THE CUSTOMER INTERACTION MEETING HELD AT ICF ON 21ST

AND 22ND

OF MAY 2015

Members Present

ICF

S/Shri.

1 Ashok K Agarwal - GM

2 Pankaj Kumar - CME

3 Bhaskar Narang - COS

4 S.G.Hundekari - CEE

5 Jagdish Prasad - CMM/S

6 S.Srinivas - CDE/Mech

7 Shishir Dutt - CWE/Fur

8 Shashi Bhushan - CWE/Shell

9 K.S.Jain - CME/QA

10 S.Sridhar - CEE/QC&C

11 S.P.Vavre - CDE/Elec.

12 M.Chandra Kumar - Dy.CME/P/Shell

13 P.Balasundar - Dy.CME/Plg.& IE

14 M.E.Srinivasan - Dy.CME/A/Fur.

15 K.N.Babu - Dy.CME/TC

16 R Sundararajan - Dy.CME/Fur-II

17 J Nagesh - Dy.CME/QC

18 D.Neelakantan - Dy.CME/D-I

19 T.Dilipkumar - Dy.CME/D-II

20 A.P.Soni - Dy.CME/Bogie

21 Karuna Kumar u - Dy.CME/Production

22 S.Lakshmanaswamy - Dy.CEE/EMU

23 M.Ramanathan - Dy.CEE/C&D

24 J.Maran - Dy.CEE/Design

25 Mehar kure.V.D. - Dy.CC&M

Zonal Railways S/Shri

1 S K Paswan - CWM/CW/PER/SR

2 Guatam Dutta - CWM/LW/PER/SR

3 P Sivaraman - Dy.CME/CW/PER/SR

4 D Jayaraman - Sr.CDO/BBQ/SR

5 J.S. Hira - CDO/ANVT/NR

6 G.Srinivasa rao - CDO/HYB/SCR

7 Mayanak Pratap Singh - CDO/TVC/SR

8 Sanjoy Kumar Mistry - DME/Proj/SDAH/ER

9 Ramavtar Yadav - PE/C/AII/NWR

10 B.Anjaneyulu - PE/UBLS/SWR

11 Abhay kumar - WM/JUDW/NR

12 Ravinadranath - WM/TPYS/SCR

13 K.Vijaya kumar - ADME(P) CKP/SER

14 Ambarish Kumar Singh - ADME/C&W/DNR/ECR

15 Kundan Kumar - ADME/GHY/NFR

16 Shakeel Rahiman - AWM/ CW/LGDS/SCR

17 Satya prakash - SSE/C&W/ANVT/NR

18 Akhilesh babu - SSE/C&W/ASR/NR

19 V.M.Joseph - SSE/C&W/BDTS/WR

20 S.P.Singh - SSE/C&W/BE/NR

21 P.K.Gowrha - SSE/C&W/BSP/SER

22 Swarupananda Hansda - SSE/C&W/CP/ER

23 Paresh Hazarika - SSE/C&W/DBRG/NFR

24 A.K.Deshmukh - SSE/C&W/Durg/SECR

25 Brij Mohan Kain - SSE/C&W/GWL/NCR

26 Rajneesh Kumar Chaubey - SSE/C&W/MB/NR

27 T.Abdulkarim - SSE/C&W/PGT/SR

28 R.Dhasarathan - SSE/C&W/SBC/SWR

29 K.B.Rabbi - SSE/C&W/TKPR/ER

30 Raveendran P - SSE/C&W/TVC/SR

31 Manoj kumar yadav - SSE/C/AII/NWR

32 C.H.Sambasiva rao - SSE/C/BZA/SCR

33 S.N.Sharma - SSE/C/GHY/NFR

34 B.C.Jayaprasad - SSE/CRS/TPTY/SCR

35 D.Vijay Kumar - SSE/CW/PER/SR

36 V.Selvaraj - SSE/CW/UBLS/SWR

37 Ajay kumar - JE/C&W/AGC/NCR

RITES/RDSO S/Shri 1. Pankaj Agarwal 2. A K Jain 3. P K Srivastava

- - -

GGM/Corp. QA/RITES Ltd. GM/Southern Region/RITES Ltd. Jt. Director/Carriage/RDSO

RDSO Items

1.

Reporting

Railways

SR/Aug'13, SWR/Aug'13, SCR/Jan'14,

SWR/Jan'14, ECoR/Apr‟14

Type of

Coaches/Major

Assy./Specific

Item.

All Types/Seats & Berths – Upholstery Cloth.

Brief Account

of Problem.

Peeling off of rexene. Coating on the

rexene peels off and rexene starts wrinkling

in short span of service.

The rexene cloth at the edges of the side

lower berths (Foldable Bed cum Back Rest)

is getting torn frequently.

Hence foam and proper padding is to be

provided to avoid the above problem.

Decision taken

during the

meeting.

RDSO to conduct anonymous quality audits.

All tests which require one day or more to be

changed as type test. Design to write to RDSO

regarding tests.

2.

Reporting

Railways SR/Aug'13, SWR/Aug'13

Type of

Coaches/Major

Assy./Specific

Item.

All Types/DTPB - Densified Thermal Bonded

Polyester Block (Recron).

Brief Account

of Problem.

DTPB cushions are getting compressed within

first POH - AC Coaches berth cushion loses

their strength and cushioning ability after 8-10

months.

Decision taken

during the

meeting.

Design to write to RDSO repeatedly.

3.

Reporting Railways NR

Type of

Coaches/Major

Assy./Specific Item.

AC/Upholstery Cloth.

Brief Account of

Problem.

Loose skinning (wrinkling) of Upholstery

Cloth (oil cloth)

on berth and seats.

Decision taken

during the meeting.

Other Rlys to check and report in the next

meeting.

4.

Reporting

Railways

SWR/Aug'13, SCR/Aug'13,

SCR/Jan'14, SR/Jan'14

CR/April „14

Type of

Coaches/Major

Assy./Specific

Item.

All Types/Paneling – LP Sheet.

Brief Account of

Problem.

LP Sheet - Crack/breakage.

As the marking of manufacturer‟s

initials are on the back side of the sheet

it is not possible to trace the

manufacturer without disassembling the

panels for initiating warranty claim.

Coaching Depots are complaining that

they do not have sufficient man power

to disassemble the panels and the coach

is forced to run in service until the next

POH.

Decision taken

during the

meeting.

CME - No coach should be despatched

from ICF with LP Sheet crack. QA &

Design to check the back pieces. Design

to identify areas where the screws are

not to be provided.

5.

Reporting

Railways SR/Aug'13, SR/April „14

Type of

Coaches/Major

Assy./Specific

Item.

All Types/Brake Gear Bushes.

Brief Account of

Problem.

Manufacturer initial and year of

manufacture is not traceable and

getting defaced on run in the brake

gear bushes within 9 months. Hence

raising warranty claim is very

difficult. Specific clause/condition to

be stipulated in the RDSO

specification with the marking

should be permanent and clearly

visible up to the condemnation

period of brake gears for raising

necessary warranty claims.

Elongation of brake gear lever pin

holes and Wearing of pin number 3

due to poor performance of HPPA

brake gear bushes.

Decision taken

during the

meeting.

Rlys are requested to write to RDSO,

RB with a copy to ICF & RCF

indicating vendor wise, vintage wise

failure analysis.

CME instructed CDE/Mech to raise

this issue in the CMG meeting and

go for a solution and advised Rlys to

write to RB and RDSO repeatedly.

CME - We should revert back to

nylon bushes.

In the HPPA brake gear bushes supplied by trade, the Drg. No. and date of manufacturing

code are printed as per extant drawings.

During POH/IOH, it is noticed that the name are defaced/smeared away.

Due to the names defacing, it is very difficult identify the date of manufacturing and

hence the warranty claim also

6.

Reporting

Railways CR/Aug'13, SWR/Aug'13, ECoR (CDO/Waltiar)

Type of

Coaches/Major

Assy./Specific

Item.

Conventional coaches/ Hytrel Washer.

Brief Account of

Problem.

Hytrel washers – crack.

AXLE BOX CANTED & GRAZING

o ECoR - In recent years, there is increase

in the cases of canting and grazing of

primary suspension unit with wheel. In

East Coast Railway nearly 40% of cases

of sick marking of coaches during

primary examination is due to above

reason. Further due to canting the

collars of rear cover of the Axle Box

assembly get damage and metal

particles get contaminated in grease.

ICF being manufacturing unit, may

relook into the modification done in

primary suspension like use of hytrel

washers etc. and take measures to

prevent such cases and thus increase the

coach reliability & reduce the down

time.

o SR - Axle box getting canted due to

wearing of hytrel washer. The limit of

radial clearance of bearing in service to

be reduced.

Decision taken

during the

meeting.

It was decided in the CMG meeting that RDSO to

submit a report to RB within 2 months. Rlys (with a

copy to ICF) and ICF/Design to write to RB &

RDSO repeatedly.

7.

Reporting

Railways SR, ER

Type of

Coaches/Major

Assy./Specific

Item.

All Types/Composite material wearing piece

Brief Account of

Problem.

Unusual sound and jerk observed from the

bogies. The side bearer with polymer

bearing piece is having no groove.

Detached and lifted the coach. All side

bearers provided with Non-metallic piece

(Thermoplastic Polyurethane wearing)

causing generation of friction and

abnormal heat. Resulting rubbing marks

on hard ground steel wearing plate.

Composite material wearing pieces found

cracked condition.

Decision taken

during the

meeting.

The item has been introduced as a trial only.

Defective wearing piece

8.

Reporting

Railways

SWR/Aug'13, SCR/Aug'13 CR/Aug'13,

SCR/Jan'14, SWR/Jan'14, SR/Jan'14

Type of

Coaches/Major

Assy./Specific

Item.

AC & Non – AC Sleeper Coaches/PU coated

ladder.

Brief Account

of Problem. PU Peels off and forms sharp edges.

Decision taken

during the

meeting.

ICF to implement the new design SS ladder.

Newly designed SS Ladder

9.

Reporting

Railways SR, SCR

Type of

Coaches/Major

Assy./Specific

Item.

Non-AC/FRP Window

Brief Account of

Problem.

FRP shutter unit guide rails are getting

torn/cracked at louvre shutter catch

engaging location, locking hole in the

FRP frame getting oblong

Damage of rubber liners lead to jamming

of shutter The Shoot Bolt Locking

Mechanism in FRP window shutters can

be provided as a replaceable unit, so that

during POH, the locking mechanism can

be replaced separately without

condemning the entire shutter.

Decision taken

during the

meeting.

Already highlighted to RDSO

Damaged guide rail

Non-replaceable Shoot bolt Arrangement

10.

Reporting

Railways ECoR

Type of

Coaches/Major

Assy./Specific

Item.

Non-AC Coaches/Brake Gear/Alarm

Resetting Wire Rope

Brief Account of

Problem.

In Non-AC coaches, the Alarm resetting

rope is provided at one side of end wall.

In case of chain pulling by passengers, the

en-route Driver and Guard face difficulty

as they have to go through the coach to

reach the other side for resetting.

This causes hardship and also extra

detention time. Provision for resetting of

PEASD on both side of the end wall is

required

Decision taken

during the

meeting.

ICF has revised the Drawing to have both

side resetting arrangement in GS and SLR

Coaches and trial conducted in one coach.

Drawing has been sent for the approval of

RDSO and awaiting feedback.

11.

Reporting

Railways SWR/Feb‟15

Type of

Coaches/Major

Assy./Specific

Item.

All Types/Bogie/Compensating Rings

Brief Account of

Problem.

In newly built coaches - approximately 30

mm packing below the bolster coil springs

is given.

It shows that the free height of the bolster

springs is low.

Decision taken

during the

meeting.

After the introduction of Bio-toilets the

tare weight of the coaches have increased

by 2 Tonnes (0.5 x 4 Nos.) approx..

To maintain the bolster clearance excess

Compensating rings are used.

RDSO to re-design Springs.

Items pertains to ICF

1.

Reporting Railways SR/Aug'13, ECoR/Aprl‟14, SCR/July‟14 ,

SWR/July‟14

Type of Coaches/Major


All types/Primary and Secondary

Suspension/Equalizing Stay

Brief Account of

Problem

Corrosion problems are more in Epoxy

painted equalizing stays of ICF design.

The RDSO design, Galvanized, equalizing

stays are corrosion resistant and last for

more than 3 POHs.

The bracket holding the Equalizing stay

and the equalizing stay unit get bend

during service and it becomes virtually

impossible to remove the long pin for

replacing the defective member.

Interchangeability problem of Bush on

Equalizing Stays

Action taken/Drawing

No./Remarks

Procurement of new forged design

equalizing stay to drg.329-0-5-012 and 013

dtd.07/01/2014 (UL No. 08139513550101)

is under progress.

For 2015-16, Procurement advice given

for 800 numbers.

Implementation status

of the modification in

the coaches/ Decision

taken during the

meeting.

To be implemented immediately.

2.

Reporting Railways SR/April‟14


Assy./Specific Item. SLR Coaches/Shell Items/SLR Luggage Door

Brief Account of

Problem

Dropping of luggage door from its guides:- To

prevent this, a bolt is welded on side pillar.


No./Remarks

New Stainless Steel Sliding Door with

Rollon Guide has been developed and the

drawing is under issue.

Weight of the SS Door will be 110 Kg as

against MS of 130 Kg.

Stainless Steel doors with Rollon make

guide rails will overcome the dropping of

luggage door and corrosion issues.




taken during the

meeting.

Under Implementation

3.

Reporting Railways SCR/April‟14



AC Coaches/Furnishing Items/Emergency

Window

Brief Account of

Problem

Working out of chain from rubber beading

while pulling due to lesser thickness of split

pin


No./Remarks

Drawing has been altered – Size of the

split pin altered from 2 to 4 mm, Washer

Size altered from Inner Dia.3.4 to Inner

Dia.5.5 to IS 2016/67. Drg. No. ICF/SK

54-275 Alt‟d‟ Aug/2014.

Amendments have been issued in two

existing POs on 17/02/2015 for getting the

balance materials as per the latest drawing

as there is no financial implications.

New PO Nos. 07141141709 &

07141141862 - Delivery due on 30/05,

071401662140 & 071401662227 -

Delivery due on 30/06, have been released.




taken during the

meeting.

Under implementation

Furnishing Div. has to cut in immediately.

4.

Reporting Railways SR/April‟14


Assy./Specific Item. All types/Brake Gear/Brake cylinder

Brief Account of

Problem

Wheel grooving on account of brake

binding.

SR made the BMBC stroke 40mm against

32 mm to reduce brake binding- number of

brake binding cases have come down.


No./Remarks

Vide Letter No. MC/MTG/CMG/XIV

Dtd.24/02/2015 RDSO has instructed to

provide BMBC having 40 mm piston

stroke for all new GS and SLR Coaches.

106 sets of air brake equipment with

40mm piston stroke Brake Cylinders of

M/s.Stone India is under RITES

Inspection.

New UL has been initiated for Air Brake

Equipment with 40mm piston stroke Brake

Cylinders for GS & SLRD coaches.




taken during the

meeting.


Furnishing Div. has to cut in immediately.

5.

Reporting Railways SR/Aug‟13, SCR/Aug‟13, CR/Aug‟13, SWR/Aug'13

NCR/April‟14, ER/July‟14

Type of

Coaches/Major


All types/Furnishing Items/PVC Flooring

Brief Account of

Problem

PVC Flooring sheets in the toilet and gangway areas

generally get uprooted at skirting places. It should be

properly pasted.

Falling/uprooting of PVC in lavatories - Moulding's

gripping should be strengthened.

Action

taken/Drawing

No./Remarks

As an immediate measure aqua putty sealant to

ICF/MD/SPEC – 114 is issued to seal the PVC ends with

the pan.

An alternate material like Polymerized PVC flooring as per

RDSO Specn. C-9704-1997 has been tried; Drg. No. 283-

4-1-701 dtd.16/09/2014 and 286-4-1-501 dtd.16/09/2014.

Implementation started in coaches with SS Modular toilets.

100% implementation has been planned in all coaches

during 2015-16 itself, Supply and Installation PO No.

061500411143-Delivery due on 15/06/2015.

The Feedback received on the Polymerized Flooring from

SWR is that the Flooring is peeling off and the colour is

also fading.

As such additional properties are being added as special

condition in the existing specification.

Procurement will be made as per revised UL Description.

PDC 30/05/2015.

Implementation

status of the

modification in the

coaches/ Decision

taken during the

meeting.


6.

Reporting Railways SR/Aug‟13, SCR/Aug‟13, SWR/Aug‟13,

ECoR/Jan‟14


Assy./Specific Item. Non-AC Coaches/Furnishing Items/Roof Ceiling

Brief Account of

Problem

Passengers occupying space on the luggage rack

tear NFTC sheets provided below the roof sheet

at the joints and insert wrappers, tea cups and

paper items etc. in GS/SLR Coaches.

These are vulnerable to fire accidents.

NFTC being soft material, easily get damaged by

miscreants.

Further it is very difficult for Depot to repair

these ceiling damages.

Hence roof ceiling of GS/SLR coaches may

please be provided with alternate material of

higher strength and with minimum joints to

prevent such intentional damages by passengers.


No./Remarks

In Three Coaches (ECR GS 14410, SR GS 14432

and SCR SCN 14240), Roof ceilings have been

provided with 0.8 mm thick Stainless Steel Sheet

against existing NFTC material as a trial

measure; Drg.No.286-4-3-504 dtd.21/07/2014.

Further height of Luggage rack has been lowered

to earlier position of 1368mm (Luggage rack

Drg. GS6-6-1-601 alt 'f‟ 09/05/2014).

The customer feedback received from Southern

Railway is satisfactory; 100% implementation is

planned.




taken during the

meeting.

To be implemented 100%, Furnishing to cut in

within 3 months in GS, SLRD and SCN.

7.

Reporting Railways ECoR/Jan‟14

Type of

Coaches/Major


Non-AC Coaches/Furnishing

Items/Lavatory Roof Ceiling

Brief Account of

Problem

In some trains there are frequent cases

of intentional damages of toilet ceiling

of SCN coaches below the water tank.

These damages are caused by

miscreants in en-route.

The material is used for ceiling below

the water tank is NFTC sheet. Design

may replace this material by any other

material of better strength to prevent

damages.


No./Remarks

Roof ceiling of lavatory has been

changed from NFTC to 0.8 mm thick

Stainless Steel sheet as a trial measure

in three Coaches (ECR GS 14410, SR

GS 14432 and SCR SCN 14240).

The customer feedback received from

Southern Railway is satisfactory; 100%

implementation is planned.




taken during the

meeting.

To be implemented 100%.

Furnishing to cut in within 3 months in

GS, SLRD and SCN.

8.

Reporting Railways SR/Aug‟13, NR/April‟14, SCR/July‟14



AC Chair Car/Furnishing Items/AC Chair Car -

Seats

Brief Account of

Problem

Different designs of AC Chair Car Chairs cause

maintainability problems like removing the

Chairs completely even for attending minor

defects

Because of different designs of chairs arranging

spares is difficult

As the qualities of chairs are very poor and

frequent damages of Snack table, Reclining

Mechanisms, Arm Rests etc. are noticed.

Due to defacing/deficit of manufacturers name

plate on the Seats it is difficult to find out the

manufacturers of the seats.


No./Remarks

Design of seats for AC chair car revised with

imported gas spring for reclining mechanism,

wider snack table &.back rest stopper. Detail

drawings indicating dimensions and material

has been made for frame work, back rest, back

rest cover , arm rest cover and foot rest for

standardization and to maintain uniformity

among all suppliers.

UL Description has been revised to new

specification No. ICF/MD/119 Rev.03

Dt.16/04/2014 and Drg. No.140-6-1-011 dtd.

11/02/2014.

Tender for procurement is due for opening on

16/06/2015.




taken during the

meeting.

QA to ensure the quality of Snack Tables

9.

Reporting Railways SWR/Aug'13, SWR/Aug'13, CR/Apr „14, ECoR/Apr „14,

SCR/July‟14, SWR/Feb‟15, SR/Feb‟15

Type of

Coaches/Major


All types/Furnishing Items/Painting

Brief Account of

Problem

Exterior paint of the coaches gets faded within a span of one

year.

Also, peeling off, cracks, Improper application and Bubbles

formations, dark patches, etc. are seen

Becomes dull, water base PU paint glossiness requirement is

80% but after one year the glossiness retention is only around

50%.

Fading of Satin Blue Markings on Exterior body in 2012

coaches - Coach Number, Class , capacity markings in Satin

blue not visible.

Action

taken/Drawing

No./Remarks

The Supply and application orders are under progress through

Non-Stock Indent for evaluating the performance of

Commercially Available Branded Paint for Exterior Application

in one LHB ACCW and two Conventional ACCW Coaches to

M/s.Dupont and three Conv. AC Coaches to M/s. Nerolac.

Three Coaches are completed by M/s.Nerolac and further order

for three coaches is released on M/s.Dupont.

Pasting of advertisement and touch up with the alkide paint

over the PU Exterior Paint to be avoided otherwise paint will

peel off.

Implementation

status of the

modification in the

coaches/ Decision

taken during the

meeting.

CME/QA to write to all the railways to use only permitted

cleaning agents for coach washing. CME/QA to connect the

instruction of joint circular of mechanical and commercial

department regarding advertisement in Railway coaches to

DME coaching RB to withdraw the painting, stickers etc.

CDE/Mech to write to open railways regarding permitted

detergents/washing agents.

Paint manufacturers to audit the coaches at User Railways

regarding cleaning agents, performance of paint.

10.

Reporting Railways NR/April‟14



All types/Furnishing Items/Plumbing- Flush

Valve

Brief Account of

Problem

Prone to theft.

Rlys want Polytetrafluoroethylene (PTFE)

material.


No./Remarks

As a stop gap arrangement, procurement of

100 Non-AC Coach sets of Plastic material

Flush Valves (CDC Make) is under

progress.

Similarly, 25 Coach sets of Stainless Steel

material Push Type Controlled Discharge

Flush Valve is also under progress through

single tender.




taken during the

meeting.

Controlled Discharge Flush Valve to be

implemented immediately.

All toilet fittings must be of branded

fittings

11.

Reporting Railways SWR/Aug‟13, SR/Jan'14, ECoR/April‟14,

SR/Feb‟15



Conventional coaches/Furnishing

Items/LITTER BIN

Brief Account of

Problem

Dust bin cover securing arrangement in

Non-AC coaches is giving problem during

service.

The link mechanism of the Litter Bins is

frequently getting damaged and not user

friendly.

Stainless steel litter bins may be provided in

place of existing litter bins.


No./Remarks

Stainless Steel Litter Bin is under

procurement.

Proto-type Stainless Steel Litter Bin of

M/s.Dynamic Air Engg. has been approved.

50 numbers are offered for RITES

Inspection. PDC 30/05/2015.

Subsequently, based on Railway Board‟s

advice, the existing litter bin volume of 29

litres has been increased to 47 + 43 litres by

introducing additional bin and modifying the

existing bin (separate bins for biologically

degradable and recyclable waste). Trial

conducted in Shell No. GS 6020.




taken during the

meeting.

Under Implementation.

12.

Reporting Railways CR/Aug‟13, ECoR/April‟14



Pantry Car/Furnishing Items/Gas Cylinder

Securing Brackets.

Brief Account of

Problem

The bracket provided to hold the gas

cylinders in Pantry cars get damaged/

distorted during handling by pantry car

staff.

The present steel brackets may please be

altered by flexible member of sufficient

strength to clamp these cylinders.


No./Remarks

Chain type securing arrgt. was Introduced

(Drg. No. WCB5-6-4-502, ALT-„d„

dtd.07/2014 ).

But the material received as per latest

drawing from trade was rejected during

load test.

In-house manufactured items as per latest

drawing have been provided in three

Coaches.

Drawing is re-modified with commercial

quality chain (Drg. No. WCB5-6-4-502,

ALT-„e„ dtd.18/05/2014 ).




taken during the

meeting.

Furnishing to cut in immediately.

13.

Reporting Railways ER/July‟14



Conventional coaches/Vestibule/Rolling

shutter

Brief Account of

Problem

Failure of Rolling shutter due to corrosion.

SS sheet may be used to avoid corrosion.


No./Remarks

At present no vendor is available to supply

SS Shutters. New vendor is under

development for SS Shutters.

Since the maximum corrosion is on the

bottom piece, Locking plate material has

been changed to SS to AISI 304. Drg. No.

140-25-004 alt.„h‟ Dtd.18/05/2015.




taken during the

meeting.

Stainless steel to be introduced.

14.

Reporting Railways ECoR/April‟14



SLR Coaches/Shell Items/Partition wall

between luggage portion and passenger area.

Brief Account of

Problem

There are frequent cases of damage of

partition wall between luggage portion and

passenger area by miscreants. The metal

plates of partition walls are found cut to

pilfer material by miscreants.

Recently, in Train No.12808 in which the

metal partition wall of 1.6mm sheet of

SLR coach was cut to a total length of

700mm by the miscreants from the Guard

Van end.

It is suggested to provide metal sheet of

higher thickness or corrugated sheet of

2mm thickness to overcome this problem.

Further, the Hylem panel on the other side

to be eliminated so that damage caused to

the side walls can be seen easily.


No./Remarks

Design (Drg. No. 242-1-0-225 & 242-1-0-

226 dtd.26/09/2014) of SS partition

frame with 2.0 mm thick Stainless Steel

paneling in luggage room side is issued.

Will be implemented from June 2015

onwards in SLR Coaches.

CAI issued to all Railways on

dt.19/05/2015.




taken during the

meeting.


15.

Reporting Railways NCR/April‟14



GS Coaches/Furnishing Items/Wash Basin out

let pipe.

Brief Account of

Problem

Outside wash basin underneath area should

be covered by LP Sheet to prevent hitting

of wash basin drain pipe with passenger

luggage.

This measure will improve cleaning of that

area also.


No./Remarks

The present design of the outlet pipe is

standardized for SCN, GS and SCZ

Coaches. The bend of the pipe is designed

for accommodating Dust Bins in SCN

Coaches.

Wash basin outlet pipe material has been

revised with Stainless steel for better

strength and durability.

UL number received and will be

implemented after exhausting the existing

stock.




taken during the

meeting.


16.




AC Coaches/Furnishing Items/Plumbing - GI

Pipe

Brief Account of

Problem

IN ICF AC coaches connection between

centrifugal pump and water tank is with GI

pipe line.

In LHB coaches, the above is with

stainless steel wire mesh protected flexible

pipe, which is easy for maintenance.

Hence the same may be considered for ICF

AC coaches also.


No./Remarks

Drg. issued on 02/09/2014 – No.268 63

707 alt „l‟.

Out of three items two items are common

with LHB items. One item is new,

procurement under progress through non-

stock indent.

Three POs have been released and the

delivery is due on 29/06/15, 30/10/15,

30/06/2016.




taken during the

meeting.


17.

Reporting Railways NR/April‟14

Type of

Coaches/Major


All types/Furnishing Items/Dropping of lav.

Doors

Brief Account of

Problem

Dropping of Lav. Doors are noticed due to

:-

weak base channel on which hinges of

doors are screwed.

Weak hinge capacity in terms of size.

Base channel on which hinge and doors

are screwed should be thicker to achieve

more gripping of screw.

Size of door hinge should be increased to

4" from 3" to increase number of

screws/hinges.


No./Remarks

Lavatory door with door frame has been

introduced in AC coaches (Drg. 469-5-6-

002 alt „b‟ 08/09/2012).

The same design is under implementation

in Non-AC Coaches also (Dr.No.286 56

501 alt „c‟ and 283 56 701 alt „c‟).

Soft copy of the new drawing has been

issued to all the Railways..




taken during the

meeting.


18.


Type of

Coaches/Major


All types/Shell Items/Main Door Window

Brief Account of

Problem

In Main doors, the window bars are

provided at close frequency.

Hence during washing, brush cannot

reach the glass surface and it is difficult

to clean these glasses.

It is suggested that the Window Bars are

to be provided at a distance same as other

windows of the coaches.

Further the window is at a very lower

level and this prevents passengers to

view from inside. Design may review

elimination of window by glass at upper

level, same as Non-AC LHB coaches.

Action

taken/Drawing

No./Remarks

Drawing No. 140-5-1-002 Alt „v‟

Dt.05/09/2014 has been issued with less

number of window bars.

UL No. 08305114580101 has been

amended vide letter No. MD/G/UL/444

dtd. 05/05/2015.

Will be implemented from the next

procurement cycle.


issued to all the Railways.

Implementation

status of the

modification in the

coaches/ Decision

taken during the

meeting.


19.

Reporting Railways SWR/Aug‟13, SR/Aug‟13, CR/Aug'13,

ER/July‟14, SR/Feb‟15


Assy./Specific Item. All types/Bogie /Modified Crown pad

Brief Account of

Problem

Bolt and nut of diamond shaped modified

'A' dimension pad (Crown Clearance)

cannot be attended in Pit-lines during rake

maintenance if worked out.

Without taking out wheels in sick line, bolt

& nut cannot be unscrewed from outside

which results in detachment of Coaches.

CW/PER - The Diamond shaped rubber

stopper pads which are received in the

First POH ICF coaches are removed and

reverted back to RDSO design SK-97068

during POH for the following reasons.


No./Remarks

New Design Crown Pad, Drg.No. T-0-1-

640 has been introduced.

27 Coach sets have been completed out of

100 Coach Sets planned (Coach Nos.

ECoR SLR 15704, SLR 15705, CR SCN

15225, SCR SCN 15218, SECR SCN

158208, SCN 158201, SR SCN 14378,

SECR SCN 15219, ER SCN 09057, SR

SLR 14738, 14739, 15705). Implementation status



taken during the

meeting.

To be implemented in all coaches.

20.

Reporting Railways ECR/July‟14, ER/July‟14, SWR/Feb‟15



AC Coaches/Furnishing Items/Fire

Extinguisher

Brief Account of

Problem

Arrangement to be provided for keeping

Fire Extinguishers at both ends of AC

Coaches.

Fire Extinguisher hanging hook open out -

Fire Extinguisher bracket (Similar to

Guard van equipment lobby) to be

provided in all AC coaches for easy

operation


No./Remarks

The following drawings have been issued

for all AC Coaches with modified design

for fixing the fire extinguisher outside the

linen room.

WGSCWAC7(268)-.6-4-701 Alt ‟c‟

WGFSCWAC(143)-6-4-703 Alt „f‟

WGFAC12(524)-6-4-201 Alt ‟a‟ - Oct

2014

CAI issued to all Railways on

dt.19/05/2015.

UL description has been changed will be

implemented from 2016-17 onwards.




taken during the

meeting.

Since the item is a safety item, Shell/Fur to cut

in immediately.

21.

Reporting Railways SR/Aug‟13



All types/Brake Gear/Wire ropes for manual

release of distributor valve

Brief Account of

Problem

Wire ropes for manual release of

distributor valve can be provided in

Stainless Steel instead of G.I.


No./Remarks

Bi-metal corrosion at the soldered joint is

the reason of failure.

New Drg. Nos. 285-35-504, 285-35-804,

268-35-753, 242-35-209 have been issued

for wire rope of Stainless Steel with ferrule

type joint .

Will be implemented from 2015-16,

through next procurement cycle.




taken during the

meeting.


22.

Reporting Railways SR/July „14



Sleeper Coaches/Furnishing Items/Foldable

snack table

Brief Account of

Problem

Hinges, Screws, Table Support, Compreg

Side Piece etc. are frequently worked out.

Colour to RDSO shade code for shaded

compreg sheet may be incorporated in the

drawing.


No./Remarks

Revised drawing No. 204-6-4-601 alt „q‟

dtd.11/2014 has been issued duly taking

care of the above problems, will be

implemented in the next procurement

cycle.

In LHB coaches, the old design of water

bottle holder to be followed.




taken during the

meeting.

Almost all the Railways are in the view of

discarding the snack table in SCN

Coaches.

Railways to obtain dispensation from

Board for non-provision of snack tables in

SCN Coaches.

23.

Reporting Railways SR/Aug'13, July‟14, Nov‟14, Feb‟15



Non-AC Coaches/Furnishing Items/FDB

cover

Brief Account of

Problem

Passengers are inserting waste material

through the gap of the FDB Cover in the

Roof paneling.

ICF has not implemented the modification

of FDB (Fuse Distribution Board ) Cover

as per RDSO latest instruction in GS, SCN

& SLRD Coaches


No./Remarks

FDB inspection cover redesigned and

implemented (329-4-4-023

Dt.01/03/2013).

As a long term solution centralized FDB at

Doorways has been introduced in GS

Coaches as per RDSO‟s Instruction. –

Implemented in 10 GS Coaches (SR

14415. 14432, 14434, 14436, 14437,

14438, 14439, 14440, 14442 and 14443).

SR to give the feedback on the 10 coaches.

Railway Board‟s approval for 100%

implementation has been obtained.

Procurement action (Enq. No. 06/15/005)

is initiated.

Implementation

status of the

modification in the

coaches/ Decision

taken during the

meeting.

As Railway Board‟s approval for 100%

implementation has been obtained for

centralized FDB, Electrical to cut in

immediately.

24.

Reporting Railways SR/Aug‟13


Assy./Specific Item. Pantry Car/Shell Items/Floor Side Moulding

Brief Account of

Problem

Stainless Steel Floor side mouldings may

be provided to arrest corrosion in pantry

cars


No./Remarks

Drawing (No.140-1-0-040/col II 2004)

has already been modified with stainless

steel (AISI 301)material instead of IRS M-

41, which is same as trough floor.

Trial conducted in few coaches.

100% implementation has been planned

for SLR & WCB from 2015-16 onwards.

Raw material is under procurement stage.




taken during the

meeting.

Railways to submit life cycle analysis of Floor

Side Moulding.

25.

Reporting Railways SCR/Aug'13, SWR/Jan'14


Assy./Specific Item. Non AC Coaches/Shell Items/Window sill

Brief Account of

Problem

Almost all windows manifest gap at sill

level, between sidewall sheet & window

resulting in rain water seepage.

Putty filling by ICF does not last long and

also not properly filled.


No./Remarks

Window Sealing Angle Design has been

modified with upward lip. Detail Drg. No.

140-1-4-015, Assembly Drg.No. 287-1-4-

802 Alt „b‟ 08/2014. –This design will not

allow water to enter inside the shell. Thus

filling the gap with putty is eliminated.

This will also control the accumulation of

muck in those areas.

Trial conducted in one coach Shell No.

SCN 5197 – Feedback is awaited from Fur

Div.

UL No.05301472700101 description has

been revised on date 18/12/2014.

Against two existing POs of old design,

issued in 09/2014, 20564 Nos. (571 Coach

Sets) are due for receiving. On exhausting

this stock, the new design will be

implemented.




taken during the

meeting.

Under implementation.

26.

Reporting Railways SR/July‟14


Assy./Specific Item. SLR Coaches/Shell Items/Dog Box

Brief Account of

Problem

Dog box modification in SLR - GOC has

modified the dog box to SR Drg. No. SK

C&W 4154/BG. The features are –

Height of the Dog Box is increased from

1070 mm to 1370 mm.

Front side of the Dog Box is covered with

weld mesh for proper light and ventilation.

Provision of drain pipe.

Vertical Sliding Door modified to

Horizontal Sliding Door for easy

operation.


No./Remarks

New Design of modular Dog box drawing

(Drg.No.242-64-212 dtd.19/05/2015) has

been released.

Proper ventilation, watering and toileting

facility are incorporated in new design.

UL Description is under modification.




taken during the

meeting.


27.

Reporting Railways SR/Aug‟13, SCR/Aug‟13, SWR/Aug‟13,

ECoR/April‟14



Non-AC Coaches/Shell Items/Luggage Rack

Top Wire Mesh

Brief Account of

Problem

Wires of Luggage rack top mesh panel are

coming out from frame.

Possibility of using old model diamond

type wire mesh can be explored.


No./Remarks

Design revised from square weld mesh to

Diamond (OBLONG) weld mesh.

UL description has been revised on

23/07/2014 (UL No.08301002880101).

Procurement action has been initiated vide

letter No.MS320 dtd. 23/07/2014.

Will be implemented from June 2015

onwards in SLR Coaches, mid 2015-16 in

SCN Coaches and from 2016-17 onwards

in GS Coaches.

Drawing has been issued to all the

Railways.




taken during the

meeting.


28.

Reporting Railways SWR/July‟14


Assy./Specific Item. All types/Plumbing – Lav. Drain Pipe

Brief Account of

Problem Non-standard Drain pipe


No./Remarks

Design of drain out pipe location modified

vide Drg. No. 140-6-3-084

Dtd.05/02/2014.

Implemented from Jan 2015 in FAC

coaches, will be implemented in other

coaches from May 2015.




taken during the

meeting.

Implemented

29.

Reporting Railways CR/Aug‟13, CR/Nov‟14


Assy./Specific Item. Pantry Car//LPG Gas Room Pipe Lines

Brief Account of

Problem

LPG gas store room pipe lines at less

height without NRV & gauge

Central Railway modified the location of

the pipe lines


No./Remarks

In the Customer Interaction Meeting held

at ICF during 22nd and 23rd January 2014,

all the Railways demanded modification of

existing features of Pantry Cars.

A joint committee was formed during the

above meeting with the members from

Railways and ICF

(Dy.CME/Coaching/HQ/CR,

Sr.CDO/BBQ/SR and

Dy.CME/Design/ICF) to review the

features of Pantry Cars.

The recommendations of the committee

are implemented since September 2014.

The above point is not figuring in the

recommendations.

Location of pipe line is at 700 mm from

the floor level as per the drawing to

accommodate the commercial gas cylinder.

However, drawing No.039-64-121 alt‟y‟

dtd. 05/15 with increased height (730 mm)

has been released.




taken during the

meeting.

Furnishing to cut in immediately

QA to ensure the same.

30.

Reporting Railways SR/Nov‟14


Assy./Specific Item. All types/Plumbing/Gravity Cock

Brief Account of

Problem

More water Leakages are noticed in

Powder coated Grey Alumimium Alloy

(ICF Design) Gravity Cocks compared to

Chrome plated Brass cocks of RCF

Design.

During POH, the Renewal rate of Gravity

cock is 66 % due to breakage, jamming,

Leakage.

JAYSON Brand gravity cocks not

available from the trade supply.

ICF is requested to incorporate test

procedure (Hydraulic pressure test for 2

bars for 2 minutes as in the RCF Design)

for the gravity cocks to eliminate water

dripping / leakage problem in new gravity

cocks.


No./Remarks

ICF will include hydraulic pressure test in

the drawing.

Possibility of introducing SS Gravity Cock

will be explored.

Procurement of 100 Coach Sets of Spring

loaded Cocks in Non-AC Coaches is under

progress.




taken during the

meeting.

Only branded quality pipe fittings and

accessories to be provided in the lavatories.

31.



Assy./Specific Item. All types/Shell Items/Side Bearer

Brief Account of

Problem

Chamfer for side bearer of body bolster to

ICF Drg No.T-1-1-740 is required for

effective overhead welding of New Side

bearer to the Body Bolster during POH.

In House manufactured side bearers are

manufactured with chamfer and effective

welding could be ensured.

Hence, ICF is requested to review the

drawing to enable the Workshops to

procure to the side bearer with end

chamfering.


No./Remarks

Drawing modified with a „NOTE‟ for

workshops to procure the side bearer with end

chamfering, Drg. No.T-1-1-740 Alt „f‟.




taken during the

meeting.

Implemented.

32.

Reporting Railways SR/April‟14, SR/Nov‟14


Assy./Specific Item. Sleeper Coaches/Seat and Berth/Head Rest

Brief Account of

Problem

In AC and Non-AC coaches, top berth

Head rest is fixed with two sided adhesive

tape and it is getting dropped even in the

maiden trip.

Once the Head Rest is fallen down the

adhesive tape is not suitable for

subsequent pasting and removing of

adhesive tape is also very difficult.

RCF and MLR / BPL do not provide Head

Rest in SCN Coaches.

Head Rest provision has been discontinued

in CW/PER from April 2011.

Minutes of ICF interaction meeting held in

APRIL 2014, sl. No. 35, NEW points for

discussion states that “ Rlys are requested

to write to RDSO ”.

Since Headrest is implemented by ICF

vide Sl No. 16 , ICF / CAI No A – 2002

/04 dt.25.09.2002 under injury free feature,

ICF may do away head rest provision in all

coaches in line with RCF


No./Remarks

All the Railways have requested to do away

the headrest. RDSO to issue the instructions.




taken during the

meeting.

ICF will not provide the headrest in future

coaches.

33.




Non-AC Coaches/Emergency

Window/Emergency window Grill

Brief Account of

Problem

Emergency window Grill - Colour

difference noticed in Non-AC Coaches.

Galvanised finish is given in ICF Drg –

ICF / STD-5-4-005.

Air Craft Blue colour is seen on new ICF

Coaches.

Red Paint to be followed as per RDSO

SK-CSC-1728, alt-5, “ Exterior Marking

for Coaches ” , Detail –N and Note-6.

ICF is requested to alter ICF Drg.No.

ICF/STD-5-4-005 in line with RDSO

Guidelines.


No./Remarks

Drawing has been revised. Drg.No. 140-54-

005 alt‟n‟ dtd. 05/15.




taken during the

meeting.

Implemented.

34.

Reporting Railways SCR/Nov‟14

Type of

Coaches/Major


All types/Shell

Items/Main Door

Handle – Operating

Instruction Notice is

required.

Brief Account of

Problem

Main Door Handle

Operating

Direction

Indication Notice

may be provided as

the passengers are

getting confused

while opening or

closing the main

doors both from

outside and inside.

Action

taken/Drawing

No./Remarks

Drawing

(Drg.No.268-64-

702 alt „h‟ 05/15)

has been issued for

immediate

implementation.

Implementation

status of the

modification in the

coaches/ Decision

taken during the

meeting.


35.

Reporting Railways SR/Feb‟15


Assy./Specific Item. AC 3 Tier/Seat and Berth/Side Berth of ACCN

Brief Account of

Problem

Nearly 80 to 90 mm gap is found between

panel and backrest-cum-side berth in

unfolded condition on both sides.

This results in falling off pillows in the

gap.


No./Remarks

Drawing (PDC – 15/03/2015) is being

modified to eliminate the gap.

As a stop gap arrangement, the gap is

covered suitably.

Modified drawing is released

(Drg.No.501-61-001 alt ‟h‟ dtd.05/15)

Will be implemented from 2016-17.




taken during the

meeting.

Under implementation.

36.

Reporting Railways SR/Aug‟13, SR/Feb‟15

Type of

Coaches/Major


All types/Shell Items/Partition Pillars

Brief Account of

Problem

Square MS partition pillar in ICF coaches

are getting corroded adjoining the floor

due to water seepage during cleaning

activities.

This square MS partition pillar is getting

damaged during service.

To avoid this, it is suggested to replace MS

partition pillar with SS material.


No./Remarks Under study.




taken during the

meeting.

Since all the other structural materials are

of IRS M-41, presently only Partition

Pillar Material cannot be switched over to

Stainless steel.

Railways to come up with suggestions for

improvement and also to give the

performance feedback on the anticorrosive

paint to RDSO Specn. M&C/PCN 123.

37.



Assy./Specific Item. All types/Furnishing Items/Door Stopper

Brief Account of

Problem

Door stopper provided in newly built

coaches for main doors as well as toilet

causes damages to the mica panels.

The orientation of door stopper and design

are to be modified.


No./Remarks

Back pieces are already available for

fixing the door stopper – Drg. No.140-1-0-

065 item No.6.

Revised drawing issued by increasing the

back piece size from 60 to 100 mm width

in the door frame - Drg. No.140-5-6-012

alt „r‟.

In in-house manufactured doors the above

modification has been implemented.

PO No. 071418062366 dtd.25/11/‟14

delivery due on 30/07/2015.


issued to all the Railways.




taken during the

meeting.

QA to ensure

.

38.




All types/Plumbing/Non-metallic Side Filling Water Pipe

Adaptors

Brief Account of

Problem

Non-metallic Side Filling Water Pipe Adaptors are

prone for damage/theft/pilferage in open line.

The half portion of the water side filling pipe

adaptors are found missing in 90% of coaches.


No./Remarks It is as per CAMTECH design.




taken during the

meeting.

Design and QA to conduct studies at BBQ and BZA

regarding the performance and the failure of the side

filling arrangement.

Single piece swiveling type design to be tried.

39.

Reporting Railways ER/Feb‟15


Assy./Specific Item. All Types/Lav. Assy/Western Commode

Brief Account of

Problem

During replacement of Commode it is difficult &

time consuming as the base bolt are getting rusted

and broken.

Extra plate/block may be provided at the bottom of

commode & design may be reviewed for easy

fitment.

SS nut & bolt may be used to prevent corrosion


No./Remarks

Stainless hardware had been introduced vide drawing

No.140-63-069 alt „nil‟. To be implemented.




taken during the

meeting.

QA to ensure the proper hardware.

40.

Reporting Railways NR/April‟14, ER/Feb‟15


Assy./Specific Item. AC Coaches/Window Assy./Window Glasses

Brief Account of

Problem

Problems are faced in the procurement and

fitment of different sizes of Window

glasses & rubber gaskets in different types

of AC Coaches.

In newly received AC Chair Car the size is

1220X762X25.5 whereas the previous

size was 1220X752X25.5

Standardization of window glass size

required.


No./Remarks

Size has been standardized to 1220X752X25.5

mm (Drg. Nos. 077-5-4-221 alt „k‟ Dt.

10/07/2014 and 251-5-4-203 alt „e‟

Dt.29/05/2008)




taken during the

meeting.

Implemented

41.

Reporting Railways SR/Aug'13, SCR/Jan'14, ER/Feb‟15


Assy./Specific Item. All Types/Lav. Assy./Lav. Door

Brief Account of

Problem

Damage of Al. ventilators of Lav. Doors

ER - It is noticed that miscreants

frequently damage the louvers fitted on

lavatory door in non-AC coaches and

privacy of passengers are under threat.

Ventilator may be shifted on side wall of

inside lavatory of Non-AC coaches in lieu

of lavatory door using louver or perforated

sheet.


No./Remarks

The damages are due to

pilferage/Vandalism. Change over to MS

will lead to corrosion problem.

Sturdy Structured Ventilators of Stainless

Steel Material design has been issued

(Drg.No.140-56-015 alt „h dtd. 06/2014).

PO has been released (No. 071418062366

dtd.25/11/‟14 delivery due on 30/07/2015).

Advice given for in-house manufacturing

also.




taken during the

meeting.


42.


Type of

Coaches/Major


SLR/Guard‟s Cabin/Hand Brake Wheel

Brief Account of

Problem

ICF may provide “ON – OFF” Indication

for Hand brake wheel operation in Guard‟s

cabin of SLRD Coaches to help in case of

emergency.

SLRD 14701, Hand brake “On and Off”

indication is not clearly visible and

incorrect. The Arrow illustrating the hand

brake wheel rotation for applying brake is

not painted


No./Remarks

“On and Off” rotating direction is available in

the wheel itself.




taken during the

meeting.

QA to check the Hand wheel marking and

Emergency Brake Valve operating direction

(only upward) in the guard van in 25 coaches.

43.


Type of

Coaches/Major


GS/Plumbing/Chute Fixing

Brief Account of

Problem

Painting instruction for Chute fixing

arrangement for Wash Basin Outlet pipe –

ICF Drg No. GS2-6-3-206, alt h/6.

There is no painting instruction given in

ICF drg No. GS2-6-3-206 and also in the

various component drawings.

ICF is requested to incorporate suitable

painting instruction in the drawing to get

the supplies in painted condition which

will eliminate painting work by

workshops.


No./Remarks

Painting instruction is added as Note in the

Drawing.




taken during the

meeting.

Implemented.

Design to advice all the Railways.

44.


Type of

Coaches/Major


GS/Plumbing/Chute Fixing Material

Brief Account of

Problem

Relaxation of Copper Bearing steel to

Chute fixing arrangement to GS2-6-3-

206, alt h/6 is required.

Out of the 8 components in chute fixing

arrangement, the material specification

of Item-3 support & item-4 Lug only are

copper bearing steel to IS : 2062 , Cu /

IRS-M-41.

All other 6 items are ordinary mild steel

, i.e., non-copper bearing steel.

Keeping only the 2 items as copper

bearing steel may not serve the purpose.

Hence, the material specification of

Item-3 support & item-4 Lug may be

changed to Non copper bearing steel.


No./Remarks

Material Specification for the two items

have been revised to IS 2062 – 2011

E250A (without Copper Bearing).

Drg. No. 001-63-071 alt „l‟ dtd.05/15.




taken during the

meeting.

Implemented.


45.


Type of

Coaches/Major


All Types/Bogie/Bogie Levers

Brief Account of

Problem

Relaxation of Copper Bearing steel for

Bogie Levers of AC & Non AC Coaches to

Drg No. T-3-2-802, WTAC4-3-2-402 is

required.

During POH, 5 % of bogie levers – AC

and Non-AC coaches are condemned

mainly due to the bush holes getting

oblong/bent/other damage and there is no

corrosion problem.

After 2009, the material specification of

these levers was changed from IS:2062

mild steel to copper bearing steel ( Cu

grade ).

Since there is no corrosion related

problem, ICF may relax copper bearing

steel to eliminate procurement problem ,

delay in Tender procedures , lab testing

during certification, etc.


No./Remarks Material of bogie levers has been modified

to IS 2062 without copper bearing.




taken during the

meeting.

Implemented.


46.


Type of

Coaches/Major


SCN/Furnishing/Racks and Partition Panels

Brief Account of

Problem

Damages are noticed in the Racks and Partition

Panels at Main Doorways of SCN coaches to Drg.

No.286-6-4-501.

RCF & BEML do not provide any Rack at Doorway

and it is maintenance free.

ICF is requested to eliminate the provision of this

Rack in SCN, SCZ & GS Coaches for the following

reasons.

This shelf is not used by the genuine passengers as

this is away from their sight.

Additional rectification work is carried out by

renewal of LP Sheet Partition panel of approx. 50

sq.ft per SCN Coach.

Post 2010 SCN, GS Coaches are provided with SS

Racks and the same are bent/hanging/missing.


No./Remarks

Shells are going with stainless steel rack as against

plywood vide drawing No.GS-6-4-501.

Racks had been introduced for the purpose of

keeping food trays. However, user Railways are

seeking dispensation.

User Railways may dispense with the racks if not

required.

Future ICF coaches will be without the racks. Drg.

No. (GS6)289-9-0-602 alt „l‟, (SCN8)287-9-0-802

alt‟w‟.




taken during the

meeting.

ICF will not provide Racks in future coaches.

47.


Type of

Coaches/Major


All types/Axle Box Assy./Cast Iron Axle Box

Front Covers

Brief Account of

Problem

Non Elimination of Cast Iron Axle Box Front

Covers in lieu of Aluminium to T-0-2-633,alt-

r/5.

One Man Committee Report on Roller

Bearings , released by Railway Board in May

1976 by Sri. K.Raman, CME/SR, para 4.3.7

reads, “the front cover should also be of

Aluminium as it will have a better heat

dissipating capacity and in the event of

working out, the cover will show the distress

which can easily be detected. If the cover is

made out of steel or cast iron, in the event of a

breakdown of the bearing, it may escape early

detection”.

ICF is requested to delete cast iron front

covers in ICF Drg No.T-0-2-633,alt-r/5 and

advise zonal Railways to stop procurement

and fitment


No./Remarks

Aluminium front cover to 000-02-633 – item

(1) is the main design.

SG Iron and Malleable Cast iron given as a

alternate design only.




taken during the

meeting.

Railways can opt as per their requirement.

48.


Type of

Coaches/Major


All Types/Roller Bearing Assy./Roller Bearing

Brief Account of

Problem

ICF is requested to mark the month and

year of roller bearing assembly, for e.g., [

ICF – 02/15] on the outer race of the roller

bearing.

This information is vital for the Railways

to decide the type of attention i.e. in situ or

strip & fit during POH.


No./Remarks

Month and year of manufacture markings

are provided on the bearings by the

manufacturers.

The purchase orders are placed to supply

the bearings on month-wise schedule.

As such manufactures marking can be

referred by User Railways to decide the

type of attention.




taken during the

meeting.

ICF to follow the RDSO instruction regarding

marking.

49.


Type of

Coaches/Major


SCN/Seat and Berth/Middle Berth

Brief Account of

Problem

Hitting of Middle Berth bottom board on

the stopper bush in SCN Coaches.

Approx . 10 Nos. of Middle Berth Bottom

Board found cracked in First POH SCN

Coaches (on both ends of the berth).

Crack is covered by Over patch during

POH.

Elimination of Berth stopper can solve the

problem since no crack is seen if middle

berth stoppers are not there.


No./Remarks

Already back pieces are available in the

middle berth frame where the stopper

comes in to contact. Drg. No. 201-61-605

Alt „f‟.

However, back piece design has been

modified from Plate to Channel as a

foolproof method.




taken during the

meeting.

Design to monitor the performance of the

modified design.

50.




Non-AC Coaches/Shell Assy./Lower Berth

Seat Brackets

Brief Account of

Problem

Lower berth/seat Brackets of Non AC

Coaches are getting corroded due to water

seepage.


No./Remarks

Fixing of chair angles have been modified

from welded design to bolted design with

sidewall after paneling.

Drawing is issued.

This will reduce the chances of corrosion.




taken during the

meeting.

To be implemented.

51.



Assy./Specific Item. Non-AC Coaches/Furnishing/Lav. Paneling

Brief Account of

Problem

Joint in Lavatory Panel of Non AC

Coaches may be avoided as it is not

required.

No Joint in Lavatory Panel of AC Coaches

and aesthetic is also good.


No./Remarks

All SCN and GS Coaches are being

provided with SS Paneling inside the

lavatory without joints.

Proposal has been approved to turnout

these coaches with SS Modular toilets in

future.

At present all AC Coaches are fitted with

SS Modular Toilets.




taken during the

meeting.

To be implemented in 100% Non-AC

Coaches, cut in to be from first week of June

2015.

52.



Assy./Specific Item. AC Coaches/Vestibule Assy/Flap Door

Brief Account of

Problem

Vestibule flap doors are getting damaged

and missed frequently.

C&W/PER/SR has stopped the provision

of flap doors except in FAC w.e.f. Dec 14

during POH.


No./Remarks

The item is appearing in the RDSO

Particular Specification RDSO Spec

2011 CG-B-05 AC2T SLEEPER.

If all the Railways demand the removal

of flap doors, the same will be elevated

to RDSO for review.

Implementation status of

the modification in the

coaches/ Decision taken

during the meeting.

ICF will provide as per RDSO directives,

User Railways may take their own decision.

53.



Assy./Specific Item. All Types/Brake Gear/PEAV Isolating Cock

Brief Account of

Problem

PEAV (Passenger Emergency Alarm

Valve) isolating cock is provided in

intricate location in ICF newly built Bio-

toilet coaches.

Operation of isolation cock is possible

only in pit line and not in en-route.


No./Remarks Design is under review.




during the meeting.

Under Design Modification.

54.




AC Coaches/Furnishing Items/Location of

Fan

Brief Account of

Problem

Fan is infringing with curtains in AC

coaches. Fans in AC coaches are to be

relocated. (SR ACCW 04126)


No./Remarks Due to space restriction it is technically

not feasible.




during the meeting.

Technically not feasible.

55.

Reporting Railways SWR/Feb‟15


Assy./Specific Item. SCZ/Seats

Brief Account of

Problem

In newly built coaches - Seat width is less

and may lead to public complaints


No./Remarks

These seats are ergonomically designed

cushioned seats with increased knee

space and the structure is of Stainless

steel material to avoid corrosion.




during the meeting.

Railways may forward any passenger

complaints received for further

improvements.

56.

Reporting Railways SWR/Feb‟15


Assy./Specific Item. All Types/Furnishing Items/Notice Board

Brief Account of

Problem

Location of emergency windows are

marked on metal plate and provided in

the roof.

These metal plates are infringing the

heads of passengers while climbing the

upper berths.

Instead of metal plate, soft material

(LIKE RUBBER SHEET) may be used.


No./Remarks

The location of the present indication

board is in centre line with the

emergency window in the bay.

The location is being modified to centre

line of the bay to avoid hitting of

passengers head.




during the meeting.

Under Design Modification

57.



Assy./Specific Item. -

Brief Account of Problem

LHB Drawings for reference during POH.

ICF is requested to issue a list of Drawings comprising POH related items viz.,

amenities, interior fittings, lavatory items, vestibule, bogie , Air brake , CBC, CDTS /

Bio toilet , seats and berths, flooring sheets, ceiling etc., required for maintenance

during IOH and POH.


No./Remarks

ICF is following RCF drawings and specifications for the manufacture of LHB

Coaches and the alterations are issued by RCF.

Hence, User Railways may obtain necessary drawings and specifications from RCF.

However, on specific request for specific item the same will be provided by ICF.

Implementation status of the

modification in the coaches/

Decision taken during the

meeting.

Railways may approach the Design/ICF for specific drawings.

58.



Assy./Specific Item. -

Brief Account of Problem

The list of new alteration details of ICF drawings, month wise, was available in ICF

website in 2012 and not available at present.

ICF is requested to restore the list of alteration number and date of the drawings altered

on monthly basis.


No./Remarks

List updated in the website. Alterations issued during Jan 2015 to April 2015 are available.

Website: 10.53.20.11 – Main Menu –Department - Mechanical - list of drawings issued.

Implementation status of the

modification in the coaches/

Decision taken during the

meeting.

Implemented.

Documents

CUSTOMER INTERACTION MEETING HELD AT ICF ... OF THE CUSTOMER INTERACTION MEETING HELD AT ICF ON 21ST AND 22ND OF MAY 2015 Members Present ICF S/Shri. 1 Ashok K Agarwal - GM 2 Pankaj