Microsoft Word - Quality Assurance Plan Radar
QUALITY ASSURANCE PLAN
FOR
DOPPLER EFFECT LOCOMOTIVE SPEED SENSOR (PATCH ARRAY ANTENNA)
ELIXIR Part No.: EE/RSSAT201204BNG
INDEX
CONTENTS PAGE No.
1) Control and Confidentiality 03
2) Profile of the Company 04
3) Overview of Some of the Products Manufactured 06
4) Quality Policy 08
5) Organization Structure/ Chart 09
6) Key Personnel Activities. 10
7) Sequence and Interaction of Quality Management System Process
13
8) Process Flow chart of the manufacturing 14
9) Process Flow Chart for Production of the Product 15
10) Product Control 16
11) Procedure for Inspection & Testing 23
12) Procedure for Purchase Vendor Selection 33
13) Block Diagram of RADAR Assembly 38
14) Technical Specifications of RADAR Assembly 39
15) Proto type Testing 41
16) Proposed RADAR test setup 42
17) Process Flow Chart of RADAR Assembly 43
18) Process Flow 45
19) List of Plant & Machinery used in Manufacturing of RADAR
53
20) List of Testing Equipments used in Manufacture of RADAR
54
21) List of Tools used in Manufacturing of RADAR 55
22) Certificate of Conformity 56
CONTROL AND CONFIDENTIALITY
This document and the information here is the property of Elixir
Engineering., It must not be reproduced in whole or in disclosed
without the prior consent in writing from Elixir Engineering., This
controlled copy of the manual is to be returned to the Management
Representative whom the holder of this document has not further
requirement for it or when the holder ceases to be employee of the
company.
Folder in possession of controlled copies shall receive
revisions or additions as and when made.
PROFILE OF THE COMPANY
We Elixir Engineering would like to introduce ourselves as a
Major Service provider for Design and Development and supply of
replacement spare parts and introducer of new electrical and
electronics equipment for the Indian Railways EMD/GM, GE – Diesel
Locomotives in India.
We established an engineering company and product development
for developing locally quality OEM Electrical & Electronics
products for EMD/GM freight and passenger locomotives in order to
bring down the purchase cost to the Indian Railways as well as
provide best local service solutions and support for the life of
the product.
We are dealing with Indian Railways from past 20 years giving
service in replacement of locomotive parts and customized design in
monitoring and control systems for railways and other industries,
also we designed and executed Indigenized automatic Emergency
Braking system for 50 Locomotives (WDG4) for the first time in
India at SWR – Hubli.
We are in the process of establishing the supply chain for
providing very fast and efficient delivery system for skilful items
in locomotives of Indian railways.
Therefore we would like to mention briefly about our company and
our works. It is our pleasure to introduce ourselves as a
Multi-disciplinary Engineering Services Company, located in
Bangalore.
We undertake new design and development, customized
manufacturing, engineering solutions, Engineering services,
Installations, commissioning and Engineering co-ordination between
the customer and the supplier.
We are number of Associated Persons having Engineering
background with vast experience in the industry around 15 -20 years
which includes engineering disciplines like Mechanical, Electrical,
Electronics, Process control and Automation Engineering, etc.
All of us are BE/M-Tech graduates and having versatile
experience and knowledge in Manufacturing, Process engineering,
Installation & Commissioning of various Turnkey Projects,
typically entail the sophisticated engineering process.
Our Capabilities further fine-tuned to timely advising us as
technical adviser on Design Development Realization of the state of
the art of Doppler Radar Assembly.
All our products will be tested to IEC571 standards and if
required to MIL202F to quality the product for environmental
reliability.
We are also capable of manufacturing various types of Electric
products and control systems for GM Locomotives, based on our
experience of manufacturing the same in our previous assignment and
projects.
OVERVIEW OF SOME OF THE PRODUCTS MANUFACTURED
PRODUCT NAME
SPECIFICATIONS
APPLICATION
CUSTOMER & PO NO.
Design Development and Installation of Microprocessor Based AEB
system for WDG4
Locomotives
For EMD Locomotives
South Western Railway - Hubli
PO. No. 1/07H/M/DSL/AEB/00 for
120 Locomotives
Design Development of GPS type Microprocessor based non- contact
type electronics speed distance travel Indication and data
recording unit
RDSO SPEC No. MP.0.370007 (REV-3)
For ALCO Locomotives
Southern Railway- Trichy
PO. No. 28055158.14 for 18
Locomotives.
Engine Notch sensing and
Loco status logging unit
As per Elixir Spec
For Alco Locomotives
South Central Railway
PO. No. 12055094149065
Computer Power Filter Panel for GE Microprocessor Based
Locomotives
For Microprocessor
Locomotives
South Western Railway
PO. No. 66/05/0336/1/25281/01
Surge Suppressor for
Electromagnetic Relay Coils
As per Elixir Spec
For Alco Locomotives
South Western Railway
PO. No. 6606007216512501
Indigenous Rotating Coil Rectifier equivalent to EMD Part No.
2803017
EMD Part No. 2803017
For EMD Locomotives
South Western Railway
PO. No. DSL/UBL/01420/494
Design Development and
Installation and commissioning of online cope
– drag Identification and temperature monitoring system
As per RWF Spec
Cope & Drag
Rail Wheel Factory
PO. No. RWF/M&P/08-09/online C&D Identification of
Temperature monitoring
Design Supply, Erection,
testing and commissioning of Data Recording system for Laddle
pre heat burns of Steel Melt Shop
As per RWF Spec
Laddle Pre- heat
Rail Wheel Factory
PO.No. RWF/M/M&P/08-09/PH-
41/Temp LPH
Installation of 5 Nos Online Mould Temperature Alerter
system
As per RWF Spec
Rail Wheel Factory
PO. No. RWF/M/M&P/08-
09/MR/WS/OTO1
Display System for Furnace
Specto meter lab
As per RWF Spec
Furnace
Rail Wheel Factory
PO. No. 200925004
Digital Speed Indicator for
WDG -4 Locomotives
As pre EMD Part No
EMD Locomotives
South Western Railway
QUALITY ASSURANCE PLAN
FOR
AC Contactor -3 Pole
Revision No.
0
Date
Page No.
Page 55 of 57
KAYSONS ELECTRICALS PVT. LTD.
Prepared & Reviewed by
Approved by
QUALITY POLICY
“WE ARE COMMITTED TO PROVIDE QUALITY PRODUCTS AND SERVICES AT
OPTIMUM COST AND TO CONTINUALLY IMPROVE THE QUALITY MANAGEMENT
SYSTEM THROUGH TQM APPROACH FOR ENSURING CUSTOMERS’ SATISFACTION ON
A SUSTAINED BASIS”
KEY PERSONNEL ACTIVITIES
DIRECTOR (FINANCE)
The director (Finance) is ultimately responsible for the
formulation of the company commercial aspects relevant to Elixir
Engineering Business.
CHIEF EXECUTIVE OFFICER
The CEO is responsible for the control of the following
Quality Assurance
Customer liaison
General office
Production
Purchasing
Secretarial services
Manufacturing and stores area
General safety
Maintenance of office and factory
Sales and export sales price lists, INDIA and overseas
agents
Director (Technical)
Director (Technical) is responsible for the administration of
the following functions within the company
Research and development
Technical feasibility and design
Product certification and approvals
Administration of technical staff
Customer support
In respect of all matters pertaining to IEC/MIL Certification,
of products
The organization and management structure of Elixir Engineering
is detailed in our organization chart of this manual. It shows an
accurate picture of the responsibilities and interaction between
departments to ensure clear and precise communication throughout
the company.
Any individual may report a potential Quality system
Non-conformance to the Quality Manager.
Only the Quality Manager is permitted to authorize agreed action
to prevent the occurrence of any non-conformities relating to
Quality system.
Engineering and Manufacturing personnel may report a potential
product non-conformance to the Director - Technical.
Engineering personnel may be authorized by the Director -
Technical to undertake agreed action to prevent the occurrence of
any non-conformities relating to product.
As general principle any individual may identify and record a
product, process or Quality system problem. The problem is verified
and its significance graded by the relevant manager.
The Quality Manager is responsible for identifying and recording
Quality system problems via, the internal audit.
Manufacturing, test, incoming inspection and engineering
personnel have specific responsibilities for identifying and
recording product problems.
Manufacturing and test personnel have specific responsibilities
for identifying and recording process problems.
Any individual may be authorized by the quality manager to
investigate the specific root causes of a non-conformance, and
develop and implement further corrective actions. All further
corrective actions are to be approved by the Quality Manager and
other personnel as designated by the Quality Manager before
implementation.
The Quality Manager is responsible for the verification of
further corrective actions.
Relevant production managers and test engineers are responsible
for the control of further processing, delivery or installation of
non-conforming product until the deficiency are unsatisfactory
condition has been corrected.
The Chief executive officer identifies management activity
requirements and ensures the provision of adequate resources and
assignment of trained personnel for such activities.
Department managers identify performance of work activity
requirements and ensure the provision of adequate resources and
assignment of trained personnel for such activities.
The Director - Technical identifies product design verification
requirements and ensures the provision of adequate resources and
assignments of trained personnel for such activities.
The Director - Technical and Quality Manager identify in house
product verification requirements.
SEQUENCE AND INTERACTION OF QUALITY MANAGEMENT SYSTEM
PROCESS
Customer Order
Non regular work Order
Regular Work order OEM Work order
Design
Purchasing Purchasing
Purchasing
Receiving Inspection
Receiving Receiving Inspection
Inspection
Production and assy
Production of Prototype
Final Inspection Dispatch
Final Inspection
Dispatch
Dispatch
Fitment trial
Joint Inspection with customer
Prototype approval
PROCESS FLOW CHART
PROCESS FLOW CHART FOR PRODUCTION
PRODUCT CONTROL
7.1 Planning of Product Realization
Planning of the realization processes is consistent with the
requirements of the organization’s
Quality management system and documented.
Quality objectives and requirements of the product
establish the processes and documentation, and provide resources
and facilities to the product along with the needs.
Criteria for acceptability with respect to verification and
validation of activities, monitoring, inspection and test
activity.
Records those are necessary to provide evidence for the activity
that has been carried out.
7.2 Customer related process
7.2.1 Determination of requirements related to the product
Elixir Engineering receives an enquiry and undertakes supplies;
the following system is implemented to meet the Quality Management
system.
All requirements specified by the customer, including
requirements for delivery and post- delivery activities are
determined.
Care is also taken to ensure that requirements not stated by the
customer but necessary for specified on intended uses are
determined.
Statutory and regulatory requirements related to the product are
also determined.
Any additional requirements considered necessary by the
organization.
The organization ensures to implement all the requirements of
the customer contractually agreed. Under these circumstances, the
document of agreement will be the basis for identifying such
requirements for reference. Marketing personnel maintain these
documents.
7.2.2 Review of requirements related to product
Customer requirements are identified and reviewed including the
additional requirements if any. This review is conducted prior to
the commitment to supply a product to the customer.
A Review is made to ensure that
Product requirements are well defined.
The customer requirements are confirmed before acceptance, where
the customer provides no documented statement of requirement.
Contract or order requirements differing from those previously
expresses (e.g. Quotation)
are revised.
The organization has the ability to meet defined requirements.
The results of review and subsequent follow up actions are
recorded.
When product requirements are changed, the organization ensures
that relevant aware of the changed requirements.
The above requirements are addressed in the procedure Sales and
Marketing.
7.2.3 Customer communication
The organization has identified and implemented arrangements for
communication with customers relating to
Product information
Enquiries, contracts or order handling, including
amendments.
Customer feedback including customer complaints
7.3 DESIGN AND DEVELOPMENT
7.3.1 Design and Development Planning
Elixir Engineering after considering the customer requirements
initiates the design and development activity by considering,
a) Stages of Design and Development
b) Stages of all design activities including, Review,
verification and validation. c) Responsibilities of Design
personnel.
As the design and development stage progresses the planning
output shall be updated accordingly.
7.3.2 Design and Development Input
The Inputs of the Design and development includes, a) Functional
and performance of the product
b) Applicable statutory and regulatory requirements c)
Information derived from previous similar designs
d) Other requirements essential for design and development
A documented procedure has been made which details the process
of Design and development activity.
7.3.2 Design and Development Output
The Design and Development output is in the form of Drawings and
specifications and shall be approved prior to release in order to
ensure
a) Whether output is meeting all the requirements of input
b) Provides adequate information to purchase and production c)
Specifies the characteristics of the product
d) Contains reference for product acceptance criteria.
A Review is made to ensure that
Product requirements are well defined.
The customer requirements are confirmed before acceptance, where
the customer provides no documented statement of requirement.
Contract or order requirements differing from those previously
expresses (e.g. Quotation)
are revised.
The organization has the ability to meet defined requirements.
The results of review and subsequent follow up actions are
recorded.
When product requirements are changed, the organization ensures
that relevant aware of the changed requirements.
The above requirements are addressed in the procedure Sales and
Marketing.
7.2.3 Customer communication
The organization has identified and implemented arrangements for
communication with customers relating to
Product information
Enquiries, contracts or order handling, including
amendments.
Customer feedback including customer complaints
7.3 DESIGN AND DEVELOPMENT
7.3.1 Design and Development Planning
Elixir Engineering after considering the customer requirements
initiates the design and development activity by considering,
a) Stages of Design and Development
b) Stages of all design activities including, Review,
verification and validation. c) Responsibilities of Design
personnel.
As the design and development stage progresses the planning
output shall be updated accordingly.
7.3.3 Design and Development review
A minuted, Design Review Meeting will take place, chaired by the
Director - Technical on a nominally fortnightly basis. This meeting
will discuss progress and problems encountered with current
development projects and also to evaluate the results of Design and
Development. The minutes of these meetings will form the basis of a
monthly report to the CEO on the progress of developments.
The development plan is updated, as necessary, after the monthly
report to the CEO.
7.3.4 Design and Development Verification
Elixir Engineering after considering the customer requirements
initiates the design and development activity by considering,
a) Stages of Design and Development
b) Stages of all design activities including, Review,
verification and validation.
c) Responsibilities of Design personnel.
As the design and development stage progresses the planning
output shall be updated accordingly.
7.3.5 Design and Development Validation
Design and Development validation carried out in order to ensure
whether the resulting product is capable of meeting the
requirements.
The prototype sample is made and all functional tests are
carried out as per test specification. The tests results are
reviewed to ensure the acceptability of the results. If the results
are acceptable the design is freeze and the drawing is released for
Production. If any changes need to be done, a review has been taken
and all the required changes are incorporated in the drawing before
releasing to production. Records of design and development
validation shall be maintained. A Documented procedure has been
prepared which explains in detail about the design and
development
7.3.7 Control of Design and Development changes
If any change needs to be carried out in the design, the same
has been reviewed, verified and validated and approved before
implementation. Records of changes and necessary actions are
recorded.
7.4 Purchasing
7.4.1 Purchasing Process
The purchasing process for selection, evaluation and control of
purchased products is ensured that they satisfy needs and
requirements that are identified and implemented. A System in the
form of documented procedures exists in order to ensure that all
purchased and sub contracted parts meet the specified
requirements.
This includes supplier evaluation, selection and approval. The
requirements relating to Quality system and Quality assurance are
taken into consideration for evaluation of the supplier.
7.4.2 Purchasing information:
Effective purchasing is on clear communication of the
requirements to the supplier/sub- contractor. To ensure this
purchase documents contain details of established specifications,
grades and standard where appropriate. Adequacies of the specified
purchase requirements are ensured before communication to the
supplier.
7.4.3 Verification of Purchase products:
The necessary verification activities of the purchased product
is identified and implemented through procedure for monitoring and
measurement of products. Where customer requires
performing verification activities at the supplier premises, the
same are to be communicated to the supplier.
7.5 Production and service provision
7.5.1 Control of production and service provision
Procedures/work instructions are maintained for control of
production and service provision to ensure that all processes
directly affecting quality are monitored and carried out under
controlled condition. These procedures and work instructions ensure
that personnel working on these processes have sufficient skill,
training and /or instructions and are adequately equipped.
The documented procedures/work instruction includes
Use of suitable equipment/working environment
Compliance with reference to standards/codes, quality plans
Monitoring and control of suitable process parameters and
product characteristics
Approval of processes and equipment’s as appropriate
Acceptance criteria including criteria of workmanship.
These procedures/instructions are accessible to operating
personnel.
7.5.2 Validation of processes for production and service
provision
The organization validates any processes for production where
the output cannot be verified by subsequent monitoring and
measurement where the process deficiencies become apparent only
after the product is in use.
The organization have established arrangements for these
processes including, as applicable
Defined criteria for review and approval of processes
Approval of equipment’s and qualification of personnel.
Use of specific methods and procedures.
Soldering is considered as a process which requires prior
validation, where validation carried out by conducting continuity
test by qualified personnel and records will be maintained.
7.5.3 Identification and Traceability
All the materials at incoming/in process / final stages are
identified by tags. The tags contain the details such Part No, Part
name, nature of the customer. Inspection status etc. Product status
with respect to monitoring and measurement requirements is
identified. The system of identification is as follows
SL NO
STAGE
Method of Identification
ACCEPTED
REJECTED
FOR INSPECTION
FOR REWORK
1
Incoming Materials
Green Tag
Red Tag
White Tag
Yellow tag
2
In process materials
Green Tag
Red Tag
White Tag
Yellow tag
3
Finished products
Green Tag
Red Tag
White Tag
Yellow tag
The identification of materials in stores shall be carried out
in following ways.
1. Items made to Elixir Engineering are identified by EE Drawing
number
2. Normal stock items are identified by a EE allocated stock
number
3. Items for use on Engineering projects are identified on
receipt by a works order reference number
4. Free issue items are identified by a works order number.
Sub-assemblies for standard products are identified by a Elixir
Engineering 'EE' drawing number. Final standard products are
identified by a 'EE' product code.
From the start of manufacture a works order number is used to
relate manufactured product to a customer’s order. Work order
documentation details the description of the product, the part
number or drawing number, quantity and the works order number which
is unique to that particular batch of products.
The works order documentation remains with the product through
all stages of manufacture and test. The works order documentation
is used to record stages of manufacture and test and remains with
the product until the point of dispatch. After successful
completion of test final product is labeled with its 'EE' number
(standard products) and works order number.
Dispatch documentation bearing the works order number
subsequently accompanies the final product
7.5.5 Preservation of product
Conformity of product is assured during internal processing and
delivery to the intended destination. This includes proper
identification, handling, packaging and storage of all the
constituent parts of the product.
7.6 Control of Monitoring and measuring equipment
Procedures are established and documented to define the methods
which ensure all equipment used to demonstrate product quality is
subjected to control, calibration, recording, inspection and
maintenance procedures. A Procedure is established for calibration,
which address the following requirements.
Determination of the measurements to be made and the accuracy
required and selection of equipments.
Identification of equipments and calibration against known
traceable standards at regular intervals and establishing basis
used for calibration in the absence of such standards.
Defining the process employed for calibration including details
of equipment, type, unique identification, location, acceptance
criteria etc and the action to be taken when the results are
unsatisfactory.
Method and basis of calibration / verification of equipments
that does not have a relation to national standards.
Maintaining status of equipment calibration
Maintenance of calibration records
Assess and document the validity of previous results when out of
calibration.
Correct handling and storage of instruments, gauges and
equipments.
Safeguard equipment against adjustments, which may invalidate
calibration setting.
PROCEDURE FOR INSPECTION AND TESTING
1 PURPOSE
This procedure defines the mechanisms for testing and inspecting
items within the following departments:
i) Incoming inspection
ii) Standard products manufacture
2 PHILOSOPHY
Every completed standard product or system manufactured by
Elixir Engineering is subjected to final test and/or
inspection.
The inspection and/or test of any item are performed in
accordance with a test and inspection schedule, or with a general
procedure against a drawing.
2.1 STANDARD PRODUCTS
The majority of standard products are intended for use in
hazardous or safety critical applications. The products are also
manufactured to order in small batches. Many of the products are
certified and have mandatory production tests as a condition of
certification.
These factors mean that statistical techniques are
inappropriate, and each standard product is subjected to a full
test or inspection.
2.1.1 IN-PROCESS TESTING
Some sub-assemblies are tested prior to incorporation in a
complete product
2.2 INCOMING INSPECTION
Every incoming item manufactured to a drawing number (i.e. an
item for a standard product) or to a Systems Project drawing is
inspected and/or tested.
Certain standard items from suppliers undergo incoming
inspection and/or test. These items are selected by the Quality
Manager with the assistance of engineering staff on the following
basis:
i) Previous component non-conformances detected in-process or
after production
ii) The supplier is known to have inadequate testing facilities
from Vendor
Assessment Questionnaire or audit
iii) The item has a critical effect upon the Quality of the
final product and the supplier does not provide a certificate of
conformity
3 PERSONNEL INVOLVED AND RESPONSIBILITIES
The Mechanical Inspector is responsible for ensuring that all
items (incoming, in-process or final)
selected for mechanical inspection conform to specified
requirements.
The Quality Engineer is responsible for ensuring that selected
incoming electrical items and Elixir Engineering manufactured
standard products are tested in accordance with formally approved
test and inspection, using controlled test rigs and equipment, and
conform to specified requirements prior to release.
Test & Validation Engineer should have the following
responsibilities
In- house prototype Testing
In-house final functional testing
In-house customer joint inspection testing
3rd party Prototype testing
4.0 INCOMING GOODS INSPECTION AND TEST
4.1 MECHANICAL INSPECTION
Incoming items to undergo mechanical inspection are placed with
an accompanying a tag in the mechanical inspection area.
If a standard item is to be inspected then parameters specified
on the specification are used.
If a Part number item the inspector obtains a copy of the
relevant drawing from the
Documentation Department.
Inspection is performed against the drawing and/or schedule
using the following guidelines as appropriate for the item
type.
After inspection the copy of the drawing used for inspection
purposes is to be filed in the respective drawing file.
4.1.1 MECHANICAL INSPECTION GUIDELINES
4.1.1.1 CASTINGS
Castings are checked for blow holes, cracks and any other
physical defects. The wall thickness of castings as shown on the
drawing is verified.
The inspector verifies that there is sufficient material for any
subsequent machining.
If the casting is to be incorporated in an Ex d item then the
inspector verifies that there is a certificate of conformity for
the item and places it in a dedicated file.
4.1.1.2 PRINTED CIRCUIT BOARDS
All whole sizes are verified and track work checked on one item
from within a batch. The remaining items within a batch are
inspected for visual defects.
4.1.1.3 GASKETS
Gaskets are inspected against the drawing.
4.1.1.4 MOULDINGS
NOTE: Sample testing is only permitted for components for
certified products when the component does not affect the
protection concept of the product. Components for certified
products are indicated by stamping of the relevant drawing as
relating to a certified product. The Technical Manager or deputy
will advise upon query.
If these items are received in batches then sample testing
against the drawing is employed. The rest of the batch is visually
inspected for cracks and other defects.
Sample dimensional testing in this situation is justified as all
items are produced by the same mould.
The percentage tested of a batch is as follows:
Number of Items Percentage Inspected Against Drawing
1 to 10 100
10 to 20 50
20 to 50 20
50 to 100 10
100 to 200 5
200 to 500 2
500 to 1000 1
4.1.1.5 MACHINED ITEMS
The following aspects of machined flame path items are
verified:
i) Flatness of flame paths
ii) Surface finish of flame paths iii)Fit of all threaded flame
paths
iv) Depth of drillings and tapings to ensure adequate residual
wall thickness v) Dimensional requirements of all flame paths
Where possible, the flatness of flame path surfaces may be
assessed by placing a straight edge on the surface under scrutiny
and sliding feeler gauges into any gap revealed.
The inspector places a self-adhesive arrow adjacent to all flame
path surfaces. This identifies the flame path surface and warns all
staff who subsequently handles the item.
Threads (on items other than screws) are to be verified using
appropriate calibrated ring and plug gauges.
The finish on a machined surface is to be verified using a
Rupert Scale.
4.1.1.5.1 Screws, Bolts, Nuts, Terminals
NOTE: Sample testing is only permitted for components for
certified products when the component does not affect the
protection concept of the product. Components for certified
products are indicated by stamping of the relevant drawing as
relating to a certified product. The Technical Manager or deputy
will advise upon query.
Such components manufactured to a Part number drawing are batch
tested as follows: Number of Items Percentage Inspected Against
Drawing
1 to 10 100
10 to 20 50
20 to 50 20
50 to 100 10
100 to 200 5
200 to 500 2
500 to 1000 1
4.1.1.6 FABRICATED ITEMS
Fabricated items are visually inspected for finishing.
Welded joins are visually inspected for mechanical
integrity.
4.1.1.7 RUBBER ITEMS
All purchased rubber items are passed through the Mechanical
Inspection department to be labeled with a self expiry date set a
nominal three years after date of inspection.
4.1.2 RECORDING OF RESULTS
Supplier name
Date
Purchase Order number
Product code Quantity involved Test results
Identity of the measuring equipment
Identity of the inspector
The test results are also noted on the route card
4.1.3 LABELLING OF PASSED ITEMS
Items passing inspection are stamped with Work Order number and
inspectors stamp where possible.
Alternately passed items are marked with a green self-adhesive
disc.
Batch items are placed in a bag and a green 'PASS' label
attached. The label is marked with the following information:
Purchase order Number Work Order No number Drawing number
Supplier’s name
Supplier’s delivery note reference
Description
Quantity
4.1.4 RETURN OF PASSED ITEMS TO STORES
The Quality Engineer is responsible for placing the pased items
on the ‘PASSED INSPECTION' shelf in Stores. The Quality engineer
ensures that the items do not become separated by using trays,
boxes or bags as appropriate.
4.1.5 NON-CONFORMING ITEMS
Non-conforming items are kept in the specified area in the
Production Hall, Quality department or in Stores.
4.2 ELECTRICAL INSPECTION
Incoming items to undergo electrical inspection are placed on
the AWAITING INSPECTION' bench in the Quality department.
The Quality Engineer requests a copy of the relevant drawing or
test schedule held by the
Quality department.
After inspection the copy of the drawing or test schedule used
for inspection purposes is to be destroyed
4.2.1 RECORDING OF RESULTS
Test results and the identity of the tester are recorded as
required by the test schedule. The Pass/Fail status of the items is
recorded.
The identity of measuring equipment, route card number and item
type is also recorded.
4.2.2 LABELLING OF PASSED ITEMS
Items passing inspection are stamped with Work order number and
inspectors stamp where possible. A green self-adhesive disc is also
attached.
4.2.3 RETURN OF PASSED ITEMS TO STORES
The Quality Engineer is responsible for placing the passed items
PASSED INSPECTION' shelf in Stores. The Test Engineer ensures that
the items do not become separated by use of trays, boxes or bags as
appropriate.
5.0 PRODUCT TEST
5.1 AVAILABILITY OF ITEMS FOR TESTING
Standard products undergoing in-process or final test are placed
on the 'AWAITING TEST' bench in the Quality department
5.2 TEST AND INSPECTION SCHEDULES
The relevant Test and Inspection schedule is withdrawn from
Technical Department. Formal production testing must be performed
in accordance with an issued approved Test and Inspection
schedule.
5.3 SELECTION OF MEASUREMENT EQUIPMENT
Equipment of appropriate accuracy is selected for use. All
equipment used for test and inspection purposes must be controlled
and within its calibration due date.
5.4 RECORDING OF RESULTS
Test results for conforming units and the identity of the
Quality Engineer are recorded as required by the Test Schedule in
the Test Report section. The identity of measuring equipment, Work
order number and item type is also recorded.
5.5 LABELLING OF PASSED ITEMS
Items passing inspection are stamped with Work order number and
inspectors stamp where possible. A green self-adhesive disc is also
attached.
5.6 NON-CONFORMING ITEMS
Non-conforming items are kept in the specified area in the
Production Hall, Quality department or in Stores.
6.0 SYSTEM TEST
6.1 MECHANICAL INSPECTION AND WIRECHECKING
Mechanical Inspection is usually performed after completion of a
complete assembly. However wire-checking may be carried out on a
sub-assembly when later checking would
6.1.1 SELECTION OF MEASUREMENT EQUIPMENT
Appropriate measurement equipment is selected for use. All
equipment used for test and inspection purposes must be controlled
and within its calibration due date.
6.1.2 RECORDING OF TEST RESULTS
Results are recorded on the generic Test and Inspection
schedule.
The identity of the Test Engineer and Test Instruments are also
recorded on the Test and
Inspection schedule.
6.1.3 NON-CONFORMANCES ARISING DURING MECHANICAL INSPECTION
Non-conforming items are kept in the specified area in the
Production Hall, Quality department or in Stores.
6.2 FUNCTIONAL TESTING
Functional tests are carried out for all Class A projects.
6.2.1 SELECTION OF MEASUREMENT EQUIPMENT
Appropriate measurement equipment is selected for use. All
equipment used for test and inspection purposes must be controlled
and within its calibration due date.
6.2.3 RECORDING OF TEST RESULTS
Results are recorded on the Functional Test schedule as
required.
The identity of the Test Engineer and Test Instruments are also
recorded on the schedule.
6.2.4 NON-CONFORMANCES ARISING DURING FUNCTIONAL TESTING
Non-conforming items are kept in the specified area in the
Production Hall, Quality department or in Stores.
6.3 PASS/FAIL STATUS INDICATION
During each stage the occurrence of non-conformances is
indicated on the sheet.
6.4 VALIDATION
The Test and validation Engineer is responsible for testing and
Validation of the product. The following procedure can be followed
to do the validation testing
Validation matrix MIL 202F Validation matrix IEC 60571
Test jigs required to conduct Prototype
The following Reference documents can be used to do the testing
and validation
Customer Spec
Applicable Standard Documents
Increase Protection Standard
Documents which Test & Validation will record while
conducting a functional test
Internal functional test report
Mutual test report
OEM test Certificate
PCB Test Certificate (For Grade and Standard) Number of Samples
under test as per customer
PROCEDURE FOR PURCHASE AND VENDOR SELECTION
1. PURPOSE
This procedure defines how requests to procure products and
services are raised and approved, and how purchase orders are
subsequently placed upon suppliers.
2. SCOPE
This procedure applies to the procurement of all products and
service that are incorporated into the design, manufacture, test,
or supply of a Elixir Engineering product.
Examples of such products include:
Standard EE parts or sub-assemblies
Capital Equipments
Test and inspection equipment
Process consumables such as solder, adhesives
Examples of such services include:
Sub-contracted design work Sub-contracted manufacture
Sub-contracted test
Calibration of test and inspection equipment
3. PERSONNEL INVOLVED AND RESPONSIBILITIES
All personnel may raise purchase requisitions and must be aware
of the requirements of this procedure.
Departmental Managers are responsible for approving purchase
requisitions.
The Purchasing Officer is responsible for reviewing purchase
requisitions, and raising orders upon preferred suppliers.
4 PROCEDURE
4.1 Orders may only be issued by the Purchasing Officer.
4.2 The product or service to be ordered must be defined in one
of the following ways:
i) Part number (for standard EE parts)
ii) Suppliers identity and order reference (for standard
supplier parts not corresponding to a standard EE part)
iii) Controlled drawing or specification (for non-standard parts
or services)
iv) Adequate description of product or service to be specified
on purchase order
(for non-standard parts or services)
4.3 Before any orders can be processed a Purchase Requisition
must be completed.
The following details are MANDATORY:
i) Definition of product or service (see above)
ii) Issue status (for items with a EE Part number reference)
iii) Required Delivery Date iv) Quantity required
v) The identity of any free issue material
The following details are OPTIONAL:
i) Suppliers identity and order reference (for standard EE
parts)
4.4 Orders for capital equipment must also be completed on a
Capital Expenditure form. Such orders are to be approved by the
Managing and Finance directors before further processing.
4.5 The originator of the requisition should check that any
specified suppliers are in
Approved Vendor list issued from the Quality Assurance
Department.
4.6 All purchase requisitions must be approved by the
Departmental Manager. The
Purchase Requisition is then submitted to the Purchasing
Officer.
4.7 The purchase requisition is reviewed by the Purchasing
Officer to ensure it meets the above requirements. The purchase
requisition may only be accepted after it meets above
requirements.
4.8 The Purchasing Officer selects the supplier upon which the
order is to be placed. This may be as specified by the originator,
or an alternate supplier.
For standard EE parts a SUGGESTED supplier may be available
within the part description on the company computer system. This
supplier has not necessarily been approved by the Quality
Department.
The Purchasing Officer must ensure that a PREFERRED supplier is
selected by consulting the Approved Vendor List issued by the
Quality Assurance Department.
Orders may not be placed upon new suppliers until the Quality
Department has evaluated the supplier and confirms their
capability.
The Purchasing Officer is required to pass the concerned
requisition to the Quality
Department to be held until the supplier’s capability is
confirmed.
4.9 After acceptance of the purchase requisition copies are
circulated as follows: Purchasing Department: White
Originator of Requisition: Pink
4.10 The order is entered onto the company computer system and a
purchase order is raised carrying the following information:
Suppliers address
Delivery address (nominally the Elixir address) Purchase order
number
Date
Standard EE Part Number or Suppliers Order Reference
Issue status of part Product/Service description Quantity
Price per item showing discount where applicable
Total value per item Delivery date Signature of buyer
4.11 The Purchasing Officer contacts the supplier to determine
whether the supplier holds a current copy of any relevant drawings
or specifications referenced within the requisition before issuing
the Purchase Order to the Supplier.
If the part concerned is related to a certified product then the
CURRENT issue of the drawing must be used by the Supplier. If the
Supplier does not hold a current issue drawing then a copy must be
forwarded with the order.
4.12 Where purchase orders and work instructions require the use
of free issue material, such material will be listed on the
purchase order.
4.13 A footnote is included as standard upon the Purchase Order
to inform the supplier those incoming inspection criteria may be
included upon the Purchase Order itself or within referenced
drawings or specifications.
4.14 Copies of Purchase Orders are issued as follows: White Copy
to Supplier
Copy to purchase order file
Copy, sent to stores when free issue material is involved
4.15 All orders are progressed as scheduled.
4.16 Each progress is registered on the order copy as follows:
Date, Comment, Signature
4.19 On receipt of a Goods Received Note for part delivery, each
quantity delivered is entered onto the Stores register. The
Purchasing Department checks the quantities against the original
order on the file.
4.20 OUTSOURCING
The principal objective of Outsourcing is the acquisition of
quality goods and services responsible sources of supply.
Outsourcing seeks a wide range of products and services from an
equally wide range of vendors. Vendors include Original equipment
manufacturers, certified job shops, and service providers of all
sizes.
If the Vendor is an OEM supplier, or a certified
dealer/stockiest like RS Components, Farnell, Mouser Electronics,
etc or an already proven source for the same product in the
territory of Railways and deference would be automatically
considered as an approved vendor. Before placing a Purchase order
for machined item or any mechanical fabrication etc Quality
department needs to assess the vendor capability (which include
vendor's capacity, infrastructure, technical competence and quality
of human resources, work location, availability of technology and
related matters such as financial stability, experience and
references, availability of experts with knowledge of their
industries and processes for managing strategic issues). The
Purchase department will verify the offer and its commercial terms
and conditions. After assessment the Vendor would be added in the
approved vendor list. All the vendors who had supplied as on
02-12-2010 would be considered as the approved vendor. EE will be
assigned a vendor number and placed on the Approved Vendor
list.
A primary responsibility of Outsourcing is to allow for open
competition among vendors. The vendor must meet minimum
specification as required by EE. The competition finalist(s) shall
be selected based on the analysis and evaluation of all proposals.
If, or when, a final proposal or proposals are selected, EE
reserves the right to request that a selected vendor or vendors
provide with further information related to their offer, if that
information is required to complete the decision making
process.
TECHNICAL SPECIFICATIONS
1.0 Electrical Specifications
· RF FREQUENCY: Transmit Frequency: 24.125 GHZ
· RF POWER: 5 to 10 mW
· TYPE OF ANTENNA: Patch array Antenna
· ANTENNA APERTURE WITH RADOME: 98x98 mm square
· BEAM DIVERGENCE ANGLE: 6° from centre
· OFFSET ANGLE ALIGNMENT: 37.5°±3.5°
· SPEED MEASUREMENT: 0.5 KMPH to 500KMPH
· TARGET DISTANCE:0.5 Meters to 500 Meters.
· OUTPUT:+15 Volt pulse wave with 50% duty cycle (square
wave).
Single – ended signal with 22.5 Hz/MPH (Miles per Hour).
· UPDATE INTERVAL: Can be configured to 20 milliseconds to 1
seconds.
· VALID FREQUENCY RESPONSE: Between 10 ms to 20
milliseconds.
· POWER SUPPLY: 14.5 to 15 VDC
· OPERATING TEMPERATURE: -20 Deg to +65 Deg. RH 95%
· MECHANICAL ENCLOSER: Shock, Vibration and Weather
Resistant.
Part numbers: EMD # 40034353 and EMD # 40081692
Climatic & Environmental Condition:
Maximum Atmospheric Temperature : 550C (in Sun) & +470C (in
Shade) Ambient Temperature (Operating) : -20…. +700C
Ambient Temperature (Storage) : -30…. +800C Normal humidity :
90%
Maximum Humidity : 100% saturation during rainy season
Altitude : 1200 m.a.s.l
Rain fall : Between 1750mm to 6250mm, the locomotive shall be
designed to permit its running at 5km/h in flood water level of
10.2cm above the water level.
Atmosphere during hot weather : Extremely dusty & desert
terrain in certain areas
Coastal Areas : Locomotive & equipment will be designed to
work even in coastal area in humid & salty laden atmosphere
PROTO TYPE TESTING
Sl No
Type Test
Routine Test
Specification
Agency/place of Test
1
Performance Test
Performance Test
IEC60571
In House
2
Dielectric Test
Dielectric Test
IEC60571
Third party agency
3
Voltage surge test
-
IEC60571
In house
4
Dry Test
-
IEC60571
Third party Agency
5
Vibration Shock and
Bump test
-
IEC61373
ETDC Bangalore
ANTENNA TESTING:
SL.no
Particular of testing
Range
Place of testing
1
VSWR/ return loss-db
1.29/18 db
In house
2
Bandwidth(MHZ)
±100 MHZ
In house
3
Beam Divergence angle
6° from centre offset angle alignment 37.5°±3°
In house
4
Trans receiver module output
35dB
In house
5
Signal strength
Minimum 35 dB
In house
6
Testing different frequency v/s speed
voltage
In house
Frequency
In house
speed
In house
PROPOSED RADAR TEST SETUP
PROCESS FLOW CHART FOR RADAR ASSEBLY
INWARD OF MATERIALS
STORES
NO
INWARD
REJECT
INSPECTION
YES MOUNTING SOLDERING OF
COMPONENTS ON PCB
NO CHECKINGTHE PCB TO ENSURE THAT ALL THE
COMPONENTS SOLDERED
YES
PCB CLEANING
STORES
IF FAIL
CONTINUIT REJECT Y TESTING
IF PASS
MECHANICAL HOUSING PREPERATION
INSERTION OF THE ASSEMBLED PCB IN TO THE HOUSING
COMPLETE ASSEMBLY OF MECHANICAL
STORES FINAL NO
INSPECTION & REJECT TESTING
YES
CLEANING PACKING DISPATCH
PROCESS FLOW
1. Collect all the necessary tools such as Screw driver set,
cavity, speed sensor, filament, PCB, Rubber grip for PCB, Slide
guides.
2. Keep the filament on one above the other and place them in a
cavity where the sensor screw matches before placing the speed
sensor.
Filament
3. Place the speed sensor in the cavity as shown in the Pic 1.0,
tight all the four screws gently.
Speed sensor
Sensor cable sensor screw
4.Place the slide guide on both the ends of the cavity as shown
in the Pic 1.1, the thicker side of the slide guide to be inserted
to the inner side of the cavity.
SLIDE GUIDE
5.The slide guide must be facing towards sensor as shown in the
Pic 1.1.
PIC 1.1
Slide guides (Black)
6.Bare Board PCB
Pic 1.2
7.Place the rubber grip to the PCB as shown in the PIC 1.3
PIC 1.3
Rubber grip
8. Insert the PCB in the cavity, Make sure that power connector
and sensor connector of PCB will be facing as shown in the PIC
1.5.
PIC 1.4
9.After placing the PCB in the cavity, Place the sensor
connector on to the board which has a mating part soldered on PCB.
The PIC 1.6 shows the over view.
PIC 1.5
Sensor cable connection to PCB
10. Insert another set of slide guide in the Cavity below the
PCB and above the previously inserted set of card slide guide. As
shown in the PIC 1.6
PIC 1.6
11.Overview of the sensor, sensor connector, PCB alignment, Card
grid.
PIC 1.7
Sensor Connector Slide guide
12. Back Panel plate rare side overview.
PIC 1.8
Back panel plate (rare side)
13.Power connector connection to the PCB as shown in PIC 1.9
PIC 1.9
sensor
14.Back panel fixture PIC 1.11
PIC 1.11
Screw placing
15.MAIN POWER SUPPLY CONNECTOR PIC 1.12
I/O CONNECTOR TO THE LOCO
PIC 1.12
16. Final Radar picture PIC 1.13
PIC 1.13
BILL OF MATERIAL FOR MODIFIED RADAR ASSEMBLY DRG NO :
SL NO
EE PART NO
DECRIPTION
Nos.
DRG
REMARKS
1
Radar Housing
1
ELIXIR DWG
Indigenous Developed Inhouse.
2
Back Cover Plate
1
ELIXIR DWG
3
Processor Board
1
ELIXIR DWG
4
Transceiver Assy.
1
ELIXIR DWG
5
Micro-Strip Antenna Assy.
1
ELIXIR DWG
6
Seal O ring
1
ELIXIR DWG
7
Cap Radar lens
1
ELIXIR DWG
8
RF Connector With Filter Assy.
1
ELIXIR DWG
9
Gasket
1
ELIXIR DWG
10
Screw M4x14 CH
1
ELIXIR DWG
11
Washer # 6 Flat
1
ELIXIR DWG
12
Screw M3x14 CH
1
ELIXIR DWG
13
Washer # 4 Flat
1
ELIXIR DWG
18
Insulator
1
ELIXIR DWG
19
Retainer Upper
1
ELIXIR DWG
20
Conformal Quoting
1
ELIXIR DWG
21
Cap PTFE
1
ELIXIR DWG
22
Insulator
1
ELIXIR DWG
23
Static control
1
ELIXIR DWG
24
2
2
2
2
2
25
AISI304
Stainless Steel
26
40033657
Housing Radar
C
EMD/DLW
27
A.I.2400
Tolerances
Elixir drg attached
ESSENTIAL TESTING EQUIPMENT:
Sl.No
Name of testing equipment
Make
Model No:
Range and specification
Accuracy
Application of this instrument
Remark
1.
Vector network analyzer
Keysight
PNAN5242A
10MHZ to 26.5 GHZ
Dynamic accuracy:0.1 dB compression with =13 dBm I/P at
receiver
High accuracy standard for test and measurement as network
analyser. For testing of Sparameter/smith chart/polar/SWR etc
High accuracy standard test and measurement equipment
2.
Signal analyzer
keysight
N9020A
10HZ to 26.5GHZ
±0.23dB absolute Amplitude accuracy
High accuracy standard for test and measurement as network
analyser. For testing signal strength
High accuracy standard test and measurement equipment
3.
Signal generator
keysight
N5173B
9KHZ to 40GHZ
±0.23dB absolute Amplitude accuracy
High accuracy standard for test and measurement as source
generator
High accuracy standard test and measurement equipment
4
Network analyzer
keysight
E5071C
300KHZ to 20GHZ
Dynamic accuracy:0.1 dB compression with =13 dBm I/P at
receiver
High accuracy standard for test and measureme-nt as network
analyser. For testing of Sparameter/smith chart/polar/SWR etc
High accuracy standard test and measureme-nt equipment
5
Digital oscillosc-ope
Tecktro-nicx
MS2022
500Mhz
Frequency accuracy:10ppm,storage sampling:1GHZ
To test and modulate DC/AC signals
High accuracy standard test and measureme-nt equipment
6
Digital multimeter
Fluke
106
AC volts:6/ 60/600V
DC volts: 6/60/ 600V Resistance:400Ω/4KΩ/40KΩ/
400KΩ/4MΩ,40MΩ
AC Volts:1.0%+3;DC volts:0.5%+3;
Resistance:
0.5%=3;
Test preliminary parameter, measure and monitor voltage/current
etc.
Test preliminary parameter
7
Wave-guide adopter WR-28
Narada
V4607
18GHZ to 40GHZ
0.01 mm±0.1dB
Waveguide to coaxial adopter
High standard to coaxial converter
8
LCR meter
CHY FIREMATE
24CS
Inductance:200µ/2m/20m/200m/2/20H
Resistance:200/2k/20k/200k/2M/20M/200M/ 2000MΩ
Capacitance:200p/2n/20n/200n/2µ/20µ/200µ/2m/20mF
Frequency:2k/20k/200k/15MHz Temperature :-20 to 750°C Diode test:
1mA, 3V
Resistance: ±(0,3% + 1 digit); Capacitance: ±(2% + 10 digits);
Inductance: ±(5% + 3 digits); DC voltage : ±(2% + 1 digit);
Frequency : ±(0,1% + 1 digits);
Test preliminary parameters, measure and monitor voltage/current
etc.
Test prelim
-nary parameter
9
Wave-guide adopter WR-42
Narada
4608B
18GHZ to 26.5 GHZ
0.01mm±0.1dB
Waveguide to coaxial adopter
High standard
to coax-
ial converter
10
Test port cables low loss RF assembly
keysight
F03A2
30774
300KHZ
-26.5 GHZ
Imped-
ance:50Ω
phase matched:
±1°
±0.01 dB vswr 1:1.05±1°
Test
and measure port 1 and port 2
Test
and measure-
ment
cables
11
Caliberation kit
keysight
85052D
300KHZ
-26.5GHZ
APC/SMA precision calibration adopter
For calibrating I/P or O/P
Calibration
kit
12
Adopter
keysight
x-series
DL-26.5GHZ, 2.4 mm-3.5mm/
2.92mm adapter
±0.01dB
Source adopter
Source(
signal adopter)
