Involvement of laboratory in addressing reliability issue has paid reach dividends especially in air brake and there is an urgent need to replicate the experiment in other sections/areas. ACMTs have to act as nodal Officer’s for quality control, failure investigation and certification of testing & maintenance practices.

1. . Labs must identify and analyze root cause of failures. Comments must cover:

·        Material issue- specific material faults/ defects /& why they develop? What checking  should be done at the time of fitment to arrest subsequent material degradation & suggested in-situ checking

·        Fitment issue- what specific acts/mistakes are leading to component failures? Factors like poor knowledge and skill level should be identified & action plan suggested.  Testing & cross-checking knowledge and skill should be jointly done.

Sr. DME. Dsls must review lab presentation personally to ensure meaningful analysis and recommendation.

2.    Vendor wise performance record to be kept for all mechanical components. Data base of failures ( line, Shed and OVH failures before 2 yrs service life) to be kept.

3.    Examination of released components: All released components after stripping during OVH should be minutely examined.  root cause wise analysis of each component which exhibit deterioration/damage should be done. Specific suggestions should be given to section so that service life can be at least doubled from present level.

4.    Lab exception list:  . Exception list should be updated every fortnight. Action taken on items featuring in exception list should be recorded with signature of the supervisor of the concerned section. Moreover, abrupt changes in viscosity and spectro report must be highlighted in the exception list.

   ACMTs must weekly review testing practices.

5.    Water system leakages- Vulnerable locations have been identified. Equalizing pipe to be converted to 1 inch dia and to be replaced during M₂₄ schedules to avoid choking. Water jumper brazing leakages, sign of seepage, hydraulic testing to be ensured by Lab . ACMT in consultation with other labs should issue list of root causes for water related failures. All Sheds must attend each loco during major/medium schedule accordingly, so that water leakages don’t happen during running schedule.

6.    Lube oil leakages- Vulnerable locations have been identified. ACMT should issue list of root causes for lube oil leakages. All Sheds must attend each loco during major/medium schedule accordingly, so that lube oil leakages are not encountered during running schedule.

7.    List of warranty claims records should be maintained for all prematurely failed mechanical components.

8.    Metallurgical investigation: Failed components are currently not being metallurgically examined. All major cases of component failures are to be analysed in major labs as comparative metallurgical testing facilities are not available in Shed.

9.    Examination of failed components by lab: All cases of line/Shed failed component sample are not sent to lab by concerned sections. Sr.DMEs must enforce discipline & make suitable maintenance system.

10. Record of corrective action: Faults recorded by lab are advised to section but corrective actions taken & results obtained are not recorded. Lab must record the same, message loop must be completed.

11. Periodical checking of all mechanical components of stores & section should be done by ACMT & his team. Irregularities noticed should be reported to Sr.DMEs & HQ.

12. Feedback to RDSO/DLW/OEMs: Product deficiency observed after analysis should be reported to firm & Inspecting Agency.

13. Focused testing of failure prone components: List of items which have failed prematurely should be compiled by lab. All such identified components should be subjected to two stage test, one during material accountal stage & another before fitment. This will ensure that material related problems do not recur. All mechanical items must be pre tested by lab before fitment irrespective of previous inspection.

14. Computerization of lab records: All lab record keeping must be computerized in all Sheds. One PC for LMG lab should be provided for record keeping.

15.  Air brake section: Air brake valve overhauling & lab involvement in testing & auditing maintenance practices should be replicated in all Sheds in all mechanical sections. This is the roadmap to be followed.  It was again confirmed by ACMT that no defect has been observed in old released rubber kits after examination of stripped Air Brake valves taken for OVH.

16. NDT:. Rejected materials should be reported to Firm for corrective action. Reason of rejection of old material should be reviewed and proper screening procedure to be devised to weed out defective material during testing of new material itself.

In case of Cam Gear and Split Gear, severity of pitting should be quantified. Rejection should be done during Shed detection preferably M₂₄/₄₈ to avoid line failures.

For traceability of rejected components, section should put ID mark by either itching or punching.

   Each Shed should devise new/additional testing methodology based on present rejection of old materials during NDT. Components to be zyglo tested as per OEM should not be subjected to DPT and prevailing practice to be stopped with immediate effect. DPT to be done only after proper cleaning e.g. grinding and polishing of welded surfaces etc.

Rejected material should not be returned to section, proper record should be maintained and after keeping samples, rest materials should be scrapped and deposited in stores to avoid recycling.

Main/ Con Rod Bearing to be tested as per MI only.

17. Lab testing practices: List of practices discontinued should be compiled and reintroduced. ACMTs must confirm the same.  Shed has started :

·        Radiator fan blades visual checking during minor schedules & dye penetration test M-2 and on ward schedule.

·        Suspension bearing oil checking in every schedule. Ultra sonic testing of suspension bearing.

·        Crackle test of Fuel Oil from cylinder head leak-off to detect nozzle sleeve crack.

·        Spectrographic analysis of Compressor oil from M₂ schedule onwards.

·        100 % checking of gaskets.

Other Sheds must start or confirm the same if already being done.

18.Analysis by Lab:

Water pump failures are due to

• Loose castle nut, free rotation of impeller, breaking of split pin
• fitment of impeller without ensuring interference and dimensional accuracy
• Poor Quality of split pin and handling of split pin.

Shed must submit action plan to arrest above root causes.

Riser pipes initially fitted at RB are susceptible to failures either due to material defect like lap or fitment fault. Shed should identify the root cause and advise OEM accordingly. All RB locos to be attended in next M₄ schedule for water riser attention.

Issue of poor quality of High pressure joint sheet was reported. All such inferior gaskets not conforming to specification and prone to failure must be rejected. However, it must be ensured that gaskets are fitted only after proper surface preparation and blue matching. Surface irregularity must not be covered by gaskets.

Gasket Specification should be collected and minimum testing facilities should be developed at Lab.

Procurement of Rubber Component should be done in split up lot only and as per six monthly requirements. Suitable clause should be incorporated.

Brainstorming after each failure must be conducted and best fitment and testing practices of leading  Sheds should be examined. List of suggestions given in current month should be shared with all Sheds