A Study On Rail Spring Workshop, Gwalior (M.P)

SITHAULI, GWALIOR
AN ISO-9001-2000 WORKSHOP
Presented by:
Ms. Rachna Marcus
1
INTRODUCTION
 Rail Spring Karkhana is the Largest and
dedicated plant for helical hot coiled Spring for
IR Rolling Stock.
 Manufactures 90000 springs (3100MT) per
annum.
 Set-Up in 1989 under TOT agreement with M/s
Ernst Komroski & Co.& Grueber, Germany.
 Purpose -To cater the increasing need of quality
Coil springs for switchover from Laminated
Springs.
2
INTRODUCTION
 The Plant has state-of-the-art facilities for
manufacturing hot coiled springs.
 Annual turnover of RSK is Rs. 49 Crores.

Major Customers Nos. of Springs supplied
during 2007-2008
RCF, Kapurthala 25000
Zonal Railways 65000
Total 90000
3
SALIENT FEATURES OF RSK
 Manpower:- 460 sanctioned.
 Initial Investment:- Rs. 54.04 Crores.
 Connected Load:- 3000 KW
 Furnaces:- LPG fired
 Certification:- ISO-9001:2000
 Machinery & Plant:- Semi-automatic CNC &

PLC based Machines.
 Total land area for the project:- 22 hectares
 Shop covered area:- 6400 sq. m
 Administrative building area:- 1800 sq. m
 Nos. of Quarters:- 60
 Associated infrastructure facilities:- 03 Nos. of Sub-Stations

4
QUALITY OBJECTIVES
• Compliance to production and dispatch target
of 90000 springs for the year 2008-2009.
• Minimize the “in house rejection” of springs to
6.5%.
• Improve skill and knowledge of the
employees.
5
QUALITY POLICIES
Commitment to supply springs according

to customer requirement.
Help in safe and comfortable rail travel.
To make continual improvement in the
Quality Management System.
To comply with all legal and other
statutory requirements.
6
ORGANISATION
CWM
DyCME SrDMO
WM(F) WM(Pl) WM(Mfg) SEE
ACMT AWM/Pl ASC APO WAAO AMM

M
7
STAFF POSITION
Category Sanctioned On-Roll

Supervisors 78 72
Other Group “C” 279 262
Group “D” 103 103
TOTAL 460 437
8
BUDGET AT A GLANCE
Figures of 2008-2009 in lakhs of Rs.
 Staff Wages:- 903

 Material Stock :- 2300
 Direct Purchase (Material) :- 700
 Miscellaneous Charges:- 230
9
MACHINERY & PLANT
 END TAPERING MACHINE
 BAR HEATING FURNACE
 COILING MACHINE
 QUENCHING MACHINE
 TEMPERING FURNACE
 HARDNESS TESTING MACHINE
 END FACE GRINDING MACHINE
contd. 10
MACHINERY & PLANT
(Cont.)
 SHOT PEENING MACHINE
 MAGNAFLUX CRACK DETECTION
MACHINE
 SCRAGGING HYDRAULIC PRESS
 LOAD TESTING HYDRAULIC PRESS
 RE-PITCHING MACHINES 2 No:s
 PRIMARY PAINT PLANT
 BLACK PAINT PLANT
 PACKING MACHINE
11
STEPS TO MANUFACTURE
SPRINGS
 Secure firm orders.
 Purchase Raw Material.
 Inspect Raw Material.
 Processing.
 Inspection of springs.
 Packing.
 Dispatch.
12
PROCESS FLOW CHART
Raw Material
Peeled bar
End Tapering
13
PROCESS FLOW CHART
Bar Heating (Cont) Dispatch
Coiling
Colour Coding
Quenching
Black Painting
Tempering
Primary Painting
Resizing
End Grinding
Shot Peening Under/over

Height
Crack Testing Scragging Load Testing 14

15
END TAPERING OPERATION
16
END TAPERED BARS 17
SPRING COILING IN OPERATION 18
QUENCHING MACHINE 19
END GRINDING MACHINE 20
END GROUND SPRING 21
22
MAGNA FLUX CRACK DETECTION OF SPRING
23
SPRING DEFLECTION TESTING MACHINE
24
25
REPITCHING MACHINE
26
RED OXIDE PAINT PLANT
27
SPRINGS ON BLACK PAINT PLANT
UNLOADING FROM BLACK PAINT & CODING
28
OF SPRINGS
PACKING CARTON OF SPRING 29
PACKING OF SPRING 30
31
TYPES OF SPRINGS
RSK is manufacturing springs for:-
Coaching:- Axle & Bolster springs
for AC & Non-AC, 4 types.
Loco Springs:- Inner & Outer for BG

locomotives. 2 types.
High Capacity
Parcel Van:- Axle box & Bolster 3 types
32
RANGE OF SPRINGS & RAW MATERIAL
PARAMETER Minimum Maximum
Wire Dia (mm) 16.0 53.5
Free Height (mm) 123.0 877.0
Spring Outer Dia. (mm) 86.0 450.0
Weight (Kg./spring) 3.8 171.2
MATERIAL
52Cr4Mo2V For larger dia above 33 mm.
60Si7 For smaller dia below 33 mm up to
16 mm
33
QUALITY ASSURANCE
 RSK has got ISO-9001: 2000, certification.
 Arrangement available for testing of raw material.
 Stage wise in process quality assurance system
during production.
 Well equipped LAB for assessing & assuring the
quality of springs at each stage of production.
 Having proper system for customer feedback &
continual improvement in quality.
34
MAJOR JOBS DONE DURING
LAST 4 YEARS
 New heat exchanger system for cooling of quenching
oil.
 Installation of fire fighting arrangement at LPG Yard.
 Developments of indigenous substitute for imported
spares.
 Installation of Air Dryer & Moisture Separators in
compressed air circuit.
 Installation of isolation transformers and voltage
stabilizers for control panels.
 Installation of Effluent Water Treatment Plant.
Contd
35
 Provision of air-conditioners for control
panels.
 Provision of new water-cooling towers for
improving efficiency of water-cooling
circuit.
 Provision of DM plant to prevent choking of
water-cooling circuit due to hard water.
 Compliance of mandatory requirements such
as public liability insurance and approval of
disaster management plan etc.
 Installation of DG set (1000 KVA) to ease
out the power problem.
36
PRODUCTION AND ITS VALUE
S. Year Target Production Value in

No: No: No: crores
1 2002-03 72711 68161 23.8
2 2003-04 90000 90000 29.4
3 2004-05 90000 79000 34.8
4 2005-06 90000 92705 42.5
5 2006-07 90000 92150 42.4
6 2007-08 90000 81000 41.0
7 2008-09 90000 92750 49.0
37
ACHIEVEMENTS
 About 90,000 springs produced per year
covering 9 types of coaching and loco
springs.
 Set-up of Phosphating plant to reduce
corrosion.
 Re-conditioning of important machines.
 Spring production cost is less than
market.
38
INVESTMENT PLANS
 Additionalinfrastructure for manufacture of
FIAT springs- sanctioned.
 Replacement of old and obsolete machines of

existing production line sanctioned.
 Planning of new BOXN wagon spring

production Line.
39
BOTTLENECKS
• Remote geographical location of plant.
• Shortage of officers and staff.
• Inadequate local market.
• Poor communication.
• Old & obsolete machines.
40
ASSISTANCE REQUIRED
Communication: more and better Rly

phones.
Mobile phones.
Security.
More delegation for machine repairs.
Approach road without railway
crossing.
41
RECOMMENDATIONS TO
IMPROVE
 Civil engineering officers to be

placed under workshop in charge.
 Enhancement of procurement
powers.
42
43

A Study On Rail Spring Workshop, Gwalior (M.P)

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SITHAULI, GWALIOR

 Annual turnover of RSK is Rs. 49 Crores.

 Initial Investment:- Rs. 54.04 Crores.

 Connected Load:- 3000 KW

 Furnaces:- LPG fired

 Machinery & Plant:- Semi-automatic CNC &

 Total land area for the project:- 22 hectares

 Shop covered area:- 6400 sq. m

 Administrative building area:- 1800 sq. m

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

Commitment to supply springs according

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

ACMT AWM/Pl ASC APO WAAO AMM

Category Sanctioned On-Roll

 Staff Wages:- 903

Shot Peening Under/over

Crack Testing Scragging Load Testing 14

Loco Springs:- Inner & Outer for BG

S. Year Target Production Value in

 Replacement of old and obsolete machines of

 Planning of new BOXN wagon spring

Communication: more and better Rly

 Civil engineering officers to be

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