AQRM-2019

PATIL RAIL INFRASTRUCTURE PVT., LTD.

-BY HARSH K. KAPADIA (G.E.T.)
 POINTS TO BE COVERED

• AREAS OF IMPROVEMENT.
• AREAS OF CONTROL AND SUGGESTIONS ON REJECTIONS.
• TYPES OF REJECTION AND REASONS.
• STATUS OF C.A.P.A. ON REJECTIONS.
• CASE STUDY ON REJECTIONS. (SD AND CRACK).
 AREAS OF IMPROVEMENT.

• WASTAGE CONTROL.
• REJECTION CONTROL IN HORIZONTAL CRACK AND SD.
• HOUSE KEEPING AND MOULD TOP CLEANING.
• MOTIVATION IN MANPOWER AND APPRECIATING THEIR EFFORTS.
• CUBES FAILURE.
• HAND PULLING OF WIRES.
 AREAS OF CONTROL AND SUGGESTIONS
ON REJECTIONS.
• CRACKING DUE TO LACK OF GREASING IN THE INSERT.
• Happened due to improper greasing.
• Dipping insert method is suggested for the greasing/oiling of insert.
• WASTAGE OF CONCRETE:-
• Providing taper cover plates on top of the bench, so that the concrete falls directly in the moulds
rather than being wasted, which is a major issue in our plant.

• CUBE FAILURE DUE TO IMPROPER FITTING AND LEAKAGE OF CEMENT SLURRY:-

• Usage of plastic moulds for cube casting. (light weight, accurate and easy to handle.)
Insert resting on
the arrangement

Grease+oil

Submersible type greasing of the insert

 12 INCHES
6 INCHES TAPER
HIGH METAL SHEET
METAL SHEET
“C” TYPE CLAMP TO
HOLD
ONTO THE BENCH.

Prototype for the reduction of

wastage
Plastic
moulds
Wire placing and sorting
arrangement
Wires placed in the
arrangement
 Types of rejections and their reasons
RSL SURFA Dowel /
SL NO. APRIL PLANT SBT IS/IT Slope DIMN
/Slope
OS
CE (SD)
GR/ OG Crack H.COMB EB NCS Damage
ND
DryMix NFTC camber TG OTHERS TOTAL

Apr'18 4 12 16

May'18 8 4 1 13

June'18 22
14 5 3

July'18 22 1 1 3 3 30

Aug'18 38
11 2 13 12

Sep'18 19
10 3 5 1
UDV
Oct'18 17
9 2 6

Nov'18 61
44 9 6 2

Dec'18 20
7 5 8

Jan'19 6 4 9 1 1 21

Feb'19 2 2 7 2 13

March'1
3 9 8 20
9

Total 4 148 0 0 1 0 46 0 69 0 17 0 3 0 0 0 0 0 2 290

2018-2019
• SD:-
• Usage of dry concrete.
• Improper proportioning of the concrete mix. (excess aggregate dumping
through the weigh batcher.)
• Not being able to control the wastage.
• Type of aggregate (10 mm flaky and elongated above 40%). Presence of
dust in the material.
• CRACK:-
• Insert oversized.
• Mis-handling of bench placing in the chambers
• Non-removal of pin locks.
• Over jacking.
• Direct cutting.
• Moulds being suspended after tensioning.
• Insert holes not being greased properly.
• Mishandling during the placing of the bench in the chamber.
• INSERT TILT/SINK:
• Manual error.
• Pocket damaged
• Mould surface was not levelled.
• Pocket surface problem in the old moulds of turnout sleeper.
• Pin locks being improper.
 STATUS OF C.A.P.A. ON REJECTIONS.

DEFECTS ROOT CAUSE CORRECTIVE ACTION PREVENTIVE ACTION

• SD:- ● Change of wooden ● Regular monitoring by

 Improper compaction through vibration. battens. supervisors to check whether
 Taking the sample from varying stocks ● removing the faulty the benches have wood battens
which affects the moisture content and vibrators. in a good condition.
Surface pores/
its workability. ● Taking the materials ● Faulty vibrators, that
SD
 Improper proportioning of the mixes like from the specified repeatedly causes problems to
taking excess aggregates than specified stock, correction of be removed. Mixes are being
and lesser cement than the required. load cells in the monitored regularly for the
batching unit. proportions.
 ● The insert cheking zig was
replaced with a newer one ● Periodic checking of the

• CRACK:-
●
●
Oversized inserts.
The zig used to check the dimensions of inserts
and all the inserts that
were oversized were
insert zig is scheduled once
a week with the master
rejected. gauge.
had suffered wear and tear and due to this
● Over jacking was only ● Labourers are strictly told
even oversized inserts were being consumed
Crack done in the presence of not to overjack the
for production.
the Prod in-charge. sleepers. If it is not being
● Factors like overjacking, leaving pin locks in
● Pin lock tally is regularly demoulded, the prod. In-
the moulds, reckless placing of bench in the
being carried out and charge is called and he will
chamber.
various other factors are take the further necessary
being thoroughly action.
monitored.
 INSERT TILT:-

• we changed the damaged

• pin lock handing over is
pins, replaced the old ones
• Initially it was more in BG. being carried out.
with the newer ones and the
• It happened due to the non-usage of pin locking • Tally of pin locks is being
handing over of pins were
arrangement. Some benches didn't have the pin done and whenever an IT/IS
I/T followed.
lock and thus it caused IT/IS. occurs, all the concerned
• In P&C, the moulds were
• In P&C sleepers the rejections were more due to people are informed about it
repaired for their
the faulty moulds. and the fine is levied upon
dimensions and near the
them.
insert pocket.
 CASE STUDY ON REJECTIONS :-
SD:-

• PROBABLE ISSUES:-
• Inconsistent mixes were found and the proportions were not maintained,
which lead to the failure of the steam cubes.
• A/C ratio was not controlled. Excess aggregate fell in the mixes for which
the cement, admixture and water were not accounted.
• Compaction was not proper as the SD were observed in one particular side
of the bench.
• Usage of dry concrete in the casting of the sleepers to control the wastage.
• Resolution:-
• Informed to QC head about the issue and with the support of the STR team,
the proportioning of the mixes were controlled.
• The faulty vibrators were marked and they were replaced.
• The dry concrete was removed from the site and was dumped far so that it
is not used in the casting.
• We’re currently developing the cover plates for the same so that the
wastage is not generated in the first place and it can save up huge amounts
of money.
• Whatever wastage is generated, is being used to cast blocks which are then
used for the civil works.
 CRACK

• PROBABLE ISSUES:-
• Oversized insert.
• Constant changing of the de-moulding workers.
• Improper greasing of the insert hole.
• No pin lock handing over system was followed.
• Pins were not removed in the green stage and the information regarding it was
not passed on.
• Resolution:-
• The insert checking gauge had suffered wear and tear and hence the
oversized insert were also used. Hence upon changing the jig gauge the
usage of oversized insert was controlled.
• We have made some workers permanent in the de-moulding area so that
the cracks can be controlled.
• We are currently doing an R&D for the dipping system of the insert so that
the application of the grease in the hole is proper. Also we are constantly
checking the insert for the greasing on a random basis, daily.
• We have made a stand for the pin lock stacking so that one can see how
many pins are there and if they are missing the workers in the demoulding
area can be alerted.