QUALITY ASSURANCE PLAN (QAP)

ITEM Fuel Pump Motor Date: 27-02-2023

SPECIFICATION: MISC 632 REV -02 Rev. Nil

FIRM DETAILS:

Firm Name AUTO INDUSTRIES

Address Plot No-209 & 522, Ecotech-III, U.K.-II, Gr. Noida, UP-201306
Contact Person Deepak Chauhan
Email [email protected]
Phone
Mobile No. 9873777916

Signature Not
Verified Auto Industries
PlotbyNo -209 & 522, Ecotech-III, UK-II,
Digitally signed
NIKHAT Greater Noida Signature of Quality Head Page 1 of 16
Date: 2023.03.09
UP-201306
15:14:20 IST
Reason: IREPS-CRIS
Location: New Delhi
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

Amendment History:

Sl.No. Amendment Date Version Reason for Amendment

Table of Contents
1. Purpose: ................................................................................................................................................ 3
2. Scope of Application: ............................................................................................................................ 3
3. Item Details: ............................................................................................................................................
4. Reference Documents:.......................................................................................................................... 3
5. Organization Setup ............................................................................................................................... 4
5.1. Organization Chart ........................................................................................................................ 4
5.2. Qualification of Personals ............................................................................................................. 4
6. Manufacturing Process ......................................................................................................................... 5
6.1. Process Flow Chart ........................................................................................................................ 5
6.2. Machinery and Plant (M&P) ...........................................................................................................
6.3. Testing & Plant ................................................................................................................................
6.4. Details of Sub-assemblies/Components Manufactured ............................................................. 11
6.5. Details of Sub-vendors ................................................................................................................ 12
7. Quality Control .................................................................................................................................... 13
7.1. Quality Certification .................................................................................................................... 13
7.2. Calibration Plan for Testing & Measuring Equipment ................................................................ 13
7.3. Incoming Raw Material & In-process/Final Inspection ............................................................... 14
7.4. Handling of Rejected Material .................................................................................................... 15
7.5. System for Customer Complaints/Warranty Failures ................................................................. 15
7.6. Details of after Sales & Service ................................................................................................... 15
8. Additional Information........................................................................................................................ 16
Annexure: .................................................................................................................................................... 16

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 2 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

1. Purpose:
The primary purpose of the Plan is to define how quality will be managed throughout the
life cycle of the FUEL PUMP MOTOR in the following areas:
• Quality Planning – provides the documentation standards and framework for quality
during the lifecycle of the FUEL PUMP MOTOR.
• Quality Assurance – provides the necessary attention to detail for continuous
improvement of activities and processes to achieve quality.
• Quality Control – monitor and inspection process that ensures every deliverable and
work product is measured, tested, and ensures results conform to quality standards.
• Quality Improvement–identifies quality improvement opportunities and implements
corrective action or process improvement.

2. Scope of Application:
Applicable for DC/AC converter based 15 AC motor driven Fuel Transfer Pump for ALCO &
HHP Locomotives.

3. Item Details:

Item Name FUEL PUMP MOTOR

Specification no. MISC 632 REV -02
Drawing no. 11815565 Rev. nil
STR No. N/A

4. Reference Documents:
ISO : 9001 : 2015

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 3 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

5. Organization Setup
5.1. Organization Chart

5.2. Qualification of Personals

a) Production

Sl.No. Name Dsgn. Qualification Experience Remarks

1 Himanshu Yaduvanshi Engineer B Tech 6 Years
2 Nitish Kumar Engineer Diploma 3 Years

b) Quality Control

Sl.No. Name Dsgn. Qualification Experience Remarks

1 Kuldeep Sharma Manager B Tech 8 Years

2 Anmol Tyagi Engineer Diploma 3 Years

c) After Sales & Service

Sl.No. Name Dsgn. Qualification Experience Remarks

1 Swarup Bhakta Manager Graduate 10 Years

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 4 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

d) R&D/Design

Sl.No. Name Dsgn. Qualification Experience Remarks

1 Biswaranjan Baliar Dy. B Tech 11 Years
Manager

6. Manufacturing Process
6.1. Process Flow Chart

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 5 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 6 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

6.2. List of M & P

SN Description Capacity Make

1 CNC VMC 1500 x 600 x 600 mm BFW

2 CNC CMM 1300 x 600 x 500 mm Mitutoyo

3 CNC VMC 900 X 450 X 500 mm BFW

4 CNC Lathe 400 mm Dia Chuck BFW

5 CNC VMC 900 X 450 X 500 mm BFW

6 Laser Marking Machine 50W UGAM

Tooltech
7 Bench Vice 6"

8 Surface Grinding Machine 14" Guru Arjan

9 Grinding Machine 1 HP Bharat

10 Gas Cutting Sets 1 - 200 mm Sunder

11 Swaging Machine 700 Bar Jupiter

12 Drill Machine 1" Relience

13 Lathe 6 Relience

14 Rolling Machine 6 mm x 2000 mm -

15 Ultrasonic Cleaning Machine 10 Gallon Emcolite Ultrasonic

16 Tig Welding Machine 200 Amps ESAB

17 Tig Welding Machine 300 Amps ESAB

18 Spot Welding Machine 300 Amps Kirpekar

19 Hand Press Machine 1T -

20 Shearing Machine 4X2500 PAC

21 Leak Detector Machine - Tifax

22 EOT Crane 3T Unicon

23 Drill Machine 2HP -

24 Drill Machine 13MM DWD

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 7 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

25 Punching Machining 25MM ESSL

26 Toggle Grinder 1000W DM

27 Air Compressor 10 HP Airflic

28 Air Compressor 10 HP Airflic

29 Laser Cutting Machine 1000W Yawei

30 Bending Machine 35T Yawei

31 Bending Machine 80T Yawei

32 DG SET 125 KVA Cummins

33 Hydro Pop River Tool 312 Amps -

34 Dot Pin Marking Machine - -

Semi Automatic Expanding Machine
35 - -

36 ARC Welding Machine 400 Amps Warp

37 Angle Grinding Machine 4" Bosch

38 Cylindrical Grinding Machine 350 mm Omecamate

39 Polishing / Buffing Machine - Makita

40 Bearing Pressing Facility 200 Bar -

41 DG SET 82.5 KVA Kirloskar

42 Shearing Machine Up to 6 mm -
Bhagwan Sons, Ludhiana
43 Centerless Grinding Dia 100 mm
Capable to test all locomotive fuel pump Paragon, USA
44 Test Bench for Fuel pump
Paragon, USA
45 Facility for Fuel pump Assemble -

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 8 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

6.3 Testing & plant

SN Measuring Equipment Range/Accuracy Frequency In-house/Outsourced Name of Calibration Agency

1 Yearly Outsourced Pascal Physical Laboratory

Dial Indicator 0-0.140mm
2 Yearly Outsourced Pascal Physical Laboratory
Combination Set 0-180°
3 Yearly Outsourced Pascal Physical Laboratory
Dial Vernier Caliper 0-12"
4 Yearly Outsourced Pascal Physical Laboratory
Analog Vernier Caliper 0-200mm
5 Yearly Outsourced Pascal Physical Laboratory
Analog Vernier Caliper 0-200mm
6 Yearly Outsourced Pascal Physical Laboratory
Digital Height Gauge 0-600mm
7 Yearly Outsourced Pascal Physical Laboratory
Surface Plate 630x630mm
8 Yearly Outsourced Pascal Physical Laboratory
Analog Micrometer 0-25 mm
9 Yearly Outsourced Pascal Physical Laboratory
Digital Vernier Caliper 0-300mm
10 Yearly Outsourced Pascal Physical Laboratory
Digital Micro meter 0-25mm
11 Yearly Outsourced Pascal Physical Laboratory
Digital Micrometer 25 to 50
12 Yearly Outsourced Pascal Physical Laboratory
Digital Micro meter 50-75mm
13 Yearly Outsourced Pascal Physical Laboratory
Bore Gauge 50-150mm
14 Yearly Outsourced Pascal Physical Laboratory
Bore Gauge 35-60mm
15 Yearly Outsourced Pascal Physical Laboratory
Analog Micrometer 75-100 mm
16 Yearly Outsourced Pascal Physical Laboratory
Dial Indicator 0.01-10 mm
17 Yearly Outsourced Pascal Physical Laboratory
Bore Gauge 18-35 mm
18 Yearly Outsourced Mitutoyo
Coordinate Measuring
Machine X-500,Y-700,Z-400
19 Yearly Outsourced Pascal Physical Laboratory
Analog Micrometer 100-200 mm

20 Yearly Outsourced Pascal Physical Laboratory

Analog Micrometer 200 - 300mm

21 Yearly Outsourced Pascal Physical Laboratory

Internal Analog Micrometer 50-1000 mm

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 9 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

22 Yearly Outsourced Pascal Physical Laboratory

Plunger Dial Gauge 0 to 1 mm
23 Yearly Outsourced Pascal Physical Laboratory
1 to 1 mm
Plunger Dial Gauge
24 Yearly Outsourced Pascal Physical Laboratory
Bore Gauge 6-10 MM
25 Yearly Outsourced Asian Technologies
Torque Wrench 125 Nm
26 Yearly Outsourced Pascal Physical Laboratory
Surface Roughness Tester ±80µm
27 Yearly Outsourced Pascal Physical Laboratory
Insulation Tester 500 V DC UPTO 1000V
28 Yearly Outsourced Pascal Physical Laboratory
HV Tester 0-5 KV 0-5 KV
29 1999 Micro Ohm- Yearly Outsourced Pascal Physical Laboratory
Digital Micro Ohm meter 19.99 Ohms
30 Yearly Outsourced Pascal Physical Laboratory
Digital Vernier Caliper 0 - 200 mm
31 Digital Multimeter Yearly Outsourced Pascal Physical Laboratory
Continuity Tester (2000 Milli Volt)
32 Yearly Outsourced Pascal Physical Laboratory
Dielectric Tester UPTO 1000V
33 Tensile tester for crimping Yearly Outsourced Pascal Physical Laboratory
socket 500N MAX
34 Yearly Outsourced Pascal Physical Laboratory
Steel Scale 1000 MM
35 Yearly Outsourced Pascal Physical Laboratory
DC Power Supply 5 KVA

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 10 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

6.4 Details of Sub-assemblies/Components Manufactured

a) Part I: Details of in-house manufactured (Components/sub-assemblies)

Sl.No. Item Name Drawing No

1 Inverter
2 Gear Cover Plate
3 Pump Body
4 Base Plate
5 Bearing Support
6 Shaft
7 Inverter Housing

b) Part II: Details of components/Sub-assemblies purchased from DLW/RDSO

approved vendors

Sl.No. Item Name Drawing No Approved source Name/Address of the

of RDSO/DLW source
1 Motor 11815565 DLW Paragon Products USA

2 Fasteners/Hardwares 11815565 CLW TVS/LPS Bossard

3 Bearings 11815565 DLW SKF/FAG

c) Part III: Details of items outsourced from other than DLW/RDSO approved items

Sl.No. Item Name Drawing No Name/Address of the source

1 Rotar, stator 11815565 Dahra Engineering

2 All Types of seals 11815565 MAX SPARE

3 O Rings 11815565 MAX SPARE

d) Part IV: Photos of some parts.

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 11 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

6.5 Details of Sub-vendors

Sl.No. Vendor Name Item Name ISO QAP Frequency of

Certified Approved review of the
(Yes/No) (Yes/No) performance of sublet
source
Not Applicable

Note: Following points to be taken in due consideration in providing information about

manufacturing process:
• Details of Work Instruction for each stage as mentioned in process flow chart.
• Inspection in Plant (Stage & Final)
• Bill of Material
• Stages of manufacturing should be clearly indicating that

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 12 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

• M&P and T&P required for each stage should be clearly mentioned.
• Pre manufacturing stage and after manufacturing stage inspection & testing should
be clearly mentioned along with checklist.
• Checklist should be attached with the QAP.
• Please attach ISO certificates of sub-vendors.

7 Quality Control
7.1 Quality Certification
a) ISO
b) Any other Document/certification

7.2 Calibration Plan for Testing & Measuring Equipment

a) Part I: Inhouse Testing facilities available for calibration with the firm

Sl.No. Name of Master Make Range Frequency of Traceability to

calibration national standard
All Calibration Certificates are Outsourced from NABL Approved Agencies

b) Part II : Personnel trained for inhouse calibration

Sl.No. Name Qualification Experience

Not Applicable

c) Part III: Calibration plan for the items identified for specified calibration in
STR/Specification

Sl.No. Measuring Ref. para of Range/ Frequency Inhouse/ Name of agency

Equipment STR/Spec. Accuracy Specified in Outsourced if outsourced
STR/Spec

d) Part IV : Calibration plan for other measuring equipment

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 13 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

7.3 Incoming Raw Material &In-process/Final Inspection

Stage inspection detailing inspection procedure, inspection parameters, method of
testing/test procedure including sample sizes for destructive and non-destructive
testing etc.

a) Part I: Incoming raw materials/parts/sub-assemblies

SN Incoming Sample Size & Parameters Mode of Acceptance Rejection & Trace-ability Register No.
Product/Assy. its Frequency for Inspection/ Limits/Criteria Disposal/
of Inspection Inspection Equipment /Specified Reprocessed/S
Used Value craped
1 All Casting Parts 100% Per Lot As per AS per AS per Internal Reject & Incoming Inspection
Internal drg Internal Control Plan Return to F-1/8.4C
Control Plan Supplier
2 All BOP items 100% Per Lot As per PO AS per AS per Internal Reject & Incoming Inspection
Internal Control Plan Return to F-1/8.4C
Control Plan Supplier
3 Fasteners/Hardw 100% Per Lot As per AS per AS per Internal Reject & Incoming Inspection
ares Internal drg. Internal Control Plan Return to F-1/8.4C
Control Plan Supplier
4 Bearings 100% Per Lot As per AS per AS per Internal Reject & Incoming Inspection
Internal drg. Internal Control Plan Return to F-1/8.4C
Control Plan Supplier
5 Rotar, stator, 100% Per Lot As per AS per AS per Internal Reject & Incoming Inspection
motor Internal drg. Internal Control Plan Return to F-1/8.4C
Control Plan Supplier
6 All Types of seals 100% Per Lot As per AS per AS per Internal Reject & Incoming Inspection
Internal drg. Internal Control Plan Return to F-1/8.4C
Control Plan Supplier
7 O Rings 100% Per Lot As per AS per AS per Internal Reject & Incoming Inspection
Internal drg. Internal Control Plan Return to F-1/8.4C
Control Plan Supplier
8 Bar Stock 100% Per Lot As per AS per AS per Internal Reject & Incoming Inspection
Internal drg. Internal Control Plan Return to F-1/8.4C
Control Plan Supplier

b) Part II: In process inspection (of the product)

SN Incoming Sample Size Mode of Acceptance Rejection & Trace-ability Register No.
Product/Assy. & its Inspection/Equipm Limits/Criteria/Specified Disposal/
Frequency ent Used Value Reprocessed/S
of craped
Inspection
1 All Machining 100% As per Internal As per Internal Control Plan Reject/Rework In process Inspection
items Drawing F-1/8.4F

2 Motor end plate 100% As per Internal Diameter = 151.2 mm Reject/Rework In process Inspection
assembly Drawing Thickness = 24.1 mm F-1/8.4F
Mounting Hole PCD = 129 mm
3 Motor outer 100% As per Internal Overall Diameter = 143 mm Reject/Rework In process Inspection
body and stator Drawing Inner Diameter = 139 mm F-1/8.4F
assembly Overall Height = 114 mm
4 Rotor and shaft 100% As per Internal Overall length = 128.6 mm Reject/Rework In process Inspection
assembly Drawing Overall Shaft Dia = 31.7 mm F-1/8.4F
Hole Dia = 6.3 mm

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 14 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

5 Pump Gear & 100% As per Internal Overall length = 124.15 mm Reject/Rework In process Inspection
Shaft Assembly Drawing Overall Width = 121.96 mm F-1/8.4F
Overall Thickness = 36.85 mm
Inlet & Outlet Holes distance =
71.3 mm
6 Complete motor 100% As per Internal Height = 134.62 mm Reject/Rework In process Inspection
& Pump Drawing Width = 215.90 mm F-1/8.4F
assembly Thickness of Mounting Plate=
12.70 mm
7 Inverter 100% As per Internal As per Internal Control Plan Reject/Rework In process Inspection
assembly Drawing F-1/8.4F

c) Part III: Final internal inspection of the product by the firm

SN Name of the Sample Size & Parameter for Mode of Acceptance Rejection & Trace-ability
Test/ Its Frequency Inspection Inspection/ Limits/Criteria/ Disposal/ Register No.
Process of Inspection Equipment Used Specified Value Reprocessed/
Scraped

1 Dimensional 100% As Per Internal As per Internal As per tolerances Reject/Rework Final Inspection
check Drawing Control Plan F-2/8.6
2 Final 100% As Per Internal As per Internal As per tolerances Reject/Rework Final Inspection
Performance Drawing Control Plan F-2/8.6
test

7.4 Handling of Rejected Material

• Incoming Rejection – Returned to supplier
• In process/ Final Rejection – Rework/Scrap

7.5 System for Customer Complaints/Warranty Failures

Warranty failures/In-service failures reported from customers

Classification of failure
Complaint received

Date of compliance
person deputed for

in case of warranty

C & P action taken

Failure analysis &
Date of report of

cause of failure
Brief details of

collecting field
end rejection

Whether any

Date of joint
inspection /
failure/ Call

Consignee

complaints

inspection
complaint

complaint

failure/ In

/ General
Warranty
Letter no

for joint

sample
service
Sl.No.

from

Format Noted
* The firm shall maintain a complaint register in the above format and the summary
required to be given during renewal

7.6 Details of after Sales & Service

Name of Service Engineer Location/Place Contact Detail

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 15 of 16
UP-201306
 QUALITY ASSURANCE PLAN (QAP)
ITEM Fuel Pump Motor Date: 27-02-2023
SPECIFICATION: MISC 632 REV -02 Rev. Nil

Praveen Singh Bhadouriya PU’s/Zonal railways 8532908445

8 Additional Information
• The firm can furnish any other information which they wish to submit on items other than
furnished above.

Annexure:
1. Work Instruction for each stage:
2. Inspection check sheet for:
a. Incoming material:
b. In-process/stage inspection:
c. Final material:
3. ISO Certificate:
4. Any other quality/design certification

Auto Industries
Plot No -209 & 522, Ecotech-III, UK-II,
Greater Noida Signature of Quality Head Page 16 of 16
UP-201306