G 105

INDIAN RAILWAYS

Standards
of
Infrastructure, Manufacturing, Testing and
Quality Assurance Systems

to qualify as

Railway Wagon Builder

Month/Year of Revision / Page

S.No. Reason for Amendment
issue Amendment No.
1.
May 2011 - - First issue

Price: Rs 3100/-
 G-105

CONTENTS

Clause No. Description Page No (s)

1.0 Preface 3
1.1 Scope 3–4
1.2 Procedure for certification to G 105 Standard 4–8
1.3 Procedure for re-validation/enhancement of 8–9
certificate to G 105 Standard
1.4 Midterm withdrawl of certification 9 – 10
1.5 Submission of compliance of infrastructural 10 – 11
requirements by the applicant
1.6 Amendment to G 105 and migration to the 11
amended standard
1.7 Upgradation of G 105 standard 11
Annexure I Indicative list of documents to be submitted 12
along with application for registration to G 105
standard
Annexure II Indicative Checklist for Confirmatory Audit of 13 – 15
Prospective Wagon Builders
Annexure III Infrastructure, Manufacturing, Testing and 16 – 29
Quality Assurance Requirements to qualify as
Railway Wagon Builder
Annexure IV Format of letter to be issued for Initial Audit 30
Completion
Annexure V Format of certificate to be issued for 31
certification to G 105 Standard

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1.0 Preface

The railroad industry is characterized by advancing technology and correspondingly

increasing concerns about safety, interchangeability, and cost. In this environment, it is
essential that the products and services be designed and processed so as to conform to the
requirements of the Indian Railways and that the processing be effected as economically as
practicable.

This Standard, G – 105, is issued in supersession of G-93. This standard lays down
requirements of infrastructure, manufacturing, testing facilities, quality assurance systems
and the procedure for approval as Railway Wagon Builder. The standard is also intended to
make the existing as well as the prospective private manufacturers aware of the compliance
standards they have to fulfill to achieve certification. The Standard also lays down a system
to permits growth of a certified wagon manufacturer in respect of installed capacity and
types of wagons manufactured. The Standard also takes into account the possibility of
complacency towards conformance after certification and lays down a system of continued
conformance assurance and decertification under certain circumstances.

The standard incorporates modern manufacturing processes with levels of automation

appropriate for wagon industry to promote a globally competitive wagon building industry in
India . A considerable portion of the inputs to this effect have been drawn from the detailed
deliberations done with the existing wagon builders after the quality audits done in May –
July 2010. The process of certification to this standard, including registration, initial audit,
confirmatory audit, Grant of certificate, annual verification audit , periodic re-validation and
withdrawal of certification constitute an integral , transparent part of this Standard.

A certificate issued to this Standard shall form a prerequisite for a wagon Manufacturer to
be able to participate in wagon procurement RFP and Tenders issued directly by Indian
Railways. Un-certified private wagon manufacturing works will not be permitted to
manufacture wagons for Indian Railways.

However a wagon builder holding a certificate to this standard should have supplied a
minimum of 500 wagons against Indian Railway orders or WIS/MWIS/LWIS out of which at
least 250 numbers should have been in satisfactory service for a period of one year before
being considered for regular procurement.

1.1 Scope

This standard covers the norms for objective evaluation of the Infrastructure, Manufacturing,
Testing and Quality Assurance Requirements for manufacture & supply of Railway wagons.
It also incorporates a regime of certification to this standard, including registration, initial
audit, confirmatory audit, Grant of certificate, annual verification audit , periodic re-validation
and withdrawal of certification.

1.1.1 One time provisional certification:

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As this Standard replaces earlier system of verification against STR No. G 93 (Rev 5 of Feb
2009) , a special one time provision of issuing a provisional G 105 certificate has been
included to permit erstwhile G-93 compliant wagon manufacturers who were considered
eligible for placement of regular orders against centralized wagon procurement tender of
Railway Board for the year 2009-10. A provisional G 105 certificate shall be issued by
RDSO , suo-moto, along with publication of G 105 Standard. This certificate will be valid for
a period of 18 months from the date of issue and will cover all the facilities of a
manufacturer considered G-93 compliant against the centralized wagon procurement tender
2009-10 of Railway Board. The provisional certificate will not include type and capacity
endorsement. This is a special one-time measure adopted to provide continuity and grant
sufficient time to existing wagon manufacturers to migrate to new G-105 Standards. There
shall be no extension of the provisional certificate for any reason whatsoever on any
grounds and all existing regular wagon manufacturers are required to obtain G 105
certification for each of their wagon manufacturing works, failing which, the defaulter
manufacturing works of a private wagon manufacturer shall cease to be eligible for wagon
manufacture for Indian Railways. Such defaulter wagon manufacturing works shall require
fresh certification under these Standards.

1.2 Procedure for Certification to G 105 standard

1.2.1 Introduction

i. The prospective wagon builder will apply to Executive Director Standards (Wagon), RDSO,
Lucknow on prescribed application form for registration. The prescribed application form for
registration shall be uploaded on RDSO’s website for free down load. Lump sum fees, as
indicated in the application form shall have be deposited by the prospective wagon builder
in accordance with extant instructions on the subject. Supporting Documents, as need be,
may be attached with the registration form duly self attested by the prospective wagon
builder. Separate applications are required for each separate facility manufacturing facilities,
regardless of common ownership or control of those facilities. An indicated list of such
documents is listed at Annexure I. The applicant shall be liable for truthfulness and
correctness of disclosures and submissions made to RDSO during the process G 105
certification . Any misrepresentations or frauds as defined under Indian Contract Act 1872
(latest amendment) shall make the wagon manufacturer liable for black listing and
imposition of a ban for supply of wagons for running on Indian Railways for a minimum
period of three years , extendable to five years at the discretion of Indian Railways.

ii. The prospective wagon builder shall clearly state the category of wagons for which
certification is sought viz.

a) Category I : Open/Flat/Well Wagons

b) Category II : Tank and Special Wagons
c) Category III : Covered Wagons

iii. The application shall also mention the requested manufacturing capacity for assessment
and certification in the following brackets :

a) 2 Wagons/day equivalent of 700 wagons per annum.

b) 4 Wagons /day equivalent of 1400 wagons per annum.
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c) 8 Wagon/day equivalent of 2800 wagons per annum.

The above is considering 350 working days in a year

iv. If the application form and supporting documents submitted by the prospective wagon
builder are found adequate and satisfactory by RDSO, the registration of the application for
certification to G 105 Standards shall be confirmed and the prospective wagon builder shall
be issued a letter for initial audit of the firm to the standard.

v. If the application form and supporting documents submitted by the prospective wagon
builder are not found adequate and satisfactory by RDSO; the prospective wagon builder
shall be communicated about the deficiencies and asked to address the same in a time
bound manner.

1.2.2 Procedure of Initial Audit

i. The Initial Audit will be performed for all applicants seeking fresh
certification to G-105 Standards , including those whose existing certificate
has been withdrawn or whose revalidation period has lapsed. Initial audit
will not be required for wagons builder seeking re-validation of pre-existing
G-105 certificate within permissible time limit as laid down in this Standard.

ii. The initial audit of the prospective wagon builder will be done by auditor (s)
to be nominated by EDSW, RDSO for verification of their facilities and
capabilities as per requirements of G 105. The minimum requirements
mentioned in Annexure III against an outturn of 2 wagons per day per
facility to be certified shall be the benchmark for initial audit. Auditor under
these standards will mean be one or more Indian Railway functionaries
specifically assigned by EDS (Wagon), RDSO for the purpose.

iii. The initial audit of the prospective wagon builder shall be done to verify the
compliance of the prospective wagon builder to the mandatory
requirements specified in this standard.

iv. In case, no non conformities are found during the initial audit, a letter of
initial audit completion shall be issued to the prospective wagon builder by
EDSW/RDSO.

v. In case, non conformities are found during the initial audit, a Non
Conformity Report shall be generated after the initial audit and shall be
communicated to the prospective wagon builder for rectification in a time
bound manner.

vi. Upon receipt of Action Taken Report from the prospective wagon builder, a
follow up audit shall be done on the action taken by the Auditor.

vii. In case, non conformities found during the initial audit are found have been
adequately and satisfactorily addressed during the first follow up audit, a
letter of initial audit completion shall be issued to the prospective wagon
builder by EDSW.
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viii. In case, non conformities are found during the follow up audit, a second
Non Conformity Report shall be generated & the prospective wagon builder
shall be again communicated about the same by RDSO. The prospective
wagon builder shall be asked for rectification in a time bound manner.

ix. Upon receipt of Action Taken Report from the prospective wagon builder, a
second follow up audit shall be done on the action taken by The Auditor.

x. In case, non conformities found during the initial audit & first follow up audit
are found have been adequately and satisfactorily addressed during the
second follow-up audit, a letter of initial audit completion shall be issued to
the prospective wagon builder by EDSW.

xi. After issue of letter of Initial Audit Completion, confirmatory Audits for full
certification shall be under taken, manufacturing facility-wise as described
in these Standards.

xii. In case, during the second follow up audit it is found that the non
conformities found during the initial audit & first follow up audit have been
not addressed adequately and in a satisfactory manner, the registration of
the prospective wagon builder shall be cancelled. The same shall be
communicated to the prospective wagon builder. The decision of EDSW in
this regard shall be final. In such a case, the prospective wagon builder
shall have to apply afresh after a of minimum 6 months from the date of
cancellation of registration for the specific wagon manufacturing facility,
along with the requisite fees, to RDSO in the manner prescribed in these
Standards even if certification is sought for the same facility again.

1.2.3 Procedure of Confirmatory Audit

i. The confirmatory audit of the prospective wagon builder shall be done

within 6 months of the issue of letter of initial audit completion on request of
the prospective wagon builder. In case no such request is received within 6
months of issue of letter of initial audit completion, the registration of the
prospective wagon builder shall be cancelled. The same shall be
communicated to the prospective wagon builder. The decision of EDSW in
this regard shall be final. In such a case, the prospective wagon builder
shall have to apply afresh after a lapse of at least 6 months of cancellation
of registration, along with the requisite fees, to RDSO in the manner
prescribed in these paras even if certification is sought for the same facility
again.

ii. The confirmatory audit shall be done to verify the compliance of the
prospective wagon builder to all the requirements specified in this standard,
to the extent applicable to the applicant for the manufacturing facility
registered for G-105 certification. The applicant shall be communicated the
dates of confirmatory audit at least 30 days in advance.

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iii. The confirmatory audit of the prospective wagon manufacturing facility will
be done by the auditor (s). Auditor under these standards will mean be
one or more Indian Railway functionaries specifically assigned by EDS
(Wagon), RDSO for the purpose. Items likely to be checked in the
confirmatory audit are listed in Annexure II. This is an indicative list only
and the actual audit may expand the scope of the audit depending upon the
documents submitted and results observed in previous audits.

iv. In case, non conformities are found during the confirmatory audit, a Non
Conformity Report shall be generated and shall be communicated to the
applicant for rectification in a time bound manner.

v. Upon receipt of Action Taken Report from the applicant, a follow up of

confirmatory audit shall be done on the action taken by the Auditor.

vi. In case, non conformities are found during the follow up audit, a second
Non Conformity Report shall be generated and shall be communicated to
the applicant for rectification in a time bound manner.

vii. Upon receipt of Action Taken Report from the prospective wagon builder, a
second follow up of confirmatory audit shall be done on the action taken by
the Auditor.
The prospective wagon builder may be asked, by EDSW/RDSO, to
manufacture a prototype wagon (s) (of the category/categories for which
certification is sought) to be checked and tested as per the concerned
specification by audit team during the initial audit, New entrant may be
further asked to manufacture second prototype during manufacture of the
development lot to establish maturity of manufacturing process and
adherence to quality standard. The prototypes will be tested as first article
as per laid down drawings, specification etc.

viii. In case, non conformities found during the confirmatory audit, at any stage
,are found have been adequately and satisfactorily addressed during the
first follow up audit, a certificate of compliance to G 105 standard, in the
format given in Annexure V, shall be issued by RDSO to the applicant for
the respective Wagon Manufacturing Facility. The overall capacity
mentioned in the certificate shall only be indicative.

ix. In case, during the second follow up audit it is found that non conformities
found during the confirmatory audit & first follow up audit have been not
addressed adequately and in a satisfactory manner, a notice of 3 months
shall be given to the applicant to remove all non-conformances, call for the
final follow up audit and satisfy the Auditor within the notice period. In case
non-conformities persist at this stage, the registration of the prospective
wagon builder shall be cancelled. The same shall be communicated to
the applicant. The decision of EDSW in this regard shall be final. In such a
case, the applicant shall have to apply afresh after a gap of at least 6
months from the date of cancellation of registration, along with the requisite

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fees, to RDSO in the manner prescribed in these Standards, even if
certification is sought for the same facility again.

1.2.4 Annual Verification Audits

Annual Verification Audits of the wagon builder shall be done by the auditor (s)
nominated by EDSW. Verification audits may address all or selected requirements
stated in this standard. Product audits may be conducted in lieu of or in conjunction
with verification audits at the discretion of the EDSW, RDSO. Non Conformity
Report (NCR), generated during such audits, if any, shall have to be cleared by the
wagon builder and confirmation issued to RDSO within 6 months of issue of the
NCR. Conduct of annual verification audits of the applicant under these Standards
may be entrusted by EDSW/RDSO to suitable quality auditing agencies of
international repute at his discretion.

1.3 Procedure for Re-Validation/ Enhancement of existing certificate to G

105 standard
i. G 105 certification of railway wagon builders will have a validity of 3 years (from the date of
issue) at a time, subject to annual verification audits as required, followed by re-validation.
Re-validation of certification is not automatic and can be denied if the wagon builder has
demonstrated an inability or unwillingness to resolve non-compliances. Re-validation of
certification each 3-year period will be based on past performance and having had all non-
compliances resolved.

ii. The wagon builder will apply to Executive Director Standards (Wagon), RDSO, Lucknow on
prescribed application form for re-validation at least six months before the expiry of the
certificate. The prescribed application form for re-validation shall be uploaded on RDSO’s
website for free down load. Supporting Documents, as need be, may be attached with the
re-validation form duly self attested by the prospective wagon builder. Separate applications
are required for each separate facility manufacturing facilities, regardless of common
ownership or control of those facilities. Registration for enhancement of certificate can be
done at any time during the validity by applying on a prescribed form along with supporting
documents mentioned therein.

iii. If the application form and supporting documents submitted by the wagon builder are found
adequate and satisfactory by RDSO, the prospective wagon builder shall be issued with a
letter for Confirmatory audit for revalidation/ Enhancement of G-105 certificate for the
applicant’s manufacturing facility . This letter, in case of revalidation application, along with
a copy of expired certificate , shall fulfill the requirement of “ a Valid G-105 certificate” for a
wagon builder to participate in Wagon Procurement tenders of Railway Board provided, the
firm has not been served with the letter of De-certification by RDSO.

iv. If the application form and supporting documents submitted by the wagon builder are not
found adequate and satisfactory by RDSO; the prospective wagon builder shall be
communicated about the deficiencies and asked to address the same in a time bound
manner.

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v. Enhancement of certificate for addition of capacity or an additional wagon type to an
existing certified wagon manufacturing facility may also be requested as a part of the
application for revalidation of G-105 certificate. The procedure for revalidation shall be
applicable in such cases.

vi. The procedure for re-validation / enhancement audit will be same as that for confirmatory
audits described in these Standards which shall be performed by the auditor .

vii. In case, non -conformities found during the re-validation / enhancement audit are found
have been adequately and satisfactorily addressed at any stage during confirmatory audits
for revalidation, a certificate of conformance to G 105 standard, in the format given in
Annexure V, shall be issued to the wagon builder by RDSO. The revalidated certificate shall
indicate the certificate no. and expiry date of the previous certificate and shall be valid for a
period of 3 years from the date of expiry of the previous certificate. In case of mid term
enhancement of a valid certificate, a fresh enhanced certificate will be issued with the same
date of validity as the original certificate. The overall capacity mentioned in the certificate
shall only be indicative

If the applicant is unable to remove nonconformance, process to be followed shall be

same as clause 1.2.3 (ix) but for enhancement application , a rejection of enhancement
request will be issued by EDSW/RDSO and for revalidation application ( with or without
enhancement ), a letter of De- Certification will be issued. The applicant will be given
maximum 6 months time from the date of expiry of the previous G-105 certificate to achieve
re-validation of G-105 certificate, failing which the request for revalidation of the concerned
facility will be denied and a letter of de-certification shall be issued by EDSW/RDSO.

viii. In the event de-certification, the concerned wagon builder may, if so preferred, seek a
review by submitting a request to EDSW/RDSO within 30 days of the date of de-
certification letter.

ix. In case de-certification is upheld after appeal, the prospective wagon builder shall have to
apply afresh for certification, along with the requisite fees, to RDSO in the manner
prescribed in these paras even if certification is sought for the same facility again. Such an
application can be made after a gap of at least 6 months from the date of the letter of De-
certification.

1.4 Mid Term Withdrawl of certification

i. G 105 certification of railway wagon builder may be withdrawn upon documented adverse
performance. Documented adverse performance shall include, but will not limited to:

a) Non compliance of Annual verification audit NCRs.

b) Quality rating index below stated limits.
c) Fraud or misrepresentations resulting in losses to Railways.
d) Unattended valid warranty complaints from Zonal Railways.

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ii. G 105 certification of railway wagon builder may also be withdrawn in case the entire factory
has produced no wagons continuously for a period of 12 months on account of any reason
including closure/shutdown/lock out but excluding lack of orders.

iii. In case the certificate of the wagon builder is proposed to be withdrawn, a show cause
notice shall be served by EDSW/RDSO to the wagon builder for submission of reply within
30 days from the date of notice.

iv. Withdrawal of certification shall be communicated in writing to the concerned wagon builder.
A copy shall also be marked to Mechanical, Finance and Stores Directorate of Railway
Board.

v. G 105 certification of railway wagon builder can also be withdrawn directly by RDSO in
case the wagon builder is black listed or business dealing with the wagon builder is banned
by Government of India or its offices on communication of such a ban by Railway Board. In
such a case, no show cause notice shall be given to the wagon builder.

1.5 Submission of compliance of infrastructural requirements by the

applicant:

1.5.1 Method of indicating compliance to the requirements

a) Some of the requirements apply to manufacture of specific types of wagons, as

mentioned in the respective clauses
b) The applicant shall clearly indicate the compliance of requirements by indicating YES
or NO or NA (not applicable) for the concerned wagon manufacturing facility. The
brief details of compliance shall be furnished. The reasons and brief justification for
the requirement which is not applicable shall also be furnished
c) While submitting the compliance of Annexure-III to these standards, the wagon
builder shall indicate the following details:

S.No. Clause of G 105 Brief Status of Details of

description of Compliance Compliance
the requirement YES/NO/NA

d) A summary shall also be given by the wagon builders as below:

S.No. Total Fully

Category requirements complied
1. Mandatory
2. Others

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1.5.2 Requirements

The prospective wagon builder must fulfill the requirements as listed in Annexure-III, to the
extent applicable (depending upon the type of wagon proposed for manufacture).

1.6 Amendment to G 105 and migration to the amended standard

The amendment to this standard, if any, in the future shall be serially numbered. Normally
18 months time shall be given to the wagon builders to migrate to the amended Standards
which shall normally be checked through Annual Verification Audits and Revalidation audits.
All new certifications will only be done to the prevailing current version of the G-105
Standards. Amendments to the standard shall be issued after approval of Railway Board.

1.7 Upgradation of G 105 standard

The Railways have recently entered in to a consultancy contract for developing many other
things procedures and standard for wagon manufacturing and quality assurance. The
outcome of these measures will lead to further upgradation of these standards.

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Annexure I

Documents/formats to be submitted by the prospective wagon builder

(with proper index and each page having numbering in the format ‘x of y’)

1. Organization Chart
2. Quality Control Organization Chart
3. Name, Qualification & Experience of Key Personnel of Quality Control Organization
4. Description of Quality Control of raw material, free supply items, bought out items, tooling, jigs,
fixtures, templates, dies, cutting, welding, riveting, shot blasting, painting, etc.
5. Compliance Status of G 105 Requirements (Separately for Mandatory and Others) with
Description, Quantity, Machine No, Identification Number, Make, Capacity, Year of
Commissioning, Status (working/not working), Ownership & Calibration Status.
6. Calculation of manufacturing capacity of the facility
7. List with description, quantity, identification number, make, year of
manufacturing/commissioning, calibration frequency and calibration status of following:
a. Drilling jigs b) Welding fixtures, c) Marking templates, d) Profile Templates, e) Forging
dies, f) Gauges
8. Procedure of Calibration of M& P, tools, equipments, jigs, fixtures, templates, etc.
9. Production Flow Chart
10. Sequence of Operations with list of components in the format containing following columns (it
should include all components of an assembly/sub-assembly):-
a) Name of Assembly/Sub-assembly/Component
b) Nos. required per Wagon/Assembly/Sub-assembly
c) In-house or Bought Out
d) Grade of Material
e) Dimensions of sheets (L X W x H/T)
f) Approx. Weight (in Kg)
g) Acceptance Criteria/Tolerance
h) Operation performed
i) Done by (means)
j) Sample size of Internal Inspection
k) Frequency of internal inspection
11. List of bought out items.
12. List of shop made components
13. Inspection formats
14. List of welding personnel, along-with their qualification & experience
15. Format for checking of welding equipment
16. Procedure of purchase of components
17. Procedure of removal of non-conformities
18. ERP Capabilities Details
19. Customer complaint redressal system:
a. Key person responsible for complaint redressal (Give contact No. also).
b. Complaint redressal mechanism.

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Annexure II
Indicative Checklist for Confirmatory Audit of Prospective Wagon Builders
In addition to verifying the facilities mentioned in Annexure III, as applicable to the prospective wagon builder, the following would also be checked during the
confirmatory audit:
1. Management and Line Supervision Status of the firm
1.1 Does wagon builder’s quality assurance policy indicate recognition of separation of
responsibility for production and quality control supervision functions?
1.2 Does the organization chart clearly show lines of plant management authority and
responsibility down to principal plant departmental supervisors?
1.4 Are assigned personnel for key positions in manufacturing qualified by training and
experience?
1.5 Are supervisors qualified by experience and/or education or training programs?
2. Specifications
2.1 Are there adequate procedures to ensure that obsolete drawings and documents are destroyed
or isolated from use?
2.2 Are there adequate procedures for distributing new and revised drawings to the shop force?

2.5 System for raw materials inspected upon receipt and marked for permanent identification?
2.6 System for all other purchased materials (wheels, brakes, castings, etc.) checked for
conformance with the purchasing document upon receipt?
2.8 System for raw material test reports kept on file?
2.10 Marking system that ensures the intended application of material cut from larger pieces?

3. Welding, Fabrication, and Construction Practices

3.1 Does the facility have a welding technician or an outside expert available on call to perform
welding tests and resolve welding questions?
3.2 Does the person have the authority to control welding procedures in the shop?
3.3 Does this person control and/or “police” the setting of welding machines?
3.4 Are welders, welding operators, and welding procedures qualified per IS Specification latest
revision?
 G-105

3.5 Is there a record of welder and welding operator qualifications?

3.6 Are welds and procedures acceptable under the provisions of RDSO’s latest WPS ?

3.7 Are electrode wire, and gas shield properly stored and identified?
4. Quality Control
4.1 Does the quality control organization include a quality control supervisor who can demonstrate
an adequate knowledge of the car construction process?
4.3 Is there an in-process inspection procedure to ensure that the car is properly fabricated and
assembled?
4.4 Does Quality Control have authority to stop and responsibility to inform operating supervision
of nonconforming work?
4.5 Are there adequate procedures for correcting nonconforming material or work in process
rejected by Quality Control forces?
4.7 Are there adequate procedures for the inspection of purchased material and manufactured
items?
4.9 Are contract specifications and special provisions in the Quality Control file?
4.11 Do all wagons receive an adequate final inspection, and is a record kept of this inspection?
4.12 Is there office space for outside inspectors?
4.13 Are there procedures for liaison with outside inspectors?
5. Facilities
5.1 Does the wagon builder have a mechanism to simulate minimum curve requirements?
5.2 Does the wagon builder have possession of weighbridge with valid calibration by weight and
measures department of the concerned state government?
5.3 Does the wagon builder have designated level track for adjustment of side bearings and
coupler height?
5.7 Is there proper storage for paint and brake components, particularly valves, cylinders, and
pistons?
6. Operations
6.1 Are grade of material and marking verified prior to fabrication?
6.2 Is raw material blocked and handled to prevent permanent distortion?
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6.3 Does the facility have yard space, handling, and other equipment to store and handle
materials?
7. Test Devices
7.1 Does the wagon builder have brake force measuring devices available?
7.3 Does the wagon builder have a single car test device?
7.4 Is the single car test device tested in accordance with the latest RDSO requirements?
7.5 Are torque wrenches periodically calibrated?
8. Maintenance of Equipment
8.1 Is there an adequate plan for the systematic maintenance of equipment?
8.2 Are the equipment and tools periodically inspected and restored to intended tolerance?
8.3 Are welding machines periodically checked to ensure correct amperage and voltage readings?
9. Engineering and Drafting
9.2 Do personnel have an adequate knowledge of the applicable codes and specifications?

9.3 Is there a current reference library of specifications, including the latest revisions of all relevant
RDSO/IS/AAR/UIC codes/manuals
9.6 Is a current list of design and shop detail drawings with latest revisions maintained?
9.7 Are copies of approved special procedures, in addition to welding, furnished to quality control
and production supervisors?
9.10 Does the wagon builder have access to engineering testing support facilities? A list of major
testing equipment should be provided.

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Annexure III
Infrastructure, Manufacturing, Testing and Quality Assurance Requirements to qualify as Railway Wagon Builder

1. General Requirements

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
a) The wagon building works must be served by a Railway Mandatory Yes Yes Yes
siding connected to a Railway station or Railway yard to
facilitate easy movement of the freight stock from/to the
manufacturing unit.
b) Siding Connection to a Railway station or Railway yard Mandatory Yes Yes Yes
should be ready and approved by Railways for movement
of the freight stock from/to the manufacturing unit.
c) The wagon building works should have a fully Yes Yes Yes
computerized system for real time maintenance of records
encompassing all activities of wagon manufacturing
including receipt and consumption of free supply items,
bought out items, shop made items, sub-assemblies
manufacturing, wagon assembly, customer complaint
redressal, staff details, traceability, etc. An ERP package
shall be preferred
d) Arrangements for un-interrupted power supply for running Mandatory Yes Yes Yes
important M&Ps and testing equipments should be
available
e) The facility for which certification is sought should be Yes Yes Yes
certified ISO 9001 (latest edition) for the entire range of
manufacturing, testing and quality assurance activities.
f) Wagon building works must have ISO 14001 certification Yes Yes Yes
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S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
g) The wagon builder must have a quality assurance plan Mandatory Yes Yes Yes
covering the items listed in Annexure III
h) Wagon Builder should have a website on which information Yes Yes Yes
related to various types of wagons manufactured with
individual numbers in past years should be available. It
should have facility to log customer complaints with
automatic generation of customer complaint ID. The web-
site should also have provision for free flow of information
between Railway Board, RDSO, Wagon Builders and
Zonal Railways
2. Infrastructural Requirements
S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon
Requirement outturn/day outturn/day outturn/day
a) Covered bay area served by EOT Cranes should be Mandatory 2000 m2 4000 m2 7500 m2
available for manufacture of sub assemblies and assembly
of Wagons.
b) Height of covered area in the assembly bay served by EOT Mandatory Yes Yes Yes
cranes should be such that the cranes while carrying a
completely assembled wagon (minus bogies) should be
able to travel over another assembled wagon resting on
the assembly jig or on its wheels/bogies on the floor.
Alternately: The width of covered assembly bay should be
such that a completely assembled wagon without bogies
may be carried by the side of another assembled wagon
resting on assembly jig or on its wheels/ bogies on the floor
using the EOT cranes available in the bay
(In case and as applicable to the layout of the works)
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 G-105

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
c) A separate dispatch line of length for holding at least one Mandatory 160 m 320 m 600 m
week outturn for inspection and testing of wagons
(dispatch line) by purchaser’s inspecting Engineers should
be provided. The complete dispatch line should be served
by facilities for air brake testing
d) The dispatch line should be provided with a pit of the Mandatory Yes Yes Yes
length of minimum 20 meter length with proper drainage
and lighting.
e) The premises should have covered storage area to store Mandatory 200 m2 300 m2 500 m2
for two months requirement of components/sub-assemblies
such as air-brake equipment, coupler, draft gears, cartridge
bearings, and other bought-out components etc, which are
likely to deteriorate if stored in open.
f) There should be open/covered storage area at adequately 800 m2 1500 m2 3000 m2
higher level than the surrounding area to prevent the
damage to stores from rain water/flooding for storing two
months requirement of steel, bogies etc.
g) Covered storage area for wheel sets should be provided Mandatory 200 m2 300 m2 500 m2
with a single track or multilevel track for wheel parking.
Alternatively, wheels can be parked in specially
constructed racks well protected from possibility of
damage.
h) Separate work areas for fabrication of stainless steel (IRS: Yes Yes Yes
M44) wagons should exist
i) Separate storage area for stainless steel (IRS: M44) Yes Yes Yes
should exist.

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 G-105

3. Machinery & Plant Requirements

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon
Requirem outturn/day outturn/day outturn/day
ent
a) In case and as applicable to the wagon lifting layout of the works, Mandatory Yes Yes Yes
each covered assembly bay should be served by at least a
minimum of 2 EOT cranes, each of minimum 10 T capacity, or at
least one minimum 20 T capacity crane with suitable lifting tackles
so as to avoid any damage to wagon body while lifting
b) Each sub- assembly bay should be served by at least 2 Nos EOT Mandatory Yes Yes Yes
cranes of minimum 3 T capacity
c) The steelyard (the open/covered area for storage of steel, wheel Mandatory Yes Yes Yes
sets, bogies coupler, draft gears etc) should be served by one
EOT/Portal of minimum 5 T capacity or a mobile crane of
minimum 5 t capacity.
e) The following material handling equipments in adequate number Yes Yes Yes
should also be provided:
i. Forklifts of minimum 2 T capacity and/or Diesel/Battery
operated platform of minimum 2 T capacity or suitable
equivalent arrangement.
ii. Diesel/Battery driven shunting locomotives or loco pulsar
or suitable power winch or tractor with suitable
attachment.
iii. Traverser, wherever the layout demands its requirement.
f) Electrically driven compressors capable of FAD Capacity of about Mandatory Yes Yes Yes
30 cubic meters/minute at a Pressure of 7 bars for every one
wagon outturn per day should be provided.
g) MIG/MAG Welding Machines should be available. Centralized Mandatory 8 15 20
supply of gas for these machines should be in place, preferably.

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 G-105

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirem outturn/day outturn/day outturn/day
ent
h) Robotic Welding Facilities should be provided for manufacture of Yes Yes Yes
sub-assemblies like side walls and end walls for the wagon
production
i) One set of submerged arc-welding equipment of 1200 A rating Mandatory Yes Yes Yes
should be provided.
j) Powered mechanized welding manipulator and fixtures to Mandatory One Set One Set Two Sets
ensure down hand welding for relevant type wagon should be
provided for the following:
i) Under frame
ii) Body Side Arrangement
iii) Body End Arrangement
iv) Sub Assemblies
v) Main Assembly (Both boxing and welding manipulator
k) Under frame fixture and at least 50% of other fixtures should have One Set Two Set Three Set
hydraulic /or pneumatic clamping arrangement. In remaining
fixtures, all the critical locators/stopper faces of fixture should be
machined to achieve better accuracy, instead of gas cutting. Also,
stoppers and locators should be screwed (or) bolted instead of
being tack welded for achieving better alignment and accuracy
l) CNC Plasma/Water jet profile Cutting Machines Mandatory One One Two
m) CNC or a Gang Drilling Machines with minimum 2 drilling- Mandatory One One One
heads of 38 mm capacity for sole bar & centre sill with minimum
15m long gang-drilling bed suitable for holding centre sill & side .

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 G-105

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
n) One CNC press brake of adequate capacity should be One One One
available
o) Equipment for straightening channels and angles to bring Mandatory One One One
them within the tolerance limit laid down in IS: 1852 and
capable of achieving the camber (if applicable).
p) Cold power saw for cutting structural members. Mandatory One Two Four
q) PLC controlled Multiple Roller Type Plate Straightening Mandatory One One One
machine of 2.5 m x 12 mm capacity.
r) Plate Rolling machine 2.5m or more x 3.15 mm or higher Mandatory One One One
capacity.
s) CNC Shearing Machine of capacity 16 mm x 2.5 mm or Mandatory One One One
more
t) Portable edge preparation machine Mandatory One Two Four
u) Laser collimator with digital reading and recording for Mandatory One One One
measuring the camber and alignment.
v) Semi/fully automatic Shot Blasting Machine with auto shot Mandatory One One One
reclamation, capable of giving finish up to Sa2-1/2
w) Lock Bolting Machine Mandatory Four Eight Twelve
x) A hydraulic press of a capacity of 300 Ton should be Mandatory One One One
available (Applicable for Hopper Wagons only)
y) Six sets of Measuring instruments, gauges (weld gauges, Mandatory One Kit Two Kits Four Kits
dimensional gauges), etc. in kit form, for three wagon
outturn per day should be available Measuring instruments
should have provision of digital readout, to the extent
possible.

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 G-105

4. Testing & Measurement Requirements

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
a) The Wagon manufacturer shall have necessary Mandatory Yes Yes Yes
infrastructure for conducting load test as per the
requirement stipulated in particular and general
specification of the wagons. For this purpose, availability
of a stretch of perfectly level track is essential.
b) The manufacturer shall have the facilities for conducting Mandatory Yes Yes Yes
curve test on pattern wagon under frame as per the
general specification, inspection procedure. For this
purpose, the minimum curve of 152m for Broad or
simulation thereof is essential.
c) Facilities (as per RDSO’s latest drawings) for carrying-out Mandatory Yes Yes Yes
shower test to ensure water tightness of the Wagon
should be provided (applicable only to covered wagon
manufacturer).
d) The facilities for discharge test for Hopper Wagon should Mandatory Yes Yes Yes
be available (applicable only to Hopper Wagon
manufacturer).
e) The facilities for air assisted discharge test for covered Mandatory Yes Yes Yes
wagons suitable for carrying bulk commodities should be
available (applicable only to bulk cement/fly ash
wagons).
f) The firms should have Squeeze load test rig for giving Mandatory Yes Yes Yes
squeeze load up to 450 tonnes
g) Facility for measuring Brake Block force simultaneously Mandatory Yes Yes Yes
in one complete wagon with automatic recording should
be available
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 G-105

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
h) The Wagon builder should possess within his Works Mandatory Yes Yes Yes
electronic weigh bridge facilities with printing
arrangement suitable for weighment of a complete 8 –
Wheeler Bogie loaded 170 MT at a time.

5. Additional requirements for Tank Wagon Manufacture

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
a) Clearance of Chief Commissioner of Explosives should be Mandatory Yes Yes Yes
available for the tank wagon manufacturing facility.
b) All tank wagon manufacturers must have proper facility for Mandatory Yes Yes Yes
calibration of tank barrel. The facilities must have
approval of Central Tank Wagon Calibration Committee.
The bulk flow meter used for this purpose must be duly
certified and sealed by the inspector of Weights and
Measures.
c) The tank wagon manufacturer should either have in- Mandatory Yes Yes Yes
house facilities for radiographic examination, ultrasonic
examination and Dye penetration for testing welds or
should have a permanent arrangement from an
BARC/NABL (as the case may be) approved Source
d) The wagon builder who would manufacture pressure tank Mandatory Yes Yes Yes
wagons for carrying LPG, Liquid Ammonia, etc., must
provide the facilities for stress relieving of the barrels in
accordance with para-12 of IS: 2825.

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 G-105

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
e) Length of furnace for stress relieving should be adequate Mandatory Yes Yes Yes
enough to place full barrel and should have uniform
heating zones & automatic temp recording facilities.
f) Suitable facilities for forming of dished ends for tank Yes Yes Yes
barrels should either be provided in house

g) The tank wagon manufacturers should have Mandatory Yes Yes Yes
hydraulic/pneumatic test facilities for testing of the barrel
up-to the pressure specified in the particular
specifications.
h) Sub-merged arc welding machines provided with welding Mandatory Yes Yes Yes
booms & mechanical/ motorized rotators should be
available.
i) A facility to check the barrel / barrel plates by ultrasonic Mandatory Yes Yes Yes
test as per specified ASTM after its manufacture should
be available (this is applicable for BTPGLN Wagons only).
j) It has to be ensured that a system exist for testing of LPG Yes Yes Yes
dome fittings. Method of certification should be suitably
documented.
k) It has to be ensured that suitable stands and gantry are Mandatory Yes Yes Yes
available for attending to diaphragm plates fitted with
pipes and LPG dome fittings.
l) Plate rolling machine of the capacity up to 2.5 m or above Mandatory Yes Yes Yes
x12 mm should be available

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 G-105

6. Facilities for mounting of cartridge/roller bearings

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
a) A separate covered shed protected from dust ingress and Mandatory Yes Yes Yes
connected to wheel storage parking line by a Railway
track should be provided for pressing of cartridge/ roller
bearings on axle journals.
b) Dust proof CTRB mounting room . Mandatory Yes Yes Yes
c) Ensure that a system exists for protection of bearings and Mandatory Yes Yes Yes
grease drums to prevent ingress of dust /moisture.

7. Design infrastructure Requirements

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
a) A design office equipped with relevant computer hardware Yes Yes Yes
and softwares and competent personnel for handling the
manufacturing drawings of wagons. Personnel should be
able to fully understand the drawing, pinpoint deficiency
and make changes, if required, make process sheets for
manufacturing, make master list of parts, etc. The drawing
office must be equipped with latest issues of all drawings
and specifications (Railway, National and International)
which may be required for manufacture of wagons in
question.

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 G-105

8. Material Management Requirements:

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
a) ERP implementation at the wagon builder must include all Yes Yes Yes
stages of stores/purchase activities including purchase,
receipts and storage, consumption of raw materials,
bought out items, consumables, documentation such as
purchase orders, inspection certificate, test certificate
b) Ensure that a system exists for approval of vendors for Mandatory Yes Yes Yes
bought-out item.
c) A system to monitor that the items required to be Mandatory Yes Yes Yes
purchased from RDSO approved sources. are purchased
from such sources only. Also, system of timely updation of
list of RDSO approved sources should be in place
e) A computerized system should be available to monitor Yes Yes Yes
use of free supplied items and other major items such as
bogies, coupler assemblies, wheel sets, etc., and it should
be linked with wagon out-turn ground balance to exercise
suitable control.
9. Laboratory facilities

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
a) Laboratory facilities for the following must be provided: Mandatory Yes Yes Yes

i) Chemical Composition of Steel either by in house

spectrometer or through a NABL approved source.
ii) Universal testing machine
iii) Hardness testers
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 G-105

iv) Impact testing machine

v) All gauges & measuring instruments are to be
calibrated periodically as per ISO norms.
Digital/Dial elcometer min. 2 numbers for measuring
thickness of paint.
b) Radiographic Testing facility should be available either in Mandatory Yes Yes Yes
house for which:
i) Dark room facility shall be available.
ii) Camera for Radiographic test shall be available.
iii) Drying arrangement shall be available.
iv) Inspecting staff conducting the radiographic testing
is adequately trained and qualified by the
appropriate agency and has adequate experience.

Alternatively, there must be an arrangement with an

authorized outside agency.

10. Quality Assurance Requirements

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon
Requirement outturn/day outturn/day outturn/day
a) Periodicity of training of Engineers/Supervisor/Skilled Yes Yes Yes
Workers involved in Wagon manufacturing should be laid
down, along-with syllabus and training place for each
category. Implementation of prescribed training be
monitored on Quarterly basis
b) Welding Engineer should be requisite experience. Yes Yes Yes
Welding Supervisors should be qualified and certified by
approved/ recognized welding institutes/ test houses.
Role and duties of Welding Engineers and Welding
supervisors should be clearly defined.
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 G-105

S.No. Requirement Nature of 2 wagon 4 wagon 8 wagon

Requirement outturn/day outturn/day outturn/day
c) All welders must be qualified and certified by approved/ Mandatory Yes Yes Yes
recognized welding institute/test house.
d) Ensure that a system exists to test the welders as per Mandatory Yes Yes Yes
requirements of IS: 7310 and IS: 817 and proper records
are maintained
e) The training facilities to test the welders shall be available Yes Yes Yes
as specified in IS: 817. If such facilities do not exist in-
house training certificate from recognized training institute
should be obtained.
f) Quality Control Records must be maintained as per Yes Yes Yes
guidelines given in the latest issue of IRS: G-72.
g) A well defined documented system of internal check of Yes Yes Yes
wagons including work in progress stage must be
available.
h) Wagon builder should have Quality Control Inspectors for Yes Yes Yes
internal check
i) Record of inspections done by Quality Control Personnel, Yes Yes Yes
investigation done and corrective action taken should be
well documented
j) Customer complaint redressal system to be in place Yes Yes Yes
k) Outsourcing in Wagon Manufacturing Activities Yes Yes Yes
i) Wagon builder can outsource certain activities of
wagon manufacturing, in following ways:-
• Activities to be carried out in the premises of
Wagon Builder- called Type “A”
• Activities to be carried outside the premises of
Wagon Builder- called Type “B”
ii) For both types of outsourcing prior permission of
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 G-105

RDSO, Lucknow is to be obtained

Respective requirements laid down for M&P, Infrastructure,
personnel, work methods for wagon manufacturing will
have to be complied with for the outsourcing.
l) Wagon builder should have proper system of settlement of Yes Yes Yes
warranty claims. Position in this regard should be readily
available and it should be scrutinized periodically at the
appropriate level.

11. Use of components like Bogie, Air Brake System, Couplers etc during wagon manufacturing

S.No. Requirement Nature of 2 wagon 4 wagon 8wagon

Requirement outturn/day outturn/day outturn/day
a) During wagon manufacturing, provision of components Mandatory Yes Yes Yes
like Bogie, Air Brake System, Couplers etc during wagon
manufacturing shall be done as per extent instructions of
Railway Board/RDSO on the subject.

A record of procurement, fitment and traceability must be

kept by the wagon manufacturer.

b) In case a wagon builder is manufacturing simple wagon

components for internal consumption, they need not be
subjected to minimum order quantity (Part I /Part II vendor
approval regime applicable to such components) for their
own use provided they have obtained explicit approval of
RDSO to manufacture such components. The list of such
components will be decided by RDSO.

29/31
 G-105
Government of India Hkkjr ljdkj & jsy ea=ky;
Ministry of Railways vuql/a kku vfHkdYi vkSj ekud laxBu
Research Design & Standards Organisation ekud uxj ] y[kuÅ & 226011
Manak Nagar, Lucknow – 226 011
VsyhQksu % (0522) – 2465165
QSDl % (0522) – 2452494
[email protected]

No. : Dated :

M/s ------------------------------------------
------------------------------------------------
------------------------------------------------
------------------------------------------------

Sub : Initial Audit of your works at ---------------------------------- for

compliance to G 105 Standard
Ref : 1.
2.

In terms of letters refereed at above and initial audit of your works at ---------------------
------------- conducted on -------------------- followed by follow up audits conducted on -------------
------ & ----------------------, the non conformities communicated vide this office’s letters no. -----
------------------------ dated ----------------- & --------------------- are found to be adequately and
satisfactorily addressed.

In view of the above, the Initial Audit of your works at ---------------------------------- for
compliance to G 105 Standard is considered as completed.

Kindly advice your readiness for confirmatory audit within six months of issue of this letter.

(----------------------------------)
Executive Director Standards (Wagon)

Copy:
1. EDME (Freight), Railway Board, Rail Bhavan, New Delhi – 110 001

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 G-105

GOVERMENT OF INDIA – MINISTRY OF RAILWAYS

RESEARCH DESIGN & STANDARDS ORGANIZATION
MANAK NAGAR, LUCKNOW – 226 011

THIS CONFIRMS THAT

M/s ---------------------------------------------- WORKS AT: ---------------------------------------------------------------

HAS MET THE REQUIREMENTS OF INFRASTRUCTURE, MANUFACTURING, TESTING AND QUALITY ASSURANCE
FOR MANUFACTURE OF RAILWAY WAGONS AS SPECIFICED IN THE STANDARD G – 105 OF APRIL 2011

S.No. Category Manufacturing Capacity ( Wagons/month)*

1 I (Open/Flat/Well Wagons)
2 II (Tank and Special Wagons )
3 III (Covered Wagons)

CERTIFICATE NUMBER : -----------------

CERTIFICATTION DATE : -----------------
EXPIRATION DATE : ----------------- APPROVED : -----------------------------------------------------------
EXECUTIVE DIRECTOR STANDARDS (WAGON)

Note: * The overall capacity mentioned in the certificate shall only be indicative.
31/31