2. INTRODUCTION
Spring Karkhana is the Largest and dedicated plant for helical hot
coiled Spring for IR Rolling Stock.
Manufactures 75000 springs (3000MT) per annum.
Renovates in under…………………………..
Purpose -To cater the increasing need of quality Coil springs for
switchover from Laminated Springs.
2
4. 4
Manpower:- 460 sanctioned.
Initial Investment:- Rs. 120 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:- 30 hectares
Shop covered area:- 6400 sq. m
Administrative building area:- 1800 sq. m
Nos. of Quarters:- 90
Associated infrastructure facilities:- 03 Nos. of Sub-Stations
SALIENT FEATURES OF RSK
5. 5
QUALITY OBJECTIVES
• Compliance to production and dispatch target
of 75000 springs for the year 2018.
• Minimize the “in house rejection” of springs to
6.5%.
• Improve skill and knowledge of the
employees.
6. 6
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.
8. BUDGET AT A GLANCE
Reference Taken From Existing Plant (Rsk)
(Estimated price in lakhs of INR.)
Civil :400
Electrical :500
Mechanical:7000
Meslenious:1000
8
9. 9
MACHINERY & PLANT
Walking Beam Bar End heating Furnace
End tapering machine
Walking Beam Bar heating furnace
Coiling machine
Quenching machine
Tempering furnace
Hardness testing machine
End face grinding machine
36. TYPES OF SPRINGS
36
From To From To From To From To From To From To From To
1 001 01 006 001 00 BG/ AXLE A 01 33.5 4230 6.75 5.25 175 360 30.2 2038 281 289 281 283.7 >283.72 286.3 >286.3 289 2832 251 261 3400 229 242 3954 213 216
2 001 05 002 001 00 BG/BOLSTER B 01 42 4457 5.75 4.25 218 385 49.8 3330 304 312 304 306.7 >306.7 309.3 >309.3 312 5292 255 268 6350 229 244 6794 225 228
3 013 01 202 001 00 WTAC/AXLE A 03 33.5 4230 6.75 5.25 175 375 30.2 2694 271 281 271 274.3 >274.3 277.7 >277.7 281 3053 257 269 3664 234 247 4370 213 216
4 013 05 202 001 00 WTAC/BOLSTER B 03 42 4529 6.25 4.75 200 400 50.5 4815 294 304 294 297.3 >297.3 300.7 >300.7 304 5534 278 290 6641 253 267 7271 246 249
5 083 01 002 001 00 DC/E/T/AXLE H 25 38 3567 5.75 4.25 170 304 32.7 1575 275 278 275 276 >276 277 >277 278 3280 243 249 3936 230 237 5598 203 206
6 087 01 203 001 00 DC/EMU/M 2/AXLE H 07 40 2977 4.7 3.2 175 250 28.5 3005 212 216 212 213.3 >213.3 214.7 >214.7 216 4199 197 202 5249 183 190 6399 172 175
7 089 01 024 001 00 AC/E/M/AXLE K 10 40 3350 5.25 3.75 175 284 33.9 3009 239 244 239 240.7 >240.7 242.3 >242.3 244 4303 220 226 5164 207 215 6303 194 197
8 180 05 001 001 00 DE/TC/B/INN G 87 27 4227 9.5 8 119 400 19 1832 313 321 313 315.7 >315.7 318.3 >318.3 321 1979 305 314 2375 287 298 3351 246 249
9 180 05 001 002 00 DE/TC/B/OUT G 88 41.5 4515 6.5 5 190 400 47.9 4105 313 321 313 315.7 >315.7 318.3 >318.3 321 4433 305 314 5319 287 298 7165 253 256
10 1269513 Fiat secondary inner F19 34 6230 8.3 6.8 212 663 44.4 2576 463 468 3104 3275
11 1269514 Fiat secondary Outer F18 50 7410 6.6 5.1 318 707 114.22 4798 507 512 5783 6101
12 1268836 Fiat Gen2 secondary Outer F16 55 7870 7 5.5 317 702 146.79 6043 510 515 7098 8337
13 1268837 Fiat Gen2(2) secondary F17 37 6280 8.5 7 206 658 53.01 3489 466 471 4098 4813
14 1277145 Fiat Gen1 secondary Inner F15 38 6425 8.7 7.2 205 664 57.2 3948 463.5 468.5 4029 4062
15 1277146 Fiat Gen2 secondary Outer F14 57 7855 7 5.5 315 708 157.36 7294 507.5 512.5 7443 7503
16 1267412 FIAT Chair Car Pri. Inner F02 26 3175 7.6 6.1 112 324.5 13.23 1737 260 264 1902 2177
17 1267411 FIAT Chair Car Pri. Outer F03 38 3640 5.6 4.1 181 324.5 32.4 2950 260 264 3231 3696
18 1277143 FIAT Generator car Pri. Inner F04 27 3300 7.9 6.4 111 337 14.83 2692 248 252 2967 3021
19 1277142 FIAT Generator car Pri. Outer F05 40 3800 5.8 4.3 179 337 37.48 4829 248 252 5322 5419
20 LG01101 FIAT GS Pri. Inner F06 27 4240 7.7 6.2 111 313 14.5
21 LG01100 FIAT GS Pri. Outer F07 40 3690 5.6 4.1 179 313 36.4
22 LG05100 FIAT GS Sec. Inner F08 36 6530 8.75 7.25 209 593 52.18
23 LG05101 FIAT GS Sec. Outer F09 55 7365 6.5 5 321 637 137.37
Inner. DIA
TARE
LOAD (in
Kgs)
Permissible Height
at Tare Load
Springs for FIAT design Bogies
Springs for ICF design Bogies
GRD. BAR
DIA (MM )
(without
scaling
allowance)
DRG. No. DESCRIPTION CODE 2 Wire 3 Wire
428
SPRING
WEIGHT
CUT
LENGTH OF
BAR
Total No.
OF
COIL
No. OF
Effective
COIL
Permissible Height at Tare Load
SPRING DATA (Revised Dtd: 09.10.14)
Sl.
No.
Shock Load
(in kgs)
Gross Load
(in kgs)
Home Load (in
kgs)
FREE
HEIGHT
Permissible
Height at
Shock Load
Permissible Height
at Home Load
Permissible
Height at Gross
Load
1 Wire
248.6
472
482.5
438.5
508.5
464.5
258.2 189.8
258.2
243.3
243.3
415
459
444.2
400
462.9
506.9
268.6
310
316.2
300
315.4
376.2
201.4
205.2
220
NOTE: The above data are indicative only. The respective Spring drawings shall be referred for authenticity.
248.6
241.6
241.6
37. RANGE OF SPRINGS & RAW MATERIAL
1. Major Parameters
1.1 Bar diameter 20 to 65 mm
1.2 Bar
length
2500 to 10,200 mm
1.3 Outer diameter of
spring
100 to 450 mm
1.4 Free height of
spring
200 to 950 mm
1.5 Number of
coils
3 to 12
1.6 Weight of
spring
200 Kg (Maximum)
1.7 Productivity Shall be tested on B01
type springs
37
52Cr4Mo2V For larger dia above 33 mm.
60Si7 For smaller dia below 33 mm up to
16 mm
MATERIAL
38. QUALITY ASSURANCE
Needs 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. 38
39. THESE ARE ALSO REQUIRED
FOR THE PLANT
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
39
40. 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.
40
41. NEED S PRODUCTION AS PER
CONTRACT
About 75,000 springs produced per year
covering all types of springs as listed
above.
Set-up of Phosphating plant to reduce
corrosion.
Re-conditioning of important machines.
Spring production cost is less than
market.
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42. INVESTMENT PLANS
Additional infrastructure for manufacture of springs-
sanctioned.
Replacement of old and obsolete machines of existing
production line sanctioned.
Planning of new Bolster (B01) wagon spring production Line.
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44. ASSISTANCE REQUIRED
• Communication: more and better Rly
phones.
• Mobile phones.
• Security.
• More delegation for machine repairs.
• Approach road without railway
crossing.
44
