Inspection Matrix RPR5MA7

Project: PACIFIC NATIONAL\MOURA LOCO Customer: DEDIR Model: RPR5MA7 Section Responsible & Number Of Defauts Total Defect Qty Electrical Panel Asssembly & Refrigiration Sheet Metal Sheet Metal
8 15 14 37 37 74 17 76

Defalt No

Items Inspected On Units

Inspection: Each Unit Electrical

Finishing

Finishing

Electrical

Test Bay

Serial Numbers: 35341 - 008 ... 35341 - 028

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Cable ties not trimmed Sharp edges in accessible areas Damaged coil fins Electrical Enclosure Lids tight Pipe Spacing prevents rubbing/wear Wires/Cables rubbing or wearing Grills not fully welded Cable glands loose Missing Washers Major components/structures not witness marked Cover Hinge pins not correctly installed & witness marked Loose bolts/screws Debris in unit Checklists not completed/signed Sharp weld spatter EMKA seal joints glued with Loctite Position and security of TX Bulbs Pipe quality no wrinkles, etc Insulation not sealed/damaged/well affixed Application of sealant is presentable Significant case/cover scratches Other TOTAL FAULTS BY DEPARTMENT 2 3 6 3 1 3 2 8 4 4 2 2 1 5 5 1 3 2 1 5 5 1 3 3 3

Asssem

bly & Electric

Electric Finishi

Metal Test

ng Sheet

3 5

2 2 1 1 3 23 1 21 1 1 1 1 13

8 3 6 0 3 0 1 7 4 21 0 14 5 15 2 0 0 2 4 0 2 7 104

008-028 029-048 049-062

38 27 36 101

23 24 14 61

21 24 4 49

13 14 15 42

Electric

al Panel Finishi

Metal Test
6 3 1

ng Sheet

A&R

Unit

RPR5MA7 RPR48MA3 LPR8CX10

101 123 83

61 57 48

49 46 45

42 67 55

307 166 140 164 128

10

221 137 132 126

38

Bay

al

Bay

Test Bay
1 1 4 6

A&R

Panel

Fault Findings - RPR5MA7 Serial No. 33251-008...33251-028

40 38

35

30

25 23 21 20
Section

15 13

10 8

1 0 A&R Electrical Panel Finishing Sheet Metal Test Bay

10

15

20

25

0 21 Wwitness marks missing 15 Incomplete checklists 14 Loose bolts/screws 8 Cable ties not trimmed 7 Loose cable glands 7 Other 6 Damaged coil fins 5 Debris in unit 4 Missing Washers 4 Insulation Issues 3

Fault Findings - RPR5MA7 Serial No. 33251-008...33251-028

Pipe Spacing rubbing/wear

Sharp edges in accessible areas

Pipe quality no wrinkles, etc

Sharp weld spatter

Significant case/cover scratches

Grills not fully welded

Inspection Matrix RPR5MA7

Project: PACIFIC NATIONAL\MOURA LOCO Customer: DEDIR Section Responsible & Number Of Defauts Total Defect Qty
20 0 7 7 0 0 0 0 2 6 2 2 4 5 4 1 6 1 3 3 1 8 1 7 4 1 2 1 9 2 21 0 4 7 17 4 0 0 0 3 3 2 1 15 27 24 24 1 14 1 1 2 1 6 5 2 1 0 105

Defalt No

Model: RPR5MA7 Asssembly & Refrigiration Inspection: Each Unit Sheet Metal Electrical

Electrical Panel

Items Inspected On Units

Serial Numbers: 35341 - 029 ... 35341 - 048

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Cable ties not trimmed Sharp edges in accessible areas Damaged coil fins Electrical Enclosure Lids tight Pipe Spacing prevents rubbing/wear Wires/Cables rubbing or wearing Grills not fully welded Cable glands loose Missing Washers Major components/structures/control settings Witness Marked Cover Hinge pins not correctly installed & witness marked Loose bolts/screws Debris in unit Checklists not completed/signed Sharp weld spatter EMKA seal joints glued with Loctite Position and security of TX Bulbs Pipe quality no wrinkles, etc Insulation not sealed/damaged/well affixed Application of sealant is presentable Significant case/cover scratches S/S shaft (F/A supply blower) protected with cold gal Other TOTAL FAULTS BY DEPARTMENT

Finishing
1

Test Bay

Fault Findings - RPR5MA7 Serial No. 33251-029...33251-048

30 27 25

24

24

20 Section 15 14

15

10

1 0 A&R Electrical Panel Finishing Sheet Metal Test Bay

10

15

20

25

21

Witness marks missing

20

Cable ties not trimmed

17

Checklists incomplete

Loose cable glands

Debris in unit

Damaged coil fins

Insulation issues

Sealant application issues

Sharp weld spatter

Loose bolts/screws

Fault Findings - RPR5MA7 Serial No. 33251-029...33251-048

Significant scratches

Missing washers

S/S shaft not painted

40 30 20 1 10 1 14 4 0 Test Bay 15 Sheet Metal 24 36 27 14 Finishing 4 Panel A&R Electrical Panel 008-028 029-048 049-062 A&R Sheet Metal Finishing Test Bay Electrical

8
13 21 38 23 24 14

15

Faults by Section on Rail A/C Units

123

101
83

140

120

61

49 A&R 42 Electrical Panel

46

67

45 55 74

100

Number of Faults

57

48

RPR5MA7 RPR48MA3 LPR8CX10

80 60

37

17

40 20 1

Section

Finishing 3 6 Test Bay

Sheet Metal

Faults By Section On Rail Models

250

221

200

150 137 132 126 Section

100 76

50

4 0 Asssembly & Refrigiration Electrical Electrical Panel Finishing Sheet Metal Test Bay

Inspection Matrix RPR5MA7

Project: PACIFIC NATIONAL\MOURA LOCO Customer: DEDIR Model: RPR5MA7 Inspection: Each Unit Electrical Panel Sheet Metal Total Qty
1 0 2 5 4 2 8 3 3 2 1 2 5 0 6 8 0 3 3 3 0 0 0 3 6 2 1 3 1 1 3 11 3 0 0 0 0 0 3 1 4 3 5 1 4 3 9 9 0 0

Section Responsible

Defect No

Electrical

Serial Numbers: 35341 - 049 ... 35341 - 062

1 2 3

Not 12 pins on each evap lid covered with caps & silver tape External welds on the unit & covers not passivated Sharp corners on unit Weld spatter around welds Grilles not welded (tacks broken off) SIKA Firesil not applied neatly and presentable Joints (corners) of insulation not covered with silver tape Incorrect type seal used on evaporator covers Damaged insulation in evaporator area Damaged evaporator/condenser coils Pipe/wire rub or wear against each other Uniseal not placed under the S/A blowers Incorrect position of TX valves Pipe quality with dents, wrinkles, bending tool marks etc. S/A shafts not coated with antirust Cold Gal paint Bolts not witness marked Loose bolts/screws/nuts Missing or damaged washers Cracks or damage on condenser fan blades No clearance on pipe header and cond bracket Pressure transducers with no gasket fitted Firesil not applied between chamber & electrical panel Electrical lids not tight Cable ties not trimmed flat Cable glands not tight and witness marked Cable glands in cond. area not fully sealed with Firesil Cover hinge pins incorrectly installed & not witness marked

Items Inspected On Units

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Finishing

Test Bay

A&R

28 29 30 31 32 33 34 35 36

Debris in unit (especially in evap drip tray) Decals missing (Live Wires, No Step, 415V etc.) Kazoo's not cut parallel (10mm) and pins not installed Nyloc nuts not installed on the RHS Significant case/cover scratches UHC and checklist not been filled in/signed off Evap & Cond covers not tightened/witness marked Evap cover hexserts not sealed with SIKA Firesil Other faults TOTAL FAULTS BY DEPARTMENT 14 36 9 4 4 2 1 3

3 3 1

3 3 1 0 2 4 A&R Fin S/M Electrical Panel Test Bay 36 18 14 9 4 4

1 2 18

1 2 0 85

Fault Findings - RPR5MA7 Serial No. 33251-049...33251-062

40 36 35

30

25

20

18

15

14

10

Fin

A&R

S/M

Electrical

Panel

Bolts not witness marked 11 Cable ties 9 Fault Findings - RPR5MA7 Serial No. 33251-049...33251-062not trimmed flat Cable glands not tight and witness marked 9 12 Insulation not covered with silver tape 8 SIKA Firesil not applied neatly and presentable 6 Weld spatter around welds 5 UHC and checklist not been filled in/signed off 4 10 Debris in unit (especially in evap drip tray) 3
9 9 8

11

6 5 4

Decals missing (Live 3 Wires, No Step, 415V etc.) Electrical lids not tight 3 S/A shafts not coated 3 with antirust Cold Gal paint Pipe/wire rub or wear against each other 3 8 Damaged evap/con coil 3 Damaged insulation 3 Sharp corners on unit2 Significant case/cover scratches 2 6 Evap cover hexserts not sealed 2 Evap & Cond covers loose & W.M m 1 Not 12 pins on evap lid 1

Test Bay

4 3 3 3 3 3 3 3 2 2 2 2 1 1

Bolts not witness marked Cable ties not trimmed flat Cable glands not tight and witness marked Insulation not covered with silver tape SIKA Firesil not applied neatly and presentable Weld spatter around welds UHC and checklist not been filled in/signed off

Debris in unit (especially in evap drip tray)

Decals missing (Live Wires, No Step, 415V etc.) Electrical lids not tight S/A shafts not coated with antirust Cold Gal paint Pipe/wire rub or wear against each other Damaged evap/con coil

Damaged insulation
Sharp corners on unit Significant case/cover scratches Evap cover hexserts not sealed Evap & Cond covers loose & W.M m Not 12 pins on evap lid
0

RPR48MA3 16 17 2 5 6 1 7 11 0 12 7 1 0 5 1 0 0

Wwitness marks missing Incomplete checklists Loose bolts/screws Cable ties not trimmed Loose cable glands Other Damaged coil fins Debris in unit Missing Washers Insulation Issues Pipe Spacing rubbing/wear Sharp edges in accessible areas Pipe quality no wrinkles, etc Sharp weld spatter Significant case/cover scratches Grills not fully welded EMKA Seal Issues

21 15 14 8 7 7 6 5 4 4 3 3 2 2 2 1 1

LPR8CX10 14 17 3 16 9 0 6 9 3 10 1 0 0 2 0 0 1

RPR5MA7

51 49 19 29 22 8 19 25 7 26 11 4 2 9 3 1 2

51 49 19 29 22 8 19 25 7 26 11 4 2 9 3 1 2

70 70 70 70 70 70 70 70 70 70 70 70 70 70 70 70 70

73% 70% 27% 41% 31% 11% 27% 36% 10% 37% 16% 6% 3% 13% 4% 1% 3%

066-089 036-065 010-035 33 44 29 20 25 10 18 13 28 26 23 14 4 28 14 0 0 1

Units

A&R Finishing Sheet Metal Electrical Electrical Panel Test Bay

Asssembly

& Electrical Electrical

Finishing

Test Bay

27

24

24

15

14

Packing
0 Witness marks missing Cable ties not trimmed Checklists incomplete Loose cable glands Debris in unit Damaged coil fins Insulation issues Sealant application issues Sharp weld spatter Loose bolts/screws Significant scratches Missing washers S/S shaft not painted

Metal

Panel Sheet

21 20 17 9 7 7 6 5 4 4 2 2 1

Month

June 3 3565-001 3565-002 1 2 3 4

July 3 3565-003 3565-004 3565-005 3565-006 -

August 6 3565-007 3565-008 3565-009 3565-010 3565-011 3565-012 -

September 12 3565-013 3565-014 3565-015 3565-016 3565-017 3565-018 3565-019 3565-020 3565-021 3565-022 3565-023 3565-024

October 6 3565-025 3565-026 3565-027 3565-028 3565-029 3565-030 -

November December -

January -

February -

March -

April 3565-031 3565-032 3565-033 3565-034 3565-035 3565-036 3565-037 3565-038 3565-039 -

Serial number & number of units per

# of units

month

5 6 7 8 9 10 11 12

Month

June 1 3 1 0 0 1 6 2 3

July 4 19 4 0 0 9 36 4 9

August 9 31 14 0 0 11 65 6 10.83

September 25 36 17 5 4 22 109 12 9.08

October 10 13 2 0 0 5 30 6 5.00

November -

December -

January -

February -

March -

April -

Sheet Metal A&R Electrical Panel Test Bay Finishing Total Number of units built Fault average per unit

Total faults per section & average per unit 49 102 38 5 4 48 246 30 7.38

Section

Number of units built 30 30 30 30 30 30 30

Section & Total Fault Average 1.6 3.4 1.3 0.2 0.1 1.6 8.2

Faults Analysis Per Month For RPR43MX1

120 109 100

ber of faults per month

Number of faults per month

80 65 60

40

36 30

20 6 0 0
Series1
June 6 July 36 August 65 September 109 October 30 November 0

0
December 0

0
January 0

0
February 0

0
March 0

0
April 0

40 31 36 22 25 35 30 25 9 11 14 17 1 20 15
Sheet Metal

A&R
Electrical

19

Panel Test Bay

11 14 17 1 0 4 0 0 2 5 0 0 0 0 4 0 Test Bay Finishing 5

20

Panel
Test Bay

15
10 5 0

1 4

9 10

3 13

Finishing

Sheet Metal

A&R

Electrical

Panel

Section
Sheet Metal A&R Electrical Test Bay Finishing No, of units built Fault target per unit Target for units built Score Achieved Fault average per unit

Jan Feb Mar Apr May Jun -

Jul

Aug 2 82 80 11 34 21 5 105 209 9.95

Sep Oct Nov Dec 0 5 2 0 1 1 5 5 8 8.00

0 0 0 1 27 32 21 67 6 19 2 34 0 4 1 6 11 32 23 41 6 12 8 15 5 5 5 5 30 60 40 75 44 87 47 149 7.33 7.25 5.88 9.93

Total faults per section & average per unit 3 234 143 22 142 63 30 315 544 8.06

Number of units built 63 63 63 63 63

Section & Total Fault Average 0.0 3.7 2.3 0.3 2.3

Monthly Fault Analysis RPR43MX1

250 209
Number of faults per month

200 149

150

100
44

87

50

47

0 Apr May Jun Jul Aug

27 32 0
Apr May
Jun Jul

67 82 619 34 21 2

80 0 4 1 6

11

32 23 41 34

100
80 60 40

0 0 1 2 0 5
Aug
Sep

11 1 0 Finishing Testing

20 0

Electrical A&R Sheet Metal

Sheet Metal A&R Electrical Testing Finishing

Fault Breakdown Per Seciton RPR43MX1

A&R Electrical Finishing Test Bay

234 143 142 22

4%

26%

43% A&R Electrical Finishing Test Bay

27%

Faults Per Section RPR43MX1

250 234

200

150

143

142

Section 100

50

22

0 A&R Electrical Finishing Test Bay

A&R Electrical Finishing Test Bay Total 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 Incorrect amount of pins Welds not passivated Sharp corners on unit Sharp weld spatter Mtg stud incorrectly located Grilles broken off Firesil not applied neatly Joints not covered with S.T Damaged Insulation Fins/coils damaged Pipes rubbing eachother Uniseal not installed TX Valve incorrect position Shafts not coated

Sheet Metal A&R Electrical Test Bay Finishing Total 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Tacky tape not applied on pipes Pipe quality dents/wrinkles etc. 15 16

FAULT BREAKDOWN ANALYSIS ON RPR43M

17

ANALYSIS ON RPR43MX1 S.No 031-059

2 18 0 0 0 0 0 0 0 1 0 0 1 1 1 1 0 0 0 0 0 3 1 0 2 6 1 Total Sharp cable ties Glands not fully sealed in cond Hinge pins not engaged/marked EMKA seals not glued together Debris in unit Decals missing Case/cover scratches UHC & C/lists not signed/check Evap & Cond cover not tighted El. Lids not tightened Cond fan bolt not sealed Transducers missing gasket Damaged/spread washers Cracked/damaged cond fan blades Witness marks missing 19 23 Cond. term. Box not sealed with firesil 24 20 21 22 25 26 27 28 29 30 31 32 33 39

1 1

Bolts/Nuts/Glands not tight

QTY

QTY

QTY

QTY

QTY

QTY

QTY

QTY

# of units 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

6 3565-1-031 3565-1-032 3565-1-033 3565-1-034 3565-1-035 3565-1-036 -

12 3565-1-037 3565-1-038 3565-1-039 3565-1-040 3565-1-041 3565-1-042 3565-1-043 3565-1-044 3565-1-045 3565-1-046 3565-1-047 3565-1-048 -

8 3565-1-049 3565-1-050 3565-1-051 3565-1-052 3565-1-053 3565-1-054 3565-1-055 3565-1-056 -

6 5 8 7 10 8

5 6 8 9 7 10 10 14 8 1 7 4

14 12 11 13 3 4 9 12

15 3565-1-057 3565-1-058 3565-1-059 3565-1-060 3565-1-061 3565-1-062 3565-1-063 3565-1-064 3565-1-065 3565-1-066 3565-1-067 3565-1-068 3565-1-069 3565-1-070 3565-1-071 -

9 8 6 16 17 12 9 17 13 15 13 8 17 14 12

10 3565-1-072 3565-1-073 3565-1-074 3565-1-075 3565-1-076 3565-1-077 3565-1-078 3565-1-079 3565-1-080 3565-1-081 3565-1-082 3565-1-083 3565-1-084 3565-1-085 3565-1-086 3565-1-087 3565-1-088 3565-1-089 3565-1-090 3565-1-091 3565-1-092

12 19 9 7 8 7 5 7 8 9 15 10 9 8 10 8 13 9 11 13 6 105 203 9.67 98 48%

3565-1-093 3565-1-094 3565-1-095 3565-1-096 3565-1-097 3565-1-098 3565-1-099 3565-1-100 3565-1-101 3565-1-102 3565-1-103 3565-1-104 3565-1-105 3565-1-106 3565-1-107 3565-1-108 3565-1-109 3565-1-110 3565-1-111 3565-1-112 3565-1-113

Falut target score per month Total fault score per month Average fault per month Faults over per month Percentage over per month

Serial number & number of units per month

30 44 7.33 14 32%

60 89 7.42 29 33%

40 78 9.14 38 49%

75 186 12.4 111 60%

QTY

Month

April

May

June

July

August

September

October

November

December

32 33 34

10

11

13

14

15

16

17

18

19

20

12

0
3565-1-031

1 6 5 9.62 8 7 10 6 5 6 8 9 7 1010 14 8 1 7 4 14 12 11 13

3565-1-033
3565-1-035

3565-1-037 3565-1-039
3565-1-041

3565-1-043
3565-1-045

3565-1-047 3565-1-049
3565-1-051

3565-1-053

3
4

3565-1-055

3565-1-055

12

9 8

3565-1-059

3565-1-061

16

17

3565-1-063

12

3565-1-065

17

13 13

3565-1-067

15

3565-1-069
3565-1-071

17

14

1212

3565-1-073

19

Number Of Faults Per Unit RPR43MX1

3565-1-075

7 8

3565-1-077

7 5

3565-1-079
3565-1-081

7 8 9

3565-1-083

15

10 9

3565-1-085

3565-1-087

10 8

3565-1-089

13

3565-1-091

11

13

3565-1-093

8
Score
Target Average

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 25 28 29 30 31 32 33 34 5 6 7 4 3 2 1

3565-1-031 3565-1-032 3565-1-033 3565-1-034 3565-1-035 3565-1-036 3565-1-037 3565-1-038 3565-1-039 3565-1-040 3565-1-041 3565-1-042 3565-1-043 3565-1-044 3565-1-045 3565-1-046 3565-1-047 3565-1-048 3565-1-049 3565-1-050 3565-1-051 3565-1-052 3565-1-053 3565-1-054 3565-1-055 3565-1-056 3565-1-055 3565-1-058 3565-1-059 3565-1-060 3565-1-061 3565-1-062 3565-1-063 3565-1-064

5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

6 5 8 7 10 6 5 6 8 9 7 10 10 14 8 1 7 4 14 12 11 13 3 4 9 12 9 8 6 16 17 12 9 17

9.62

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

3565-1-065 3565-1-066 3565-1-067 3565-1-068 3565-1-069 3565-1-070 3565-1-071 3565-1-072 3565-1-073 3565-1-074 3565-1-075 3565-1-076 3565-1-077 3565-1-078 3565-1-079 3565-1-080 3565-1-081 3565-1-082 3565-1-083 3565-1-084 3565-1-085 3565-1-086 3565-1-087 3565-1-088 3565-1-089 3565-1-090 3565-1-091 3565-1-092 3565-1-093 3565-1-094 3565-1-095 3565-1-096 3565-1-097 3565-1-098 3565-1-099 3565-1-100

5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

13 15 13 8 17 14 12 12 19 9 7 8 7 5 7 8 9 15 10 9 8 10 8 13 9 11 13 6 8

Cable Ties Not Trimmed Witness Marks Missing Checklists Incomplete Debris In Unit Damaged Coil Fins Insulation Issues Loose Cable Glands Sealant Application Issues Loose Bolts/Screws Case/Cover Scratches Sharp Edges In Accessible Areas Sharp Weld Spatter Other Pipe Quality Issues Grills Not Fully Welded Enclosures Lids Not Tight Wires/Cables Rubbing Cover Hinge Pins Issues EMKA Seal Issues TX Bulbs Issues Sealant Application Issues

26 22 20 7 7 7 5 5 4 3 3 2 1 0 0 0 0 0 0 0 0

Other

Missing Washers

Pipe Spacing Issues Pipe Quality Issues Case/Cover Scratches Grills Not Fully Welded Enclosures Lids Not Tight Wires/Cables Rubbing Cover Hinge Pins Issues EMKA Seal Issues TX Bulbs Issues