Experience from KRL KfW

1. Introduction
During Final Inspection for KRL KfW the following major issues were observed. The potential root
cause might be in
- Design
- Production Technology and
- Production
in combination with insufficient Quality Control.
These experiences shall be implemented for improvement of KRL JAL. For more details please refer
to Open Item Lists (including photos) for KRL KfW (TS1 to TS10).
Please note that all photos are taken on trains that were reported ready for final inspection.
2. Major Findings
2.1. Door System
All doors needed to be adjusted by grinding to open and close smoothly.
2.2. Corrosion
2.2.1. Underframe

Corrosion at drainage system and from inside underframe

Corrosion from inside underframe at footstep area

Corrosion between underframe and sidewall at door area

Experience from KRL KfW

2.2.2.Driver Door

Corrosion at driver door

2.2.3.Air Con Unit

Corrosion under Air Con frame

Corrosion under Air Con frame

2.2.4. Exterior Bolts, Nuts and Washers

Corrosion of screws for foot step cylinder

Experience from KRL KfW

Corrosion of screws and nuts of PA bos

Corrosion at gangway

Corrosion at pantograph

2.2.5.Others

Corrosion at footstep

Experience from KRL KfW

Corrosion at underframe

Corrosion between 2 parts of underframe

Corrosion at underframe

Corrosion from inside door indicator

2.3. Water Ingress

Experience from KRL KfW

2.3.1. Sealant of front windows and others

Insufficient sealing of front window

Insufficient sealing of front window

Condense water inside destination indicator

No adhesion of sealing between end- and sidewall

Experience from KRL KfW

2.3.2.Several boxes at Underframe not water proof

2.3.3.Cable Gland

Experience from KRL KfW

2.3.4. Drainage system not working

Dirt inside drainage system

2.4. Painting

Insufficient painting

2.5. Cleanliness

2.6. Quality Control

2.6.1. QC during Production and final inspection
QC and QC Final refused to issue NCR according ISO 9001 and INKA. Therefore Production
Technology and Engineering did not receive this information and were not able to

Experience from KRL KfW

implement improvements.
2.6.2. Incoming Material Inspection
Inspection insufficient
2.7. Engineering
2.7.1. No Tolerances in Engineering Drawings
2.7.2.Clearance Carbody / Bogie Frame

2.8. Production Technology

2.8.1. Lack of Process Instructions (i.e. doors, pantograph, footstep)
2.8.2.Applied tolerances for carbody not sufficient to assure function of door system
2.9. Internal Transport and Storage

Damages during transport

Corrosion because of incorrect storage

2.10.
Quality Management System
2.10.1. Lack of Implementation
2.11.
Continuous Improvement
2.11.1. No Learning Curve from 1st to 10th train set
2.11.2. Experience from KRL KfW not implemented in JAL

Experience from KRL KfW

3. Conclusion
PT INKA is requested to prepare root cause analysis for all items and implement suitable mitigation
measures until November 11, 2016.