CUSTOMER ACCEPTANCE VALIDATION (CAV) - AMC

Score ( %) Existing
Required Level up Overall
# Metrics Level Description Status Target Responsible
Min. Max. Level to Last Responsible
Year
0 0 19
1 20 39 A self-audit was conducted in July 26.09.23
Formerly known as BGWF, we have attained '23, and the report has been (Customer
2 40 59 Level 3. Currently, the name has been shared with the customer. Audit)
1 WFGA changed to WFGA, accompanied by additional Followed by external audit also
Mr. Maheshkumar Mr. Gnanasekaran
3 60 79 3 3
requirements set forth by CAT. done. We are currently awaiting 16&17.11.23
4 80 94 their rating (Completed)
5 95 100
0 <30

1 30 44 A self-audit was concluded in

February '23, and the report has 10 & 11.08.23
been shared with the customer. (Customer
2 45 59 The customer audit took place on Audit
2 BGPP 11.08.23, resulting in a level 2 Completed) Mr. Ponmurugan Mr. Gnanasekaran
3 60 75 3 3 score for A class and level 3 for B
class. A re-audit by a certified 08.12.2023
auditor is scheduled for (Re-audit)
4 76 89 08.12.2023.

5 90 100
This is a new requirement outlined by the A self-audit has been conducted,
Score yet to be 08.12.2023
3 BGCC obtained
3 NA customer. We have received a self-audit and we are currently awaiting the
(Preliminary)
Mr. Gnanasekaran Mr. Gnanasekaran
checklist from the customer. preliminary audit
Acronyms
BGWF Benchmark Guidelines for Welding Fabrication
WFGA Welding Fabrication Gap Assessment
BGPP Benchmark Guidelines for Painting Process
BGCC Benchmark Guidelines for Cleaning & Contamination
 SUPPLIER EXCELLENCE RECOGNITION - AMC
Levels Required Description Overall
# Metrics Status Target Responsible
CERTIFICATION EXCELLENT Level SQEP UOM Bronze Silver Gold Platinum Remarks Responsible

PPM 200 L12M 50 L12M PPM PPM 300 200 50 10 Mr. Gnanasekaran
Over the last two years, we did
Dollar Rejections % 0.3 0.15 0.08 0.05 It was formerly referred to as
not qualify for that due to Mr. Gnanasekaran
inconsistencies in the metrics. An
SQEP. Currently, the name has
1 SSP-Production 95% L12M 98% L12M Certification SSP - Production % 90 95 100 100 been changed to SER with
initial certification needs to be 30.01.24 Mr. Prabakaran Facility Head
obtained, and consecutive
accompanying errata
SSP-Service 95% L12M 98% L12M SSP - Service Parts % 95 96 97 98 achievements can lead to an Mr. Prabakaran
excellent rating
PPAP 95% L12M 100% L12M PPAP Completion on-time % 90 96 97 98 Mr. Gnanasekaran
Acronyms
SQEP Supplier Quality Excellence Performance
SER Supplier Excellence Recognition
 Alstom SPA Status
Alstom Target
# Special Process Self Assessment Customer Audit Status Target Responsible Overall Responsible
(Action Plan)
Completed and report Completed - 11
1 Welding 13.09.2023 20.09.2023 Mr. Maheshkumar
shared with the customer CAR reported
13.09.23
(Self
Self Mr. Gnanasekaran
Assessment)
assessment
2 Painting To be completed To be confirmed Mr. Ponmurugan
done on
20.09.23
07.09.23
(Customer
Audit)
 Alstom SPA - Welding
# CAR # Observation Responsibility Remarks Action Plan Target Status

8.1 group (SS) material qualification has

been failed last two times due to welder SS material qualification has been done
competency issues. 07.09.2023.
1 CAR - 1 1) EN 15085-2 - Scope not covering 8.1 group for 141 process Mr. Mahesh Kumar 06.09.2023 Completed
Mr. Vasanth has been qualified already, SS Welders - 3 persons recruited
he was left from service.

We have being conducted an order

1) Feasibility and capacity study not performed for AT parts Mr. Murugaraj Feasibility & technical review will be performed for
review in two phases:
2 CAR - 2 covering welding. Mr. Sundararajan & AT parts. 07.09.2023 Completed
1. Feasibility Review
2) CBC not available for DTRF 150215. Mr. Vinoth kumar CBC will be done for DTRF 150215
2. Technical Review
1) Team was unable to demonstrate the scoring criteria in terms PFMEA format will be revised.
of severity, occurrence and detection ratings of the PFMEA There is a communication gap and Training will be imparted to all.
[Link] &
3 CAR - 3 shown during audit. inadequate awareness of the Henceforth, PFMEA will be done through the 07.09.2023 Open
Mr. Vinoth kumar
2) RPN cut off number to be defined. requirements revised format.
3) Revision history to be updated. Ensure team awareness.

1) Filler wire selection for the 1.2 group is not as per the 1. Filler wire selection has been done for 1.2 group
1. Already done as per AWS name
requirements DTRF 150215 Annexure - A as per DTRF 15025 Annex A requirements. 02.09.2023
4 CAR - 4 Mr. Mahesh Kumar 2. It doesn't cover due to magnification Completed
2) Macro report of Butt weld WPS does not cover the Root 2. The magnification level has been reduced and
level is high (8x).
penetration, which is not acceptable. covered the root to top of the weld.

1) Aluminum welding WPS -009 for fillet welding is not 1. There is no specific requirements
acceptable - Uneven leg size's observed in macro image. Weld stated in ISO standards and Alsom spec 1 & 2. WPS 008 & 009 sample's weld is verified in
leg size's not mentioned in test report. Only throat size mentioned also. line with ISO 5817 level B. This will be mentioned
and no scaling available for the macro images. 2. This specimen has been tested and in the visual report.
5 CAR - 5 Mr. Mahesh Kumar 07.09.2023 Completed
2) Aluminum WPS -008 is not acceptable weld test piece passed in NABL lab by the witness of
distorted during welding and excess root gap observed. TUV NORD. 3. It will be done as per EN 15085-4 requirements
3) Production weld test coupons to be made as per EN 15085-4 3. We didn't considered due to with the help of AT.
requirements during production. production order not received.

Mr. Gnanasekaran Welding inspection is being performed Inspection check sheet parameters has to be
1) Weld defect capturing and analysis not demonstrated - Internal
6 CAR - 6 & but dimensions only recorded, others revised. The inspection will be performed 07.09.2023 Completed
performance analysis of welding defects not evidenced.
Mr. Sambath kumar defect not recorded. accordingly and report will be maintained.

1) Filler wire storage not available for the current location under 1. A permanent set up for filler wire storage will be
process - will be audited up during followup audit Mr. Senthil kumar & placed.
7 CAR - 7 10.09.2023 Completed
2) AT DTRF 150215 Annexure A guidelines to be followed for Mr. Sakthivel 2. RF 150215 Annexure A guidelines will be
Filler wire selection. followed for filler wire selection.
1) Current shop floor does not support Aluminum welding.
8 CAR – 8 Heavy risk of contamination from adjacent SS and CS welding Mr. Senthil kumar To be discussed with management Open
fumes.

1.
1) Fume exhausters not available. (#1, 2, 4 & 5) 2.
2) Bending machines to be enclosed. Mr. Senthil Kumar 3. Not feasible - It's man involved process, we
3) No safety sensors found in Bending machines. Mr. Shunmugaraj cant't put safety sensor
9 CAR – 9 To be discussed with management 31.08.2023 Open
4) Enclosed grinding stations not available. Mr. Suresh 4.
5) Welding protective screens not provided provided. (#3 & 6) 5.
6) No safety guards observed in Grinding machines. Mr. Gokula Raja 6. Safety guard has been provided in grinding
machine
# CAR # Observation Responsibility Remarks Action Plan Target Status

SS sheet is available in Unit I, it will be fixed

1) No Stainless Steel working table observed to eliminated direct Mr. Senthil kumar &
10 CAR – 10 permanently. In addition to that an aluminium sheet 07.09.2023 Completed
contact of CS and SS parts during welding. Mr. Vinoth Kumar
will be provided.

Previously all the VT procedure has been

Now, VT procedures has been reviewed and
11 CAR - 11 VT ISO 9712 Level 3 approved procedure not available. Mr. Mahesh Kumar reviewed and approved by ASME level II 02.09.2023 Completed
approved by ISO 9712 Level 3 Person.
person.