1.

Introduction and scope of the Audit

Introduction:

Chennai Metro Rail Limited has placed an order on the Alstom Transportation SA – Alstom Projects India
Limited Consortia for design, manufacture and supply as well as testing and commissioning of 42sets of
4-car train sets for the Metro Rail System of Chennai Metro Rail Limited.

This audit is an outcome of the above.

Purpose of the Audit:

The purpose of the audit is to assess the process capability of the manufacturer to design, manufacture,
inspect and test, pack and dispatch the specific material / component required by the customer.

Scope of the Audit:

The document covers the Audit of the manufacturing process, quality assurance process, general layout
of the factory, factory infrastructure, manpower and related systems and design capability

Chennai Metro Rail Limited – Factory Audit Report Page no.

 2. Audit Report – Summary Sheet

(i) Name of Factory inspected:

(ii) Location and address:

(iii) Whether subsidiary of a multinational Yes / No.

If so, Name and address of the multi-national

(iv) Details of certifications like ISO, Quality & Systems, Environmental systems etc., available with
the firm

(v) Total manpower - 5500

(vi) Of the above technical man-power - 5286

(vii) Total invested capital -

Invested Capital In Crore

Equity 862.06

Long Term Borrowing (including current maturity) 2,547.64

Short Term Borrowings 842.09

4,251.79
Less :

Long Term Investment -416.77

Long Term Loan -519.86

Total Invested Capital 3,315.16

(viii) Adequacy of manufacturing infrastructure

(ix) Adequacy of quality assurance infrastructure

Chennai Metro Rail Limited – Factory Audit Report Page no.

 (x) Adequacy of training infrastructure

(xi) Adequacy of Design capabilities

(i) Details of quality certifications

(ii) Summary of observations of the audit team

(iii) Name and designation of the signatory of the report

3. General Information

i) Factory name:

ii) Factory Address

iii) Name and Address of the corporate office

iv) Details of branches if any-

v) Details of principal - if a subsidiary of a multinational : Not applicable

vi) Main product category

vii) Railway specific products manufactured

viii) Total out-turn in US Dollars per Annum –

Revenue from Operations 7,575.55

Exchange rate as on 31.03.2017 64.85

Amount in USD Crores 1,168.165

Chennai Metro Rail Limited – Factory Audit Report Page no.

 ix) Invested capital in INR for India: (Rs Crores)

- Land & Buildings - 630.41

- Machinery & Plant - 1572.48

- Transport & Material handling -

- Testing Equipments -

- Others - 30.88

- Total - 2233.77

x) Man power – Technical

 Production line workers – 3634

 Engineers : 695

 Quality control workers - 167

xi) Manpower – Non-technical

 Administrative staff - 207

 Sales staff and - 07

 Others – 2

Chennai Metro Rail Limited – Factory Audit Report Page no.

Signature and seal of the firm audited Date & Place

Chennai Metro Rail Limited – Factory Audit Report Page no.

 5. Product Profile.

List of Products, customers (Railway / Non-Railway customers and products to be indicated

separately). Details of past supplies of the specific product, for which inspection is being carried out
to be tabulated separately – furnishing customer details, quantity, year of supply, value.

Besides, a short summary of BFG Global rail projects is also enclosed.

Signature and seal of the firm audited Date & Place

6. List of Machinery and Plant

Chennai Metro Rail Limited – Factory Audit Report Page no.

Sl. No. Name of Equipment HP Rating Quantity

1. Electric Arc Furnace (EAF) EAF-1 : 45MT, EAF-2 : 40MT 02

2. Argon Oxygen Decarburization Vessel AOD-1 : 50MT, AOD-2 : 50MT 02

(AOD)

3. Ladle Refining Furnace (LRF) LRF-1 : 50MT, LRF-2 : 50MT 02

4. Vaccum Oxygen Decarburization (VOD) VOD : 45MT 01

5. Slab Caster (Radius : 8.5M) CCS-1: 200*(690-1285)mm2, 02

CCS-2 : 200*(690-1285)mm2

6. Bloom Caster (Radius : 9/16M) 120*120mm2,160*160mm2, 01

200*200mm2,260*200mm2

Cold Rolling Division

Annealing Line No. 1 CRD I

Annealing & Pickling Line No. 2 CRD I

Pickling Line No. 1 CRD I

Pickling line No.5 CRD I

Slitting Line No. 2 CRD I

Slitting Line No. 3 CRD I

Wider Pull Through Furnace CRD I

Z-1 Rolling Mill CRD I

Z-2 Rolling Mill CRD I

Annealing & pickling Line No. 3 CRD II

Bright Annealing Line CRD II

Coil Preparation Line No. 1 CRD II

Coil Preparation Line No. 2 CRD II

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 Coil Preparation Line No. 3 CRD II

Horizontal BA Line -1 CRD II

Horizontal BA Line -2 CRD II

Horizontal BA Line -3 CRD II

Skin Pass Mill CRD II

Slitting Line No. 1 CRD II

Slitting line No. 4 CRD II

Strip Grinding Line CRD II

Z-3 Rolling Mill CRD II

Z-4 Rolling Mill CRD II

Z-5 Rolling Mill CRD II

Slitting line No. 5 CRD III

Cut to Length CRD III

Annealing & pickling Line No. 4 CRD III

Boiler-1 Utilities CRD

Boiler-2 Utilities CRD

Boiler-3 Utilities CRD

Ammonia Plant Utilities CRD

OXY/GAS PLANT Utilities CRD

Steckel Mill

Edger 
1000 2
Roughing Mill
6000 2

Steckel Mill #1 7000 2

Steckel Mill #2 7000 2

Coiler Furnace 1000 2

Chennai Metro Rail Limited – Factory Audit Report Page no.

 Down Coiler 871 1
Strip Mill

Roughing Mill 7000 1

Tandem Stand#1 2000
1
Tandem Stand#2 2000
1
Tandem Stand#3 1800
1
Tandem Stand#4 1800
1
Tandem Stand#5 2250
1
Down Coiler 750
1

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Chennai Metro Rail Limited – Factory Audit Report Page no.
Signature and seal of the firm audited Date & Place
Chennai Metro Rail Limited – Factory Audit Report Page no.
 7. List of Jigs & Fixtures

Sl. No. Name of Jig & Fixtures Purpose of Use Quantity

Signature and seal of the firm audited Date & Place

Chennai Metro Rail Limited – Factory Audit Report Page no.

 8. List of testing equipment and Testing Devices

Sl. Name of testing equipment and testing devices Purpose of Use Quantity
No.

CR TESTING R&D List Of List of Testing

EQUIMENTS.XLSX Instruments.xlsx Equipments-HR.xlsx

Signature and seal of the firm audited Date & Place

Chennai Metro Rail Limited – Factory Audit Report Page no.

 9. Process Flow Chart for the specific product

Process Flow
Chart.doc

Signature and seal of the firm audited Date & Place

Chennai Metro Rail Limited – Factory Audit Report Page no.

 10. Quality assurance Process

Quality Assurance Process Flow Chart indicating check points and hold points and the
process flow loop for non-confirming products.

Quality Assurance Process Flow Chart indicating check points & hold points [attached as
per following file]:

Process Flow Chart &

Quality Control.doc

Process Flow loop for non-confirming products:

Process Flow Loop

for Non Confirming Products.docx

Chennai Metro Rail Limited – Factory Audit Report Page no.

 Signature and seal of the firm audited Date & Place

Chennai Metro Rail Limited – Factory Audit Report Page no.

 11. List of items sub-contracted for the specific product and the sources to which
outsourced

Few Commodities are listed below

Sl. No. Item sub-contracted End-use Name of Sub-contractor

Signature and seal of the firm audited Date & Place

Chennai Metro Rail Limited – Factory Audit Report Page no.

 12. Quality Assurance Process

Quality Assurance process for incoming products and raw materials

Incoming Product
Inspection.doc

Chennai Metro Rail Limited – Factory Audit Report Page no.

Signature and seal of the firm audited Date & Place

13. Strategy for addressing environmental issues and concerns

In its pursuit of environmental sustainability alongside its business development Jindal Stainless (Hisar)
Limited has setup norms beyond the statutory requirements and has put into place systems and
processes to continuously monitor the effectiveness of such initiatives. We firmly believe that Corporate
growth is strengthened by our efforts in the area of environment protection and making a greener
tomorrow. The Company goes beyond mere compliance legislation to create a healthy environment
both within and outside plants. Our operations have a fully equipped environment management
infrastructure in place. We use suitable processes and technology to make stainless steel without
adversely impacting the environment.
We have laid fresh thrust towards enhancing our resource efficiency in operations, especially for key
resources such as energy and water. Additionally we are adopting the '3-R' (reduce, reuse and recycle)
philosophy for all types of wastes towards prevention of pollution and dispose of inevitable wastes and
set, monitor, and review objectives and targets on an ongoing basis towards continuous improvement in
environmental performance and the overall environmental management system.

 A state of the art environmental laboratory has been set up to conduct environmental
monitoring & analysis regularly.
 Environmental Management System is in place to undertake prevention and control of all
sorts of pollution.
 Efficient use of all key resources (water, energy, raw materials, etc) through its effective
management and technological measures are being practiced.
 Continuous efforts are being made to ensure that all employees are environmentally
aware.
 Air emissions are being treated with state-of-the-art facilities like Dust Extraction Systems,
bag filters, Dog House, etc.
 Best housekeeping is maintained by having all concrete / tar roads, and use of pneumatic
vacuum road sweepers, water sprinkling through tankers, rotating water sprinklers,
dedicated housekeeping crew, etc.
 We have a state of the art effluent treatment plants (ETP) designed by reputed suppliers.
Effluent is treated efficiently in effluent treatment plants and RO Plant. Entire Treated
waste water is being reused / utilized within the plant for various purposes.
 Sewage Treatment Plant has been installed to treat domestic waste water to meet the
specified norms of HSPCB. The entire domestic waste water after treatment is being
completely reused in plantation which is an established practice world-wide.
 Waste segregation is done at source.
 Proper procedures / measures are undertaken to collect, segregate and store at a
designated locations for all types of wastes, making disciplined management of solid
Chennai Metro Rail Limited – Factory Audit Report Page no.
 wastes.
 Process dusts are recycled in the process in the form of briquettes.
 No hazardous waste is presently generated from our Plant.
 Used oil is being stored at designated location and is sold to CPCB approved recyclers.

Signature and seal of the firm audited Date & Place

Chennai Metro Rail Limited – Factory Audit Report Page no.

 14. Safety Record

Sl. No. Year Major Accidents Minor Accidents

Signature and seal of the firm audited Date & Place

Chennai Metro Rail Limited – Factory Audit Report Page no.

 15. Detailed process for calibration of Jigs & Fixtures, testing equipments and
manufacturing process equipments

Selection of Monitoring & Measuring Devices / Apparatus (Instruments):

Defined in procedure of maintenance and calibration of Instrumentation system in SAP.

Calibration of Instruments: Instruments are calibrated as per SOP in SAP of different

instruments with the MASTER calibrator with defined frequency.

Calibration Records: Kept in soft form in SAP

Storage, Preservation & Protection: Yes in Sap

Calibration Non Conformance: As per SOP defined in SAP

If error in the instrument is more than the acceptance criteria, adjust the same to bring
within acceptance criteria and inform to Head of Department and concerned operation
in charge. Even after adjustment, the error remains more than acceptance criteria;
replace the instrument with pre-calibrated instrument.

Chennai Metro Rail Limited – Factory Audit Report Page no.

Signature and seal of the firm audited Date & Place

16. Design / Engineering Capabilities

(i) Does the firm have an in- house design unit?

If not do they have regular tie-up with a design organization,

Furnish the name and address.

(ii) Total number of design staff –

(iii) Break-up of staff:

Signature and seal of the firm audited Date & Place

Chennai Metro Rail Limited – Factory Audit Report Page no.

Chennai Metro Rail Limited – Factory Audit Report Page no.
 17. Conclusion and comments of Audit Team

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