CRIMPING DATASHETT

1. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2201-1
Insulation not stripped
Crimping over insulation
not permitted
 Process PA-01
 Training module
IND-RS-LRH-GDL-022
 STD NF F 00-363
 STD EN 60352-2
Visual All Zones
Rework stripping and
crimping
2201-2
Stripping length too long Visual All Zones
Rework stripping and
crimping
2201-3
Stripping length too short Visual All Zones
Rework stripping and
crimping
2201-4
Wire not positioned
adequately
Visual All Zones
Rework stripping and
crimping
2201-5
Non conforming
insulation crimping
Visual All Zones
Rework stripping and
crimping
Defect N° PS Title Who
2201 Cabling Crimping - Stamped Contacts IQ / Operator
Fiche critère - Draft v0

2. Non –Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2201-6
Stripping length too long
 Process PA-01
 Training module
IND-RS-LRH-GDL-022
 STD NF F 00-363
 STD EN 60352-2
Visual All zones
Rework stripping and
crimping
2201-7
Stripping length too short Visual All zones
Rework stripping and
crimping
2201-8
Wire not sufficiently
inserted
Visual All zones
Rework stripping and
crimping
2201-9
Strand outside the barrel
All strands must be
contained within the
crimped barrel
Visual All zones
Rework stripping and
crimping
2201-10
Crimping mark not
centered
Visual All zones
Rework stripping and
crimping
Defect N° PS Title Who
2201 Cabling Contact Crimping IQ / Operator
Fiche critère - Draft v0

3. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2201-11
Stripping length too long
Cable strands stick out
approx 1mm
 Process PA-01
 Training module
IND-RS-LRH-GDL-022
 STD NF F 00-363
 STD EN 60352-2
Visual All zones
Rework stripping and
crimping
2201-12
Stripping length too short Visual All zones
Rework stripping and
crimping
2201-13
Wire not sufficiently
inserted
Wire must be introduced
until insulation rests
against the inside of the
lug
Visual All zones
Rework stripping and
crimping
2201-14
Strand outside the lug
All strands must be
contained within the lug
Visual All zones
Rework stripping and
crimping
2201-15
Wrong crimping tool used Visual All zones
Rework stripping and
crimping
2201-16
Crimping mark not
centered
Visual All zones
Rework stripping and
crimping
Defect N° PS Title Who
2201 Cabling Crimping– pre-insulated lugs and clips IQ / Operator
Fiche critère - Draft v0

4. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2201-17
Stripping length too long
 Process PA-01
 Module de formation
IND-RS-LRH-GDL-022
 STD NF F 00-363
 STD EN 60352-2
Visual All Zones
Rework stripping and
crimping
2201-18
Stripping length too short Visual All Zones
Rework stripping and
crimping
2201-19
Strand outside the lug
All wire strands must be
contained within the lug
barrel
Visual All Zones
Rework stripping and
crimping
2201-20
Lug crimp shows « ear »
formation
Hexagonal crimp imprint
shall not reveal pinched
metal or « ear » formation.
Visual All Zones
Rework stripping and
crimping
2201-21
Crimp not centered Visual All Zones
Rework stripping and
crimping
Defect N° PS Title Who
2201 Cabling Crimping – Large section cables , middle and high voltage IQ / Operator
Fiche critère - Draft v0

5. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2201-22
Double crimp imprints
not centered
 Process PA-01
 Module de formation
IND-RS-LRH-GDL-022
 STD NF F 00-363
 STD EN 60352-2
Visual All Zones
Rework stripping and
crimping
Defect N° PS Title Who
2201 Cabling Crimping – Large section cables , middle and high voltage IQ / Operator
Fiche critère - Draft v0

6. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2202-1
Routing not respected
Routing defined by micro
process
 Micro process
 Training module
IND-RS-LRH-GDL-023
 STD EN 50343
 Process ALSTOM PA-06-
08
Visual All Zones
Rework in order to meet
micro process
requirements
2202-2
Separation distance not
respected between
various harness classes
Separation distance
defined by micro process
Visual All Zones
Rework in order to meet
micro process
requirements
Visual All Zones
Add missing ties
2202-3
Harnesses not secured
or tied
- Harness must be tie
wrapped within the
cable trays
- 150mm MAX spacing
between ties for
insulated wires
- 250mm MAX spacing
between ties for all
others
Visual All Zones
2202-4
No stress relief
Provision of stress relief
in harness routing to
prevent stress at
terminations (connector
end)
 Micro process
 Training module
IND-RS-LRH-GDL-023
 STD EN 50343
 Process ALSTOM PA-06-
08
Visual All Zones
Re-route harness to
allow stress relief
Defect N° PS Title Who
2202 Cabling Routing IQ / Operator
Fiche critère - Draft v0

7. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2203-1
Loose tie wrap : will
allow harness
movement
The ties should not be
capable of being moved
longitudinally
 Process ALSTOM PA-09
 Training module
IND-RS-LRH-GDL-023
 STD EN 50343
 STD NF F 61-010
 STD NF F 61-349
Visual All zones Replace tie wrap
2203-2
Cable tie end to harness
interference.
(impossible to rotate
cable tie)
End of cable tie should be
free enough for slight
rotation in order to
prevent interference with
other cables.
Visual All zones Replace tie wrap
2203-3
Inadequate cut of the
tie wrap . Sharp
protruding end
Tie wrap must be cut flush Visual All zones Replace tie wrap
2203-4
Tie wrap excessively
tight. Possible crushing
of conductors
Tie should be free
enough for slight rotation
and insulation integrity
must be maintained.
Visual All zones Cable replacement
2203-5
Spacing between ties
not respected
- Harness must be tie
wrapped inside cable
trays
- 150mm MAX spacing
between ties for
insulated wires
- 250mm MAX spacing
between ties for all
others
Visual All zones
Remove suspected tie
wraps and add missing
ones
Defect N° PS Title Who
2203 Cabling Cable Ties IQ / Operator
Fiche critère - Draft v0

8. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2203-6
Tie wraps criss-
crossing
No criss crossing
permitted  Process ALSTOM PA-09
 Training module
IND-RS-LRH-GDL-023
 Norme EN 50343
 Norme NF F 61-010
 STD NF F 61-349
Visual All zones
Remove tie wraps and
install one only
2203-7
Tie installed over shield
termination
No ties permitted over
shielded termination to
reduce stress on solder
joint
Visual All zones Retirer le collier
Defect N° PS Title Who
2203 Cabling Cable Ties IQ / Operator
Fiche critère - Draft v0

9. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2205-1
Traces of abrasions
Surface abrasions only
permitted.
 Training module
IND-RS-LRH-GDL-023
 STD EN 50343
Visual Inside vehicle Use As Is
2205-2
Traces of insulation cuts
Wire strand is visible +
cut only impacting
insulation
(no cut strands)
Visual Inside vehicle Rework
2205-3
Peeled insulation
Peeled insulation must not
exceed 1 cm and limited to
one occurence
(no cut strands permitted)
Visual Inside vehicle Rework
2205-4
Wire deformation
Deformation only , no
crushing
Visual Inside vehicle
Reshape to initial state ,
otherwise replace
2205-5
Crushed wires
No crushing of wires
permitted
Visual Inside vehicle Replacement
2205-6
Wire strands broken No broken strands allowed Visual Inside vehicle Replacement
Defect N° PS Title Who
2205 Cabling Damaged Cables – Small Gauge IQ / Operator
Fiche critère - Draft v0

10. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2205-7
Traces of abrasions
Surface abrasions only,
insulation not peeled.
 Training moduleIND-
RS-LRH-GDL-023
 STD EN 50343
Visual All zones Use As Is
2205-8
Traces of cuts
Cut not exposing any bare
strands.
Visual
Interior
Exterior
Rework
Replace
2205-9
Peeled insulation
Depth and length of
impacted zone.
Visual All zones
Rework or replacement
after expertise analysis
2205-10
Insulation deformation
No insulation deformation
permitted
Visual All zones
Replacement if insulation
can’t be reshaped to
initial state
2205-11
Pinched No pinching allowed Visual All zones Replacement
2205-12
Exposed and cut strands
No exposed or cut strands
allowed
Visual All zones Replacement
Defect N° PS Title Who
2205 Cabling Damaged Cables– Large Gauge IQ / Operator
Fiche critère - Draft v0

11. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2205-13
Traces of abrasions
Surface abrasions only,
insulation not peeled
 Training module
IND-RS-LRH-GDL-023
 STD EN 50343
Visual All zones Use As Is
2205-14
Traces of cut
Cut depth reaching
braided shield but no cut
strands.
Visual
Interior
Exterior
Repair
Replacement
2205-15
Peeled off insulation
Depth and length of
impacted zone. No cut
strands allowed.
Visual
Interior
Exterior
Rework with expertise
advice.
Replacement
2205-16
Insulation deformation
No Insulation deformation
allowed.
Visual All zones
Replacement if insulation
can’t be rewok to initial
state.
2205-17
Crushed No Crushing allowed Visual All zones Replacement
2205-18
Cut strands No cut strands allowed Visual All zones Replacement
Defect N° PS Title Who
2205 Cabling Damaged Cables - Shielded IQ / Operator
Fiche critère - Draft v0

12. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2205-19
Traces of abrasion Surface abrasions only
 Training module
IND-RS-LRH-GDL-023
 STD EN 50343
Visual All zones Use As Is
2205-20
Traces of cut No traces of cuts allowed Visual All zones Replacement
2205-21
Peeled insulation
Peeled insulation not
allowed
Visual All zones Replacement
2205-22
Insulation Deformation No deformation allowed Visual All zones Replacement
2205-23
Crushed No crushed cables allowed Visual All zones Replacement
2205-24
Cut strand No cut strand allowed Visual All zones Replacement
Defect N° PS Title Who
2205 Cabling Damaged Cables – Network and Coaxial IQ / Operator
Fiche critère - Draft v0

13. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2205-25
Traces of abrasion Surface abrasions only
 Training Module
IND-RS-LRH-GDL-023
 STD EN 50343
Visual All zones Use As Is
2205-26
Traces of cut
Surface cut only , affects
insulation only.
Visual All zones Repair
2205-27
Peeled off insulation
Missing insulation less
than 1 cm in length and
isolated to one area only
Visual All zones Repair
2205-28
Insulation Deformation
No Insulation deformation
allowed
Visual All zones
Replacement if insulation
can’t be reshaped to
initial state
2205-29
Crushing No crushing allowed Visual All zones Replacement
2205-30
Cut strand No cut strand allowed Visual All zones Replacement
Defect N° PS Title Who
2205 Cabling Damaged Cables – Multiple conductors IQ / Operator
Fiche critère - Draft v0

14. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2206-1
Overheated
Cable and solder sleeve
shall not exhibit signs of
overheat
 Process ALSTOM PA-02
 Training Module
IND-RS-LRH-GDL-022
 STD NF F 61-014
Visual All zones
Replacement of cable
and solder sleeve
2206-2
Solder sleeve not melted
Solver sleeve completely
melted and shows
complete wetting of shield
Visual All zones Solder sleeve replacement
2206-3
Braid excessive length .
Not centered between 2
blue rings
Braid is centered between
blue rings
Visual All zones Replace solder sleeve
2206-4
Heat shrink perforated by
wire strands
No tears or perforation
permitted on heat shrink
Visual All zones
Replacement of solder
sleeve
Defect N° PS Title Who
2206 Cabling Shielding by solder sleeves IQ / Operator
Fiche critère - Draft v0

15. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2210-1
Termination not completed
(lid/cover missing)
Connector must conform
to design requirement
 Process de montage des
connecteurs (PAC)
 Training Module
IND-RS-LRH-GDL-023
 STD EN 50467
 STD NF F 61-030
Visual All zones
Finalize connector
assembly
2210-2
Incorrect coding
Coding must allow
adequate connector
mating to its respective
designation
Visual All zones Rework coding
2210-3
Connector damaged
Connector must be free of
any damages
Visual All zones Connector replacement
2210-4
Contact pin not fully
protruded
Contact pins should not
back off when a force is
applied to it
Visual All zones
Ensure pin is fully inserted
and protruded
Defect N° PS Title Who
2210 Cabling Connectors IQ / Operator
Fiche critère - Draft v0

16. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2210-5
Bent contact pin No bent pins allowed
 Process de montage des
connecteurs (PAC)
 Module de formation
IND-RS-LRH-GDL-023
 STD EN 50467
 STD NF F 61-030
Visual All zones Replace contact pin
2210-6
Broken Contact pin
No broken contact pins
allowed
Visual All zones Replace contact pin
2210-7
Loose nut
Nut must secure wires
without incurring any
damages
Visual All zones
Tighten nut according to
micro process
2210-8
Rotation of ferrule
The ferrule shall not rotate
when applying manual
force
Visual All zones Replace ferrule
Defect N° PS Title Who
2210 Cabling Connectors IQ / Operator
Fiche critère - Draft v0

17. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2210-9
Connectors not protected
Connectors must have
some form of protection
until they are integrated in
the final product
 Process de montage des
connecteurs (PAC)
 Training module
IND-RS-LRH-GDL-023
 STD EN 50467
 STD NF F 61-030
Visual All zones
Implement protection
over connector
2210-10
Connecteurs de réserve ou
de prédisposition non-
bridés
Pas de mouvement des
connecteurs
Visuel Toutes zones
Connectors to be tied
without restrictions
2210-11
Ties near ferrule
No constraint permitted
on cable and ferrule
Visual All zones Relocate tie wrap
Defect N° PS Title Who
2210 Cabling Connectors IQ / Operator
Fiche critère - Draft v0

18. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2216-1
Thin Gauge 4 x 
 Training module
IND-RS-LRH-GDL-023
 Norme EN 50343
 Norme NF F 61-010
 Requis fabricants
Visual / ruler All zones Repair
2216-2
Large Gauge
5 x 
Visual / ruler All zones
Repair non damaged
insulation
2216-3
Shielded Cables 8 à 10 x  Visual / ruler All zones
Repair if insulation is not
damaged
2216-4
Multi-conductors cables
without shield
5 x  Visual / ruler All zones
Repair if insulation is not
damaged
2216-5
Shielded Multi-conductor
cables
10 x  Visual / ruler All zones
Repair if insulation is not
damaged
2216-6
Network and coaxial
cables
10 x  Visual / ruler All zones Consult Expertise
Defect N° PS Title Who
2216 Cabling Bend radius defects IQ / Operator
Fiche critère - Draft v0

19. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2217-1
Cables near sharp edges
No cables near sharp
edges
 Training module
IND-RS-LRH-GDL-023
 STD NF F 61-013
Visual All zones
Review routing; clipstan
clip protection over sharp
edges
2217-2
Cables resting on the
ground/floor
Cables must never rest on
floor/ground
Visual All zones
Implement carpeting for
protection
2217-3
Part resting over cable
No parts shall rest over
top of cables
Visual All zones
Remove all parts over
cables and ensure cables
were not damaged
2217-4
Presence of metal shavings
No presence of metal
shavings allowed
Visual All zones Vacuum all shavings
Defect N° PS Title Who
2217 Cabling Protection / Preservation IQ / Operator
Fiche critère - Draft v0

20. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2217-5
Damaged cable hardware
No hardware shall present
forms of damages or
deterioration
 Training module IND-
RS-LRH-GDL-023
 STD NF F 61-013
Visual All zones
Replace damaged
components
Defect N° PS Title Who
2217 Cabling Protection / Preservation IQ / Operator
Fiche critère - Draft v0

21. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2218-1
Connections not completed
All connections must be
completed according to
the micro process in
accordance with their
reference designation
 Micro processes
 Training Module
IND-RS-LRH-GDL-023
 STD EN 50343
 DTRF150222
Visual All zones Complete connections
2218-2
Connection not completed .
Hardware loose
All connections must be
completed according to
the micro process in
accordance with their
reference designation
Visual All zones Complete connections
2218-3
Incorrect connection
Criteria defined in
DTRF150222
Visual All zones Rework Connections
Defect N° PS Title Who
2201 Cabling Connections IQ / Operator
Fiche critère - Draft v0

22. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2219-1
Loose cable gland
Cable gland is in contact
with the cable. Cable shall
not be free of movement
 Supplier instructions
 Process ALSTOM PA-06-
08
 Micro process
Visual All zones Tighten cable gland
2219-2
Cable gland over tightened
Core water sealant
material is flush with top
of cable gland
Visual All zones
Replace cable gland /
replace cable gland if
damages incurred
2219-3
Damaged nut
No signs of damages on
the hardware
Visuel Toutes zones Replace Hardware
2219-4
Damaged gasket
Gasketing defined by
Micro process
Visual All zones
Replace / re-position
gasket in accordance
with micro process
2219-5
Tightening clamp
hardware too long on
compression module
Hardware in compliance
with manufacturer
Visual All Zones
Replace compression
module
Defect N° PS Title Who
2201 Cabling Water tightness IQ / Operator
Fiche critère - Draft v0

23. Non Conformance
(photo)
Defect Acceptance Criteria Reference Documentation Control Method Zone
Corrective Actions
(repair/replace /
expertise)
2219-6
Water tightness seal
improperly mounted
Seal must be fully inserted
and secured
 Manufacturer
instructions
 Process ALSTOM PA-06-
08
 Micro processes
Visual All zones Reposition seal
Defect N° PS Title Who
2201 Cabling Water Tightness IQ / Operator
Fiche critère - Draft v0