ASES OPEN POINT

Sr. No. Question Date Phenomenon Requirement from RNTBCI (From ASES report) Actions from supplier Pilot Target Date

Store department has single process but only BOP store audit is Next Audit Cycle (Dec'-20) complete store department process
1 1.1 Gaurav 16/7/2021
being performed. shall be covered and schedule to be revised.

Internal audit NC classification (Major / Minor) & closure

2 1.1 30.04.21 Internal audit NC clasification and closure timline to be update Gaurav 16/7/2021
timeline

Internal audit NC tracking sheet not updated the current

3 1.1 30.04.21 Internal audit NC tracking sheet to be updated Gaurav 16/7/2021
NC status

4 1.1 30.04.21 Internal audit NC report not evidenced. Internal audit NC report to be prepared Gaurav 16/7/2021

Process audit NC closure timeline not defined in the

5 1.1 30.04.21 Process audit NC clouser timeline to be defined Gaurav 16/7/2021
procedure

List of process & product auditor not available.

6 1.1 30.04.21 Process & product records not evidenced during the List of process and product auditor to be prepared Gaurav 16/7/2021
review.

Process parameter verification not evidenced in internal

7 1.1 30.04.21 Porcess paramter to be verified in internal audit Gaurav 16/7/2021
audit

IATF Auditors list is available but contingency for auditor not

8 1.1 ASES report IATF Auditor list to be update. Gaurav 16/7/2021
define in it.

9 1.2 ASES report Process Audit Plan available but not updated for the Aug-20 month. Process Audit to be update Gaurav 16/7/2021

Process Parameter observation for the SDH not evident in the

10 1.2 ASES report Process Audit Report to be cross-verify after audit. Ashwani, Rishu, Vinod 16/7/2021
report.

Process Audit performed for the pedal wrt customer complaint, but Customer Complaint details wrt corrective actions to be
11 1.2 ASES report Ashwani, Rishu, Vinod 16/7/2021
its observation define as "OK" considered.

Past troubles and lesson learning incorporation / Add Past troubles & lesson learnt incorporation as criteria for phase Past trouble and lesson learnt to be incorporated for phase
12 3-4 ASES Report Irshad 16/7/2021
implementation is not considered for phase approval. approval. approval
No evidenced for the Feasibility study results &
13 3-3 25.05.21 comparision study for the PPM target, Ranking target, Feasibility study results with comparision study to be prepared Anil (Design) 16/7/2021
1) No internal project review meeting & Minutes of
Warranty target.
meeting not evidenced for Nissan- Screw jack parts. No
MOM after Dec'2020. Internal project review meeting & Minutes of meeting evidenced
14 3-3 25.05.21 Internal review meeting mom ro be prepared Irshad 16/7/2021
for Nissan- Screw jack parts to be shown
2) No
1) Revised target for
evidenced datethe
not available
design for meeting
review the project review
& minutes
meetingend
open points. Evidenced to be shown for the design review meeting & minutes
15 3-3 25.05.21 before of the design milestone. Design review minutes to be prepared Anil (Design) 16/7/2021
before end of the design milestone.
2) TGW / TGR not considered during Design review
Progress review frequency is not defined in the procedure.
Capture the progress review meeting frequency in the procedure
Progress review meeting plan vs actual status is not Process review meeting frequency to be defined in procedure and
16 3-3 ASES Report and timeline in the APQP timing plan. Conduct the review Gaurav & Irshad 16/7/2021
captured in the review meeting plan vs actual to be captured in timing plan
as per plan and update the status accordingly.
APQP timing plan.
Past troubles and lesson learning incorporation / Add Past troubles & lesson learnt incorporation as criteria for phase Past trouble and lesson learnt to be incorporated for phase
17 3-4 ASES Report Irshad 16/7/2021
implementation is not considered for phase approval. approval. approval
No evidenced for the Feasibility study results &
18 3-3 25.05.21 comparision study for the PPM target, Ranking target, Feasibility study results with comparision study to be prepared Anil (Design) 16/7/2021
Warranty target.
1) No internal project review meeting & Minutes of
meeting not evidenced for Nissan- Screw jack parts. No
MOM after Dec'2020. Internal project review meeting & Minutes of meeting evidenced
19 3-3 25.05.21 Internal review meeting mom ro be prepared Irshad 16/7/2021
for Nissan- Screw jack parts to be shown
2) Revised target date not available for the project review
meeting open points.

1) No evidenced for the design review meeting & minutes

Evidenced to be shown for the design review meeting & minutes
20 3-3 25.05.21 before end of the design milestone. Design review minutes to be prepared Anil (Design) 16/7/2021
before end of the design milestone.
2) TGW / TGR not considered during Design review

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 ASES OPEN POINT
Sr. No. Question Date Phenomenon Requirement from RNTBCI (From ASES report) Actions from supplier Pilot Target Date

Progress review frequency is not defined in the procedure.

Capture the progress review meeting frequency in the procedure
Progress review meeting plan vs actual status is not Process review meeting frequency to be defined in procedure and
21 3-3 ASES Report and timeline in the APQP timing plan. Conduct the review Gaurav & Irshad 16/7/2021
captured in the review meeting plan vs actual to be captured in timing plan
as per plan and update the status accordingly.
APQP timing plan.

Ramp up
activity plan not
Ramp up activity plan to be prepared for Nissan model
22 5.1 available for Ramp up activity plan to be prepared for Nissan model Screw Jack Irshad 16/7/2021 16/7/2021
Screw Jack
Nissan model
Screw Jack

No occurrence back up data available or evidenced for

23 4.1 29.06.21 Naveen 16/7/2021
FMEA.

Past troubles / lesson learnt not applied in the Nissan

24 4.1 29.06.21 project. Ex: Bearing failure from Maruti, project. Anil/Rajiv 16/7/2021
Failure mode, Cause & actions to be captured in DFMEA

Drawing change level and control plan revision level with

change history is not captured in the control plan. Ex. Capture the latest drawing change level and control plan revision Drawing change level, control plan revision with change history to
25 4.2 ASES report Pramod 16/7/2021
Drawing revision level with change history in the control plan. be capture control sheet
level is 00 / 09.09.18
Control method assigning criteria is not respected against
procedure. Ex. Defect: Crack, Severity - 7, Control method
Revisit the control plan to capture the control method according to Revisit the control plan to capture the control method according to
26 4.2 ASES report is defined as Pramod 16/7/2021
criteria defined in the procedure criteria defined in the procedure
Sampling (3nos / 100 nos) instead of 100% visual
inspection
Some of the process parameters are not captured in the
27 4.2 ASES report control plan. Ex. Process: Blanking, Process Parameter: Revisit the control plan to include the missing process parameter Revisit the control plan to include the missing process parameter Pramod 16/7/2021
Shut height

Some of the drawing requirements are not addressed in the

28 4.2 ASES report Revisit the control plan to add the missing drawing requirements Revisit the control plan to add the missing drawing requirements Pramod 16/7/2021
control plan. Ex. Burr allowed limit is 0.15 mm maximum

Ramp up activity plan not available for Nissan model Ramp up activity plan to be prepared for Nissan model Screw
29 5.1 Ramp up activity plan to be prepared for Nissan model Screw Jack Irshad 16/7/2021
Screw Jack Jack

Operator Training manual not available for the operators

which should includes Operator Training manual which should includes
1. W.I 1. W.I 2. Management of non-conforming parts;
2. Management of non-conforming parts; 3. unusual situations;
3. unusual situations; 4. How to handle measuring instruments;
30 11.06.21 4. How to handle measuring instruments; 5. observance items of control plans; New operator training module to be prepared Chandra Pal & Indu Yadav 16/7/2021
5. observance items of control plans; 6. Product Knowledge
6. Product Knowledge 7. Rework
7. Rework 8. Environmental and Safety
8. Environmental and Safety 9..Safety and regulation product(if apply)
9..Safety and regulation product(if apply)

Timeline for some key activities is not addressed in the sub

supplier quality concerns handling procedure. Ex. Sub
Define timeline for each activities involved for sub supplier quality
31 9.4 ASES report supplier Timelines to be defined in procedure Gaurav 16/7/2021
concerns handling.
communication for quality issues, Containment actions
etc.,
Some appearance related defects (<100PPM in Sheet metal
and <500PPM in Plating parts) are not communicated to Communicate the sub supplier for all quality issues within 24 hours Sub Supplier quality Concern procedure to be revised for handling
32 9.4 ASES report Gaurav 16/7/2021
sub supplier to implement necessary actions to avoid recurrence. the sub-supplier concerns.
for cause analysis and correction action.

Some reaction rule like root cause analysis and actions Gaurav, Surjeet, Aditya and
33 7.7 ASES report Reaction Rule to be defined incase of Inspection equipment is NOK. Reaction rules to be defined for not ok equipments 16/7/2021
incase of Inspection equipment is NOK is not defined Vinod

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 ASES OPEN POINT
Sr. No. Question Date Phenomenon Requirement from RNTBCI (From ASES report) Actions from supplier Pilot Target Date

NC handling procedure is not displayed at Shopfloor.

which includes marking of defect location, put in the red Display the NC handling procedure at Shopfloor (easy access to Gaurav, Surjeet, Aditya and
34 7.10 ASES report NC handling procedure to be displayed on the shopfloor. 16/7/2021
bin, record in register immediately , end of the shift tally Operators and Inspectors). Vinod
the rej qty with register

Feedback to cause process is not defined & followed incase Add feedback to cause process in the NC handling procedure with Gaurav, Surjeet, Aditya and
35 7.10 ASES report Feedback to cause process to be defined 16/7/2021
of continuous rejection or major rejection criteria. Define and follow the feedback record. Vinod

Defect parts are not marked and not recorded immediately

by category of defects. Ex. Process: Riveting, Part: Side Educate the Operators / Inspectors to mark the defective parts
36 7.10 ASES report Defect parts to be marked and recorded Surjeet, Aditya and Vinod 16/7/2021
Door Hinge according to the procedure.
Female, Defect: Plating dull, Quantity: 1 no
Disposal of defective parts from red box is not followed
Define the rejection parts disposal frequency and follow the same.
periodically. Cross checking is not performed at end of the
37 7.10 ASES report Perform the cross checking at shift end for actual Disposal to defective part at the end of the shidt to be ensured Surjeet, Aditya and Vinod 16/7/2021
shift against
quantity in red box against recorded quantity.
actual quantity in red box and recorded quantity.
Rework decision matrix is not defined for process wise
defects. Ex. Part: Door hinge rear upper YP8, Process:
Modify the rework decision matrix for process wise defects Gaurav, Surjeet, Aditya and
38 7.11 ASES report Bush fitment Male + Rework decision matrix ti be defined as per control plan 16/7/2021
according to control plan Vinod
Bush, Defect: Bush improper fitment, Gap between male &
bush, loose after fitment etc.,
Rework instruction is not defined for some reworkable
defects. Ex. Ex. Part: Door hinge rear upper YP8, Process:
Gaurav, Surjeet, Aditya and
39 7.11 ASES report Bush fitment Male Prepare the rework instruction for missing reworkable defects Rework instruction to be defined for all reworkable defects 16/7/2021
Vinod
+ Bush, Defect: Bush improper fitment, Gap between male
& bush, loose after fitment etc.,

Rework records not available for the rework parts, which

40 7.11 09.07.21 should includes the reworkd Qty, Ok Qty, Rej Qty, Rework 16/7/2021
operaotr sign, QA signe, etc.

Some unusual situations related to Equipment and Part is

Add missing unusual situation into the procedure with appropriate Gaurav, Surjeet, Aditya and
41 7.12 ASES report not defined. Ex. Unknown defect, Defect in new location, Abnormality handling rules to be updated 16/7/2021
reaction rule Vinod
Spike rejections, etc.,

Unusual situation handling procedure is not known to Educate the concerned members on unusual situation handling Gaurav, Surjeet, Aditya and
42 7.12 ASES report Training to be provided 16/7/2021
concerned members at shopfloor. procedure Vinod

Fallen parts check details and disposal status are not Gaurav, Surjeet, Aditya and
43 7.12 ASES report Record the fallen part quality check details and disposal status Check details and disposal status to be recorded for fallen parts 16/7/2021
recorded. Ex. Part: Arm R00, Date: 15-07-2020, Qty 3 nos. Vinod

Unusual situations other than Fallen part is not recorded Follow the unusual situation handling procedure and record
44 7.12 ASES report Abnormal situation handling rules to be followed Surjeet, Aditya and Vinod 16/7/2021
with retroactive, cause and action details retroactive confirmation details, analysis, actions and restart

Poka Yoke failure retroactive confirmation not Poka Yoke failure retroactive confirmation to be defined
Retroactive conformation to be clealy defined for POKA Surjeet, Aditya and Vinod
45 7.12' 17.04.21 clearly defined in the abnormmal situation in the procedure. Ex: Checking of parts in next station, 16/7/2021
YOKE failire
procedure FG, If required transit & Customer end,.

PM is not done as per plan for some machines. No

deviation approval from QA and reschedule plan is Conduct the PM according to the plan. Incase of any delay, make
PM to be done as per plan, where schedule is delayed deviation
46 7.17 ASES report available for delayed PM. Ex. reschedule and follow additional check to avoid quality Ramesh Yadav 16/7/2021
approval is required
Press PWM 26: Frequency is 6 months once, Due on: issues.
06/20 - 2nd Week

Define target for maintenance KPI's like MTBF, MTTR etc., based
No target for maintenance KPI is defined. Ex. MTBF,
47 7.17 ASES report on past data. Monitor the monthly results and initiate the KPI targets to be defined Ramesh Yadav 16/7/2021
MTTR etc.,
correction actions incase of non achievement of target.

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 ASES OPEN POINT
Sr. No. Question Date Phenomenon Requirement from RNTBCI (From ASES report) Actions from supplier Pilot Target Date

Prepare general spare list with minimum stock level, reorder qty
General spare list and its stock level monitoring is not
48 7.17 ASES report and lead time. Monitor the spares IN and OUT to manage General spare list stock monitoring to be done Ramesh Yadav 16/7/2021
available for Machines
the availability.

Life for consuming tools / spares is not defined and

Prepare general spare list with minimum stock level, reorder qty
monitored. Ex. Die coating life, Piercing punch life,
49 7.17 ASES report and lead time. Monitor the spares IN and OUT to manage Consumable tool life to be defined and monitored Surjeet, Aditya and Vinod 16/7/2021
Projection welding electrode
the availability.
life etc..,
Timeline for some key activities is not addressed in the sub
supplier quality concerns handling procedure. Ex. Sub
Define timeline for each activities involved for sub supplier quality
50 9.4 ASES report supplier Timelines to be defined in procedure Gaurav 16/7/2021
concerns handling.
communication for quality issues, Containment actions
etc.,
Some appearance related defects (<100PPM in Sheet metal
and <500PPM in Plating parts) are not communicated to Communicate the sub supplier for all quality issues within 24 hours Sub Supplier quality Concern procedure to be revised for handling
51 9.4 ASES report Gaurav 16/7/2021
sub supplier to implement necessary actions to avoid recurrence. the sub-supplier concerns.
for cause analysis and correction action.

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