Draft audit report

Is this a remote audit? No

Report name/no 221453

Organization name OMNI AUTO LIMITED - UNIT IV

Audit start date 20.Jan.2022

Audit end date 22.Jan.2022

Audit type Stage 2

Standard IATF 16949:2016

CB identification no. NA

CB certificate no. NA

IATF certificate no. 0350249

Overall result Nonconformities issued, action required

Address

Division

State Andhra Pradesh

City Sricity DTZ

Postal code 517541

Street 1 350, North Belerica Road,

Street 2 Varadaiahpalem, Chittoor District,

Country India

Organization name : OMNI AUTO LIMITED - UNIT IV CB certificate no.: NA Cara Version 1.2.5
Audit date: 20.Jan.2022-22.Jan.2022 1/7
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Results
Audit team

Name Auditor ID no. Audit days Dates on-site

performed

Lead auditor Ravi Gurumoorthy 5-ADP-14-12-2334 3 20.Jan.2022 (1), 21.Jan.2022 (1), 22.Jan.2022 (1)

Co auditor 1 Ravishankar Jayaraman 5-ADP-13-07-2148 3 20.Jan.2022 (1), 21.Jan.2022 (1), 22.Jan.2022 (1)

All automotive customer(s)

Customer name Customer details

Name of CSR document Date of CSR Supplier code(s) IATF OEM New
document customer
since last
audit?

Timken Supplier Requirements Manual, Revision 12 – 20221014

Timken Corporate Standard 29.1 10/2021

Audit team conclusion

Comments Totally 4 minor NCs raised. Action requested.

Is a special audit needed? No

Number of nonconformities issued during the audit

Total number Due date max. 20 days Due date max. 60 days

Minor nonconformities 4 23.Mar.2022

Major nonconformities 0

Opportunities for improvement 0

Positive aspects 0

Audit summary

With ref to the audit information received and the priorities identified through the performance data - Like - On time delivery, Internal rejection
(Forging), MTTR, COPQ.
The audit was planned and conducted considering the above priorities. Verified the actions at appropriate process where the target was not
achieved.
The overall implementation of the process found good. However, 4 minor NCs were raised. Actions requested along with evidences.

Audit team recommendation

Certification is pending subject to nonconformity management

Next regular audit

Surveillance interval desired 12 Months

Next regularly scheduled audit type 1st Surveillance audit

Target date of next audit 22.Jan.2023

By entering my name, I attest that a copy of the draft or final audit report and the NC management report was left with the organization at the

Organization name : OMNI AUTO LIMITED - UNIT IV CB certificate no.: NA Cara Version 1.2.5
Audit date: 20.Jan.2022-22.Jan.2022 2/7
 Draft audit report

closing meeting.

Ravi Gurumoorthy 22.Jan.2022 This document is valid without a signature

Auditor´s name date

Auditing is based on a sampling process of the available information. The disclaimer of liabilities in point VI of the quality austria Terms and
Conditions applies.

Organization name : OMNI AUTO LIMITED - UNIT IV CB certificate no.: NA Cara Version 1.2.5
Audit date: 20.Jan.2022-22.Jan.2022 3/7
 Draft audit report

NC & actions
Nonconformity 1
To be completed by the CB auditor

NC header

NC identification no. 01 / 04 - CA

Standard ISO 9001:2015 and IATF 16949:2016

Classification minor

Due date max. 60 days 23.Mar.2022

Nonconformity observed in process Top Management

Standard clause 6.1.2

Actions to Address Risks and Opportunities

Requirement (Enter ISO 9001:2015 requirement)

Statement of nonconformity

The top Management process is not fully effective pertaining to Risk Assessment.

Objective evidence

Ref to the doc : MR/F/03- SWOT analysis & MR/F/04 - risk assessment register, the risk related to some of the processes such as HR process
were not documented and evaluated. This is not in compliance with organization defined method for process wise risk assessment

Justification for classification

However, identification of risks and actions for other processes such as QA process are found satisfactory. Overall business risks of the
organization well captured in SWOT analysis and acted upon through plans and reviews. Hence it is a lapse in systematic approach to process
wise documentation of risks. No customer risk identified, hence termed as minor.

Ravishankar Jayaraman 22.Jan.2022 This document is valid without a signature

Auditor´s name Audit closing meeting date

Nonconformity 2
To be completed by the CB auditor

NC header

NC identification no. 02 / 04 - CA

Standard IATF 16949:2016

Classification minor

Due date max. 60 days 23.Mar.2022

Nonconformity observed in process Production (Cutting, Hot Forging)

Standard clause 9.1.1.1

Monitoring and measurement of manufacturing processes

Requirement The organization shall perform process studies on all new

manufacturing (including assembly or sequencing) processes to verify
process capability and to provide additional input for process control,
including those for special characteristics.
The organization shall maintain manufacturing process capability or
performance results as specified by the customer’s part approval
process requirements. The organization shall verify that the process
flow diagram, PFMEA, and control plan are implemented, including

Organization name : OMNI AUTO LIMITED - UNIT IV CB certificate no.: NA Cara Version 1.2.5
Audit date: 20.Jan.2022-22.Jan.2022 4/7
 Draft audit report

adherence to the following:

a) measurement techniques;
b) sampling plans;
c) acceptance criteria;
d) records of actual measurement values and/or test results for
variable data;
e) reaction plans and escalation process when acceptance criteria are
not met.
Significant process events, such as tool change or machine repair,
shall be recorded and retained as documented information.
The organization shall initiate a reaction plan indicated on the control
plan and evaluated for impact on compliance to specifications for
characteristics that are either not statistically capable or are unstable.
These reaction plans shall include containment of product and 100
percent inspection, as appropriate. A corrective action plan shall be
developed and implemented by the organization indicating specific
actions, timing, and assigned responsibilities to ensure that the
process becomes stable and statistically capable. The plans shall be
reviewed with and approved by the customer, when required.
The organization shall maintain records of effective dates of process
changes.

Statement of nonconformity

‘The Production – Cutting & Forging” process is not fully effective pertaining to inspection as per control plan.

Objective evidence

Ref to Part no. WE1916-C, Material grade – 4319 BSP (40) Batch code R2141, The control plan stipulates, the part length 71.71mm, weight
09.92 Kg’s. Whereas, the In-process inspection report is done for weight only whereas, as per control plan the checking of length n=5 No’s / 2
Hrs. Hence monitoring and measurement of product not in accordance with control plan requirements.

Justification for classification

However, part length is controlled in further processes including final inspection. No customer or in house concerned observed due to
dimensional issues. No customer risk identified, hence termed as minor.

Ravishankar Jayaraman 22.Jan.2022 This document is valid without a signature

Auditor´s name Audit closing meeting date

Nonconformity 3
To be completed by the CB auditor

NC header

NC identification no. 03 / 04 - CA

Standard IATF 16949:2016

Classification minor

Due date max. 60 days 23.Mar.2022

Nonconformity observed in process Production (Cutting, Hot Forging)

Standard clause 8.5.1.6

Management of production tooling and manufacturing, test,
inspection tooling and equipment

Requirement The organization shall provide resources for tool and gauge design,
fabrication, and verification activities for production and service
materials and for bulk materials, as applicable.
The organization shall establish and implement a system for
production tooling management, whether owned by the organization
or the customer, including:
a) maintenance and repair facilities and personnel;
b) storage and recovery;

Organization name : OMNI AUTO LIMITED - UNIT IV CB certificate no.: NA Cara Version 1.2.5
Audit date: 20.Jan.2022-22.Jan.2022 5/7
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c) set-up;
d) tool-change programmes for perishable tools;
e) tool design modification documentation, including engineering
change level of the product;
f) tool modification and revision to documentation;
g) tool identification, such as serial or asset number; the status, such
as production, repair or disposal; ownership; and location.
The organization shall verify that customer-owned tools,
manufacturing equipment, and test/inspection equipment are
permanently marked in a visible location so that the ownership and
application of each item can be determined.
The organization shall implement a system to monitor these activities
if any work is outsourced.

Statement of nonconformity

‘The Production – Cutting & Forging” process is not fully effective pertaining to tool life monitoring.

Objective evidence

Ref to cutting operation, Blade change frequency defined as once in 10,000 billets, as per control plan for Rollers. But no evidence demonstrated
for blade condition check or blade change, as per defined frequency. E.g. part no. EH852401, dia 60, production quantity – 12,531 pcs

Justification for classification

However, the product checks are carried out as per control plan and process output meets specifications . No customer or in-house quality risk
identified, hence termed as minor.

Ravishankar Jayaraman 22.Jan.2022 This document is valid without a signature

Auditor´s name Audit closing meeting date

Nonconformity 4
To be completed by the CB auditor

NC header

NC identification no. 04 / 04 - CA

Standard IATF 16949:2016

Classification minor

Due date max. 60 days 23.Mar.2022

Nonconformity observed in process HR & Admin

Standard clause 7.3.2

Employee motivation and empowerment

Requirement The organization shall maintain a documented process(es) to

motivate employees to achieve quality objectives, to make continual
improvements, and to create an environment that promotes
innovation. The process shall include the promotion of quality and
technological awareness throughout the whole organization.

Statement of nonconformity

The HR process is not fully effective pertaining to employee motivation.

Objective evidence

The Employee motivation policy OALS/5000/08 defined with various scheme such as bonus, monthly good attendance award etc. and related
evidences such as photographs maintained.

Organization name : OMNI AUTO LIMITED - UNIT IV CB certificate no.: NA Cara Version 1.2.5
Audit date: 20.Jan.2022-22.Jan.2022 6/7
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However, there were no evidence of motivation schemes to motivate employees to achieve quality objectives, to make continual improvements,
and to create an environment that promotes innovation. This is not in compliance to the requirements of the reference standard.

Justification for classification

However, employees engagements ensured in the form of timely communication and reviews to enable their contribution in achieving quality
objectives. Other defined motivation schemes such as attendance award etc. found implemented. Hence it is a lapse in motivational policy in
addressing improvement related motivation. No customer risk identified, hence termed as minor.

Ravishankar Jayaraman 22.Jan.2022 This document is valid without a signature

Auditor´s name Audit closing meeting date

Organization name : OMNI AUTO LIMITED - UNIT IV CB certificate no.: NA Cara Version 1.2.5
Audit date: 20.Jan.2022-22.Jan.2022 7/7