ASES Pre-questionnaire Name: Function: Date:

Thank you to send « your answer of the following questionnaire » to Renault/Nissan,

latest 1 week before ASES evaluation at supplier’s site.
Supplier name:
Plant name:
Plant address:

1.Outline of your company

1 Please state the main parts manufactured by your com
2 Please state your main customers.
3 Do you manufacture parts with safety characteristics?

2.Quality result
1)Warranty claims occurrence ratio （ % ） Type in actual numbers
①Please state the actual figures and the ratio of «number of market claims to the total number of delivered parts of
the subject parts group» for your company in the latest 3 years.
3 Years ago 2 Years ago Last year This year
Target
Total No. of delivered parts of
subject part
No. of market claims
Result (Occurrences)
Warranty claims occurrence
ratio (%) #DIV/0! #DIV/0! #DIV/0! #DIV/0!

②concerns which have occurred in the previous years N/C; Non conformity No of N/C content of non conformity

a. Concerns where recall/service campaign and other market actions were ta

b. Serious market claims and delivery concerns which are required

repairing vehicles before vehicles shipment ( i.e. Vehicles in service )

c. Total numbers of concern of a with b 0

Please state your responsibility percentage on those concerns.
2)Delivery reject rate (ppm) Type in actual numbers
Please state the actual figures and the ratio of «the number of delivery rejected parts to the total number of
delivered parts of the subject parts group» as delivered to your customers latest 3 years.
3 Years ago 2 Years ago Last year This year
Target
Total No. of delivered parts of
subject parts group
Result
No. of rejected parts
Delivery reject rate (ppm) #DIV/0! #DIV/0! #DIV/0! #DIV/0!
3)Process reject rate (%) Type in actual numbers
1.Please state the actual figures and the ratio« the number of scrapped parts (excluding repaired parts ) » to
internal process latest 3 years.
3 Years ago 2 Years ago Last year This year
Target
Production amounts
Result Scrap amounts
Scrap rate #DIV/0! #DIV/0! #DIV/0! #DIV/0!
2.Please state the actual figures and the ratio of « the number of scrapped parts (excluding repaired parts ) to the
total number of parts produced in the subject process( 3 or 4 process selected separately ) »-in the current or
previous month.
Name of major proces Process Process Process Process Process
Production amounts
Scrap amounts
Scrap rate #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
4)Quality Crisis:
Question Answer
Is any service campaign or customer plant blockage
occurred in the past one year ?
3. Quality system

(1) Quality policy and quality assurance system

Question Answer
1) QA system
Please state the status of your certification to ISO TS
16949 , other certifications, awards from other OEM’s and
internal audit.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

2) Quality organization
Please detail the organization of the quality assurance within
your company including roles and responsibilities
(responsible people, related department, etc.)

3) Quality objectives
Please state the quality policy of your company and the
concrete targets in it with the results for three years.

(2) Analysis of the quality concerns for current products

Question Answer
1) Activity for target achievement
Please explain progress control of annual target and action
plan for delivery ppm and warranty claims.

2) Information analysis of warranty claims

Please explain procedure of collection and analysis of
warranty information.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

3) Cause analysis of non-conforming parts
Please explain methods of cause analysis for returned parts
(inc. warranty and delivery rejects) and internal defects.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

4) Prevention of recurrence
Please explain the recurrence prevention system, from
analysis of defect parts to deployment to similar
parts/processes, and knowledge building.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

5) Progress control of defect treatment
Please explain the methods of progress control for
investigation and defect analysis.
Please give the document number and the document name if
there is a standard to do it.
investigation and defect analysis.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

(3) Project management
Question Answer
1) Organization
Please explain method of establishing project team.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

2) Feasibility study
Please explain method of conducting feasibility study.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

3) Supplier Master Schedule and progress meetings
Please explain methods of making Supplier master schedule
and conducting progress meetings
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

4) Phase reviews and Design reviews
Please explain method of conducting Phase reviews and
Design reviews.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

(4) Process design and Pre-production

Question Answer
1) FMEA
Please explain method of managing FMEA.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

2) Control plan
Please explain method of establishing control plan.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

3) POKA YOKE
Please explain method of installing Poka Yoke.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

4) Process Instructions
Please explain method of establishing process instructions.
Please give the document number and the document name if
there is a standard to do it.
Document No. & Name
 5) Equipment & tools commissioning
Please explain method of conducting equipment & tools
commissioning.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

6) Process capability
Please explain how product characteristics are selected for
capability study.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

7) Production trials
Please explain method of conducting production trials.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

(5) Ramp-up activity

Question Answer
Ramp-up activity control
Please explain method of conducting ramp-up activity.
Please fill in the document number and the document name
if there is a standard to do it.

Document No. & Name

(6) Operator training

Question Answer
1) Operator training
Please explain method of operator training in project and
serial phase.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

2) Operator skill evaluation
Please explain method of operator skill evaluation.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

(7) Shop floor

No preliminary question.

(8) Change Management

Question Answer
1) Process / plant change management
Please explain method of process/plant change management.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

2) Design (product) change management
Please explain method of design (product) change
management.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

3) Change management at sub-suppliers
Please explain method of change management at sub-
suppliers.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

(9) Sub-suppliers management

Question Answer
1) Sub-supplier sourcing and quality assurance contracts
Please explain method of sub-supplier sourcing and quality
assurance contracts.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

2) Sub-supplier project management
Please explain method of project management with sub-
suppliers.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

3) Sub-supplier performance management
Please explain method of sub-supplier performance
management.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

4) Sub-supplier 8D management
Please explain management of sub-supplier 8D.
Please give the document number and the document name if
there is a standard to do it.

Document No. & Name

ASES Schedule
Participants (Departments to be represented) -
Assessment items
O= Must be represented △= If required

Chapter
Date Start Finish Duration
Plant Design And Production
Chapter Title Evaluation Items Quality Manufacturing
management Development Engineering

1st Day 8:30 8:40 10 min. Renault / Nissan explanation of Evaluation and agenda. O O O O O
8:40 9:00 20 min. 0 Supplier presentation & quality results Main products, main customers & quality results O O
9:00 9:30 30 min. Plant tour O O
9:30 11:00 90 min. 1. Quality policy & Quality 1-1 QA system O O
assurance system 1-2 QA organization and meetings O O
1-3 Quality objectives O O
Analysis of the quality concerns for
11:00 13:00 120 min. 2. 2-1 Activity for target achievement O O D D D
current products 2-2 Information analysis for warranty claims O O D D
2-3 Cause analysis of non-conforming parts O D D D
2-4 Prevention of recurrence O D D D
2-5 Progress control of defect treatment O D D D
Lunch (On site sandwich / buffet)
Project management
14:00 15:00 60 min. 3 3-1 Organization O O O D
3-2 Feasibility study O O O D
3-3 Supplier Master Schedule and progress meetings O O O D
3-4 Phase reviews and Design reviews O O O D
15:00 16:30 90 min. 4 Process design and Pre-production 4-1 FMEA O O O
4-2 Control plan O D O
4-3 POKA YOKE O D O
4-4 Process Instructions O D O D
4-5 Equipment & tools commissioning O D O O
4-6 Process capability O D O O
4-7 Production trials O D O O
16:30 17:00 30 min. 5 Ramp-up activity 5-1 Ramp-up activity control O D O O
17:00 17:30 30 min. 6 Operator training 6-1 Operator training O O
6-2 Operator skill evaluation O O
17:30 18:00 30 min. Internal debriefing (evaluation team)
＊This schedule is subject to change.
2nd Day 8:30 11:30 180 min. 7 Quality assurance at production stage 7-1 Raw materials and components receiving O O
Check at line start-up.
7-2 Control of the equipment conditions. O D O
7-3 O O O
7-4 Process instructions. O D O
7-5 5S D O O
Part cleanliness and preservation.
7-6 O O
7-7 Inspection of work in process/finished parts O O
7-8 Control by SPC sheet. O D O
7-9 Special characteristics. O O
7-10 Management of non-conforming parts. O O
7-11 Treatment of non-conforming parts O O
7-12 "Unusual" product and equipment situations. O D O
7-13 Improvement activity in the shop floor. D O D O
7-14 Control of delivery process (packaging). O O
7-15 Storage of work in process/finished parts. O O
7-16 Traceability O O
7-17 Maintenance of equipment O O O
7-18 Calibration of gauges / measurement instruments. O O
11:30 12:30 60 min. 8 Change Management 8-1 Process / plant change management . O O O
8-2 Design (product) change management O O O O
8-3 Change management at sub-suppliers D Purchasing O
Lunch (On site sandwich / buffet)
13:30 14:30 60 min. 9. Control of sub -supplier 9-1 Sub-supplier sourcing and quality assurance contraD Purchasing O
9-2 Sub-supplier project management. D Purchasing O
9-3 Sub-supplier performance management. D Purchasing O
9-4 Sub-supplier 8D management D Purchasing O
14:30 15:30 60 min. Internal debriefing (evaluation team)
15:30 16:00 30 min. Wrap-up meeting O O O O O

＊This schedule is subject to change.

Documents to be prepared
Evaluation items Expected Documents
1 Quality policy and 1) QA system Certification report
quality assurance Recommendation and follow up plan
system Standard of internal audit
Recommendations and follow up plan
Minutes of internal audits

2) QA organization and meetings Quality meeting report and minutes

Management review report and minutes
Quality Assurance organization chart

3) Quality objectives The current year quality objectives document deployed in the company
Quality results of last 3years (Warranty, external ppm and internal ppm)

2 Analysis of the quality 1) Activity for target achievement Pareto of market claims, delivery and internal defects
concerns for current Action plan for the main problems
products Quality meeting reports:
- quality meeting minutes
- management review minutes

2) Information analysis Flow chart of collection of market claim information from car makers
Warranty claim data analysis graph
Weibull analysis for main warranty claims
Alarm control standard

3) Cause analysis Analysis flow chart for returned parts

8D reports

4) Prevention of recurrence 8D reports

FMEA
Document of prevention deployed to other plants
List of past troubles

5) Progress control of defect Countermeasure control document

treatment Progress control list

3 Project management 1) Organization Standard of establishing project team

Organization chart
Phase review minutes

2) Feasibility study Feasibility study report

Contract review minutes
Project management standard

3) Supplier Master Schedule and Standard for establishing Supplier Master Schedule
progress meetings

4) Phase review and Design Supplier Master Schedule

review Phase review minutes
Lessons Learned database
Design Review minutes

4 Process design and 1) FMEA Design / Process FMEA standard

Pre-production Design / Process FMEA
List of 8D reports
Customer claims
Past trouble list

2) Control plan Manual to make-up control plan

Control plan
Drawings

3) Poka Yoke Standard of installing Poka Yoke

4) Process instructions Process instruction

Process instruction drawing-up Manual

5) Equipment & tools Procedure of equipment and tools commissioning

commissioning

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Documents to be prepared
Evaluation items Expected Documents
6) Process capability Process capability achievement chart

7) Production trials Supplier Master Schedule

Supplier product preparation monitoring plan
Production trial report

5 Ramp-up activity 1) Ramp-up activity control Ramp-up activity standard

Ramp-up activity plan
Records

6 Operator training 1) Operator training Education plan

Operator training manual
Training records

2) Operator skill evaluation Skill level sheet as ILUO

Job observation records

7 Shop floor 1) Raw materials and

components receiving
2) Check at line start-up
3) Control of equipment
4) conditions
Process instructions
5) 5S
6) Part cleanliness and
preservation
7) Inspection in process
8) Control by SPC sheet.
9) Special characteristics
10) Management of non-
conforming parts To be confirmed on shoopfloor
11) Treatment of non-conforming
parts
12) "Unusual" product and
equipment situations
13) Improvement activity in shop
floor
14) Control of delivery process
15) Storage in process/finished
16) parts
Traceability
17) Maintenance of equipment
18) Calibration of
gauges/measurement
instruments
8 Change Management 1) Process / plant change Process / plant change standard
management Process / plant change sheets
Process / plant change list

2) Design (product) change Design (Product) change standard

management Design (Product) change sheets
Design (Product) change list

3) Change management at sub- Change management at sub-suppliers standard

suppliers Change list

9 Sub-suppliers 1) Sub-supplier sourcing and Sub-supplier selection standard

management quality assurance contract Quality assurance standard for sub-suppliers
Quality Assurance agreements / contracts

2) Sub-supplier project Sub-supplier project management standard

management

3) Sub-supplier performance Quality target for sub-supplier

management Audit plan
Audit reports & results

4) Sub-supplier 8D management 8D reports and list

12 / 12