Nonconformity management

Organization name ACIL Limited

Audit start date 03.Jul.2024

Audit end date 05.Jul.2024

Audit type Recertification

CB identification no. NA

CB certificate no. 04075/0

IATF USI (Unique site identifier) Y24WSY

IATF certificate no. 0429253

Additionally to this report a digital NC management report file will be provided by the auditor which has to be completed in IATF NC
CARA at https://nc-cara.iatfglobaloversight.org. All information about the software and use is provided in the documentation
accessible at the provided link.

Organization name : ACIL Limited CB certificate no.: 04075/0 Cara V. 1.4.4

Report name/no: 256033 1/6
 Nonconformity management

NC NC Auditor´s name Standard Standard Classification Due date max. Due date max. Reviewer Date reviewed Nonconformity observed in process
no. identification clause 20 days 60 days decision
no.

1 RH-01 Rajesh Handoo IATF 16949:2016 7.2.2 minor 03.Sep.2024 HR

2 RH-02 Rajesh Handoo IATF 16949:2016 10.2.4 minor 03.Sep.2024 PRODUCTION (MACHINING &
INDUCTION HARDENING)

3 RH-03 Rajesh Handoo IATF 16949:2016 8.3.3.3 minor 03.Sep.2024 PROCESS DESIGN

4 AA-01 Abhilash Agnihotri IATF 16949:2016 8.2.3.1.3 minor 03.Sep.2024 Customer requirements, Contract
Review, Customer Satisfaction
Evaluation

Organization name : ACIL Limited CB certificate no.: 04075/0 Cara V. 1.4.4

Report name/no: 256033 2/6
 Nonconformity management

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

NC identification no. RH-01

Standard IATF 16949:2016

Classification minor

Due date max. 60 days 03.Sep.2024

Nonconformity observed in process HR

Standard clause 7.2.2

Competence - on-the-job training

Requirement
The organization shall provide on-the-job training (which shall include customer requirements training) for personnel in any new or modified
responsibilities affecting conformity to quality requirements, internal requirements, regulatory or legislative requirements; this shall include
contract or agency personnel. The level of detail required for on-the-job training shall be commensurate with the level of education the
personnel possess and the complexity of the task(s) they are required to perform for their daily work. Persons whose work can affect quality
shall be informed about the consequences of nonconformity to customer requirements.

Statement of nonconformity

The process of competence assessment is not fully effective.

Objective evidence

Refer the Job description of Mr. Rakesh Kumar joined as Sr. Engineering, Exp. 5.5 years, but as per competency mapping min. exp. Required is 6
years, which is not meeting organizational internal requirement.

Justification for classification

Other process area competency mapping was found specific to production activities and operators of induction hardening and Grinding where
in compliance and these operators were found competent when interviewed. Therefore deemed as a minor NC, no threat to the customer or the
system.

Rajesh Handoo 5-ADP-16-02-2502 05.Jul.2024 This document is valid without a

Auditor´s name Auditor ID no. Audit closing meeting date signature

Organization name : ACIL Limited CB certificate no.: 04075/0 Cara V. 1.4.4

Report name/no: 256033 3/6
 Nonconformity management

Nonconformity 2
To be completed by the CB auditor
NC header

NC identification no. RH-02

Standard IATF 16949:2016

Classification minor

Due date max. 60 days 03.Sep.2024

Nonconformity observed in process PRODUCTION (MACHINING & INDUCTION HARDENING)

Standard clause 10.2.4

Error-proofing

Requirement
The organization shall have a documented process to determine the use of appropriate error-proofing methodologies. Details of the method
used shall be documented in the process risk analysis (such as PFMEA) and test frequencies shall be documented in the control plan.
The process shall include the testing of error-proofing devices for failure or simulated failure. Records shall be maintained. Challenge parts,
when used, shall be identified, controlled, verified, and calibrated where feasible. Error-proofing device failures shall have a reaction plan.

Statement of nonconformity

The process of documenting Error proofing in PFMEA is not fully effective

Objective evidence

Refer Part: 4 CYD. CRANK SHAFT (SWARAJ MAZDA): LP 24 11 301 (H-II), Operation No. 110 Induction hardening process there is detection
error proofing i. Temp. alarm, reaction plan for the error proofing device failures not evident.

Justification for classification

Monitoring of error proofing devices are checked in daily check machine check sheet, and parts produced found meeting customer requirement,
there is zero complaint related to failure of error proofing devices , risk to customer is not witnessed, one of 5 samples checked, hence
categorized as minor.

Rajesh Handoo 5-ADP-16-02-2502 05.Jul.2024 This document is valid without a

Auditor´s name Auditor ID no. Audit closing meeting date signature

Organization name : ACIL Limited CB certificate no.: 04075/0 Cara V. 1.4.4

Report name/no: 256033 4/6
 Nonconformity management

Nonconformity 3
To be completed by the CB auditor
NC header

NC identification no. RH-03

Standard IATF 16949:2016

Classification minor

Due date max. 60 days 03.Sep.2024

Nonconformity observed in process PROCESS DESIGN

Standard clause 8.3.3.3

Special characteristics

Requirement
The organization shall use a multidisciplinary approach to establish, document, and implement its process(es) to identify special
characteristics, including those determined by the customer and the risk analysis performed by the organization, and shall include the following:
a) documentation of special characteristics in the product and/or manufacturing (as required), relevant risk analysis (such as Process FMEA),
control plans, and standard work/operator instructions; special characteristics are identified with specific markings and are documented in the
manufacturing documents which show the creation of, or the controls required, for these special characteristics;
b) development of control and monitoring strategies for special characteristics of products and production processes;
c) customer-specified approvals, when required;
d) compliance with customer-specified definitions and symbols or the organization’s equivalent symbols or notations, as defined in a symbol
conversion table. The symbol conversion table shall be submitted to the customer, if required.

Statement of nonconformity

The process of Engineering wrt monitoring strategies of critical characteristics is not fully effective.

Objective evidence

Refer Control Plan of Part: Crank Shaft-LP01 11 301A/ LP24 11 301, Swaraj Mazda Opn. 30 Journal Dia: 76mm, Tail end Dia: 32mm has been
identified as significant Characteristic ( Mj) monitoring strategy not evident

Justification for classification

There are ample controls at shop floor, wherein operator checks 100% and periodic check is done by QA Engineer, risk to customer is not
witnessed, one of 5 samples checked, hence categorized as minor.

Rajesh Handoo 5-ADP-16-02-2502 05.Jul.2024 This document is valid without a

Auditor´s name Auditor ID no. Audit closing meeting date signature

Organization name : ACIL Limited CB certificate no.: 04075/0 Cara V. 1.4.4

Report name/no: 256033 5/6
 Nonconformity management

Nonconformity 4
To be completed by the CB auditor
NC header

NC identification no. AA-01

Standard IATF 16949:2016

Classification minor

Due date max. 60 days 03.Sep.2024

Nonconformity observed in process Customer requirements, Contract Review, Customer Satisfaction

Evaluation

Standard clause 8.2.3.1.3

Organization manufacturing feasability

Requirement
The organization shall utilize a multidisciplinary approach to conduct an analysis to determine if it is feasible that the organization’s
manufacturing processes are capable of consistently producing product that meets all of the engineering and capacity requirements specified
by the customer. The organization shall conduct this feasibility analysis for any manufacturing or product technology new to the organization
and for any changed manufacturing process or product design.
Additionally, the organization should validate through production runs, benchmarking studies, or other appropriate methods, their ability to make
product to specifications at the required rate.

Statement of nonconformity

The Process of Understanding customer requirements is not fully effective.

Objective evidence

Refer to the part Part Crank Shaft 105KW, Feasibility study of the same found not to include the capacity study.

Justification for classification

On further investigation it is found that in actual there is ample capacity. Customer is not at risk, hence graded as minor NC.

Abhilash Agnihotri 4-AUD-B-2309-1233-2501 05.Jul.2024 This document is valid without a

Auditor´s name Auditor ID no. Audit closing meeting date signature

Organization name : ACIL Limited CB certificate no.: 04075/0 Cara V. 1.4.4

Report name/no: 256033 6/6