A) Non-Conformities
A root cause analysis and the implementation of corrective actions for all non-conformities must be completed and verified by the auditor latest 90 days for TS and VDA * questions <8 after the last audit day.
For non-conformities, which will be verified and checked for effective implementation (ISO and VDA) during the next audit, corrective actions must be submitted from the company to the auditor latest 14 days after the last audit day.

Chapter
ISO/TS, ISO, KBA
VDA	
Process 	Evaluation
Maj.  Min.	
Description of non-conformity
	
Root Cause Analysis 
of the company	
Corrective action 
of the company	Responsible / Date	
Corrective Action	
		NC1	nc2						Verific.	Effect.	
7.5.1.4	Mgmt		X	The process to manage established maintenance schedules has not been maintained.
Section 7.5.1.4 of TS16949 requires the organization to develop an effective planned total preventive maintenance system.
A review of the PM system noted the following:
a) Weekly PM’s have not been maintained for the 479 robot cell.  Last records available are from March 2007
b) Sheet 3 0f 6 not used to capture and record PM’s for Foam line- requirements are for January and July- no January data available when sampled  						
8.2.4	Mgmt	X		The process to ensure inspection requirements are conducted per planned arrangements has not been maintained.
Section 8.2.4 of TS16949 requires Centroy to monitor, measure and provide evidence of conformity with the established acceptance criteria
A review of inspection and test records revealed the following:
a) No records of in process bend weld testing being recorded for 1353270 from April 17 to May 2, 2007
b) Weld bend tests for part number 1353270 not being conducted per the test instruction ES-6L24-5005-AA.  Cable clip screw driver peel effort test and pin push out of 50psi not done.
c) Inspection record for U222 headrest Effort Tester requires mechanical testing to be completed twice per shift. The last record of this test was May 9th, line records show that line was run May 16th, May 18th and May 22nd. There were no entries for these days.
d) Lab dimensional check for foam bun for part L0020750AA04 calls for a 3mm gap all around when placed in the applicable fixture as per control plan . In certain sections the 3mm gap was not acceptable. This part was not rejected at the time the testing was being observed. 						
7.5.1	Mgmt	X		The process to ensure compliance with control plan requirements has not been maintained. 
Section 7.5.1 of TS16949 requires the Centroy to carry out production under controlled conditions 
A review of the control plans revealed the following: 
a) Control plan for 479/480 program requires torque validation on the retainer screws at 1.7-2.3 Nm 2 plcs.  A review of the second row line noted that although first off’s had been completed the analyzer was not in use
b) In response to Lear QN 49299 part# L0007787AA02 regarding a rattle issue a torque monitor was added to the line. This control measure is not reflected in the current control plan dated Oct 17/06.
c) Table speed at the line is set at 30 +/-5 Hz, the control plan GMT 900 dated Jan 07/07specifies 25+/- 5Hz.
d) Day tank temperature ranges on line are 80 deg F +/-5 degrees, control plan does not specify a temperature but allows a range of +/- 10 degrees						
7.6.1	Mgmt		X	The process to maintain calibration of test equipment is not implemented consistently.
Clause 7.6.1 requires Centroy  to ensure monitoring and measuring devices be calibrated or verified at specific intervals, or prior to use against measurement standards.
There were no calibration for the Force tester used on the 2nd row assembly for the U222 program.
There were no records for the thermometer gauge serial # 04167721 used on the foam line.
Nor was there was no evidence to show that calibration has been completed for the torque monitor recently added to the assembly line for Lear part# L0007787AA02.
						
7.4.3.1	Mgmt		X	The process to assure incoming product testing for chemicals (foam) has not been maintained.
     Clause 7.4.3.1 requires Centroy to have a process to ensure the quality of purchased product. Centroy’s process is receiving inspection and test of foam performance as per work instructions.
Control plan GMT900 foaming dated Jan 20/07 requires incoming testing to be performed : 
Reactivity testing is called out for each new lot of isocyanate and polyol. The last record of testing was from Sept 10/06. No records were available for recent incoming lots e.g. Polyol lot VB2801i701 and Iso lot VB0101P403 
 Also the control plan as no specification ranges for incoming foam reactivity. Ranges are stated on the inspection sheet

B) Improvement Potential

Chapter
ISO/TS, ISO, KBA
VDA	
Process 	
Improvement Potential	
Corrective action 
of the company	
Respon-
sible / Date	
Corrective Action	
						Verific.	Effect.	

May 23, 2007		David Muil		Barry Winder		
Date		Lead Auditor		Customer		

Information about the handling of corrective action      -      Criteria that must be fulfilled for auditors to accept corrective action	
1. Is immediate action required to prevent recurrence and/or delivery of nonconforming parts?	
2. Have the root causes underlying problem occurrence been identified? Has this been done using an adequate method?	
- In what instances has the system failed, allowing this nonconformity to occur?	
3. Is the problem system-related?	
- A specific incidence is not a system-related problem.	
4. Have measures to limit the problems involved in the specific incidences been taken?	
- If further external customers or projects may be concerned, have measures been taken to limit or correct the problems and protect these parties or projects?	
5. Does corrective action defined by the organization also take the following into account:	
- ...changes in the system, unspecified employees, procedures etc..?	
- ...and the identified underlying causes?	
6. Have the pertinent FMEAs (design and/or process) been reviewed on the basis of non-conformities?	
- Does evaluation of recurrence have to be revised?	
- Does evaluation of detection have to be revised?	
- Does the organization treat FMEAs as "living documents"? 	
7. Have the plans, work and test instructions of production control etc. been reviewed?	
- Does the organization treat this documentation as "living documents"?	
8. 100 % elimination of nonconformity is required:        --> 100% elimination means : 	
- Narrowing down the cause underlying the nonconformity to prevent customers from being exposed to risks	
- The root cause must be determined within the 90-day period and corrective action implemented and verified by the auditor by then. In cases involving long-term solutions (programming, new machinery, investments, etc.) proof of initiation may be furnished.	
- Documented evidence, e.g. action catalogue, instructions, records, to furnish proof that the non-conformity has been corrected, including the names of the persons responsible, or direct on-site verification within 90 days.	
- In a re-audit these measures must be followed up and verified and the nonconformity closed.