1

MIS FOR CUSTOMER SUPPORT, ECC & ICA

– WK OF 2nd Mar 2015

2

Customer Support, ECC & ICACustomer Coverage Status - OEM 2-Mar-14

RegionTransit

WHS

Norms for Domestic 1 1

Norms for Europe 6 3

                      Norms for China 7 3

STARTERSNorms for North

America7 3

# WHS PART NUMBER MODEL CUSTOMER EUROPEAN/NA/ AP WHS STOCKS

TRANSIT STOCKS

TOTALAverage Weekly Volume

CUSTOMER

COVERAGE - WKS

Shortfall Quantity to meet norms

Comments

1 A&S 3M5T 11000CF DV6Saarlouis/Valen

5209 21500 26709 2000 13.4 8709  

3 A&S 6G9N 11000AB I4 Ford OEMs 4990 9856 14846 1394 10.6 2300  

5 A&S 7G9N 11000AC SIGMA Ford OEMs 1431 6272 7703 763 10.1 836  

6 A&S 8G43 11000AA ASTON MARTIN Aston Martin 192 192 384 40 9.6 24  

7 A&S AV6N 11000CA SIGMA GTDI Ford OEMs 1673 2750 4423 250 17.7 2173  

8 A&S CV6T 11000DB V408 Ford OEMs 1066 3108 4174 260 16.1 1834  

9 A&S F1FT 11000EB F1FT Ford OEMs 1722 1875 3597 375 9.6 222  

10 A&S F1FT 11000MA F1FT Ford OEMs 1130 5628 6758 560 12.1 1718  

11 A&S DG9T 11000AA   Ford OEMs 3762  3762 260 14.5 1422  

12 SML 31285512 SIGMA GTDI Volvo 589 250 839 70 12.0 209 Obsolete on 30th Mar'15, Service will continue.

13 SML 30659314 ESM Volvo 5657 14208 19865 1660 12.0 4925  

14 SML 30659557 I5P Volvo 3022 2816 5838 512 11.4 1230  

15 SML 30659805 SIGMA SID Volvo 1612 125 1737 160 10.9 297 Obsolete on 6th April'15, Service will continue.

16 SML 30644972 DV6 - SS Volvo 1237 4250 5487 924 5.9 (57) Obsolete on 6th April'15

17 SML 31450235 I5P SS Volvo 1010 896 1906 128 14.9 754 2116 nos of 31419002 return to Comstar due obsolence

18 CHINA 31450235 I5P SS Volvo 6400 5888 12288 640 19.2 5888

Volume drop up to 50 %, Awaiting confirmation from customer. 3328 nos return back to Comstar due to foreign materials inside the container.

3

Customer Support, ECC & ICA

Customer Coverage Status - OEM 2-Mar-14

RegionTransit

WHS

Norms for Domestic 1 1

Norms for Europe 6 3

                      Norms for China 7 3

STARTERSNorms for North

America7 3

# WHS PART NUMBER MODEL CUSTOMER EUROPEAN/NA/ AP WHS STOCKS

TRANSIT STOCKS

TOTALAverage Weekly Volume

CUSTOMER

COVERAGE - WKS

Shortfall Quantity to meet norms

Comments

Domestic Customers                  

19 TVS-P 2871 15100103 X1 TML / FIAT 4250 1250 5500 750 7.3 4000  

20 TVS-P 5401 15100102 X1 COMM TML / FIAT 3264   3264 1536 2.1 192

Suddenly TML Increased their volume from 1536 Nos to 4300 Pcs. Nearly 300% increased considering last 6 month average of 1500 Pcs

21 TVS-P 2871 15100104 FIRE FIAT 500   500 1 500.0 498

Discussion is going on with customer to cater parts to them. This is because of last four months they didn't pulled as per their schedule

22 CHETAK 2818 15100105 SUPER ACE     250 250 125 2.0  Supplied as per Feb 2015 Schedule

23 AXPRESS 2834 15100110 NANO TML 504 504 1008 672 1.5 (336)504Pcs are under TML plant as starters.

24 TVS-H F2024100 ALP15 Ashok Leyland1440 768 2208 768 2.9 672  

D3 - 8G1T11000BA                  

25 BAY 8G1T 11000BA D3 Ford OEMs 50617 81024 131641 10200 12.9 29641  

26 BAY AV6N 11000CA SIGMA GTDI Ford OEMs 1795 250 2045 100 20.5 1045  

27 BAY CP7C3U 11005AA ARMATURE COMSTAR NA16079 22050 38129 3965 9.6 (1521)  

28 BAY AC3U 11390AA SOLENOID COMSTAR NA21063 22500 43563 3965 11.0 3913  

4

Code Region Nov-14 Dec’14 Jan’15 Feb’15 to date

Production

AHVFA Asia-Pacific 100 100 100 97 100

AHVFC Europe 100 100 100 94 100

AHVFG North America – Bay 100 100 100 100

AHVFH Comstar LLC USA 97 94 100 100

Service

AHVFC Europe 100 90 100 76 97 100

AHVFG North America – Bay 57 dispute rejected 57 93 Dispute Rejected 85 Dispute Rejected 100

AHVFH Comstar LLC USA 100 96 100 -

GUR4A Comstar LLC USA - 87 94 100

Refresh Date: 2nd Mar 2015Data period: 23rd Feb to 27th Feb SUPER-G Rating Summary Nov’14 , Dec’14 , Jan’15 & Feb’15:

Customer Support, ECC & ICA

Customer critical parts for next two weeks Nil

Critical parts to be produced this week at Comstar to avoid line stoppage at Customero Jatco , 98AB AC & 835X AC – After Market ( Armature Shaft Constrain)

o 3S6T AD After Market (B+ Insulator Constrain)

o Nano, F Series Armature , DV6SS – 125starters Critical Containers for next two weeks

o EMCU 1443700, TGHU 5137924 FCSD long pending parts to be produced this week to avoid lost delivery performance

Nil

Starters Produced against the production plan in %

Customer Support, ECC & ICA

Week 51

(15th Dec'14 Week)

Week 52 (22nd Dec'14 Week)

Week 2 (05th Jan'15

Week)

Week 4 (19th Jan'15 Week)

Week 5 (26th Jan'15 Week)

Week 6 (2nd

Feb'15 Week)

Week 7 (09th

Feb'15 Week)

Week 8 (16th

Feb'15 Week)

Week 9 (23rd

Feb'15 Week)

Week 10 (02nd

Mar'15 Week)

Production Plan 31453 31978 31905 31680 25430 31285 31065 30250 30056 28732

Qty Produced against the Plan 31470 31117 32157 31724 24648 31151 31460 29597 30253

Difference 17 (861) 252 44 (782) (134) 395 (653) 197

Achieved in % 100.1 97.3 100.8 100.1 96.9 99.6 101.3 97.8 100.7

6

EXT - WHS sales booking status

• SML Whs – Sales booked up to 2nd Mar’15

• A/S Whs – Sales booked up to 2nd Mar’15

• BAY Whs – Sales booked up to 2nd Mar’15

• China Whs – Sales booked up to 2nd Mar’15

Customer Reconciliation Status

• BAY Whs – Completed up to 8th Feb’15

• SML Whs & A/S Whs - Completed up to 8th Feb’15

• China Whs – Completed up to 8th Feb’15

• Comstar LLC (NA) - Completed up to 8th Feb’15

• Direct Customers – to be Completed for Feb’15

Customer Support, ECC & ICA

7

Customer Support, ECC & ICA Aftermarket Budget Volume Vs Actual

Starter Alternator

Plan So far 7400 2450

Actual so far 4886 1315

5001500250035004500550065007500

8

Customer Support, ECC & ICA Aftermarket pending orders - Approximate value is Rs. 1.9Cr

Item Number OEM Ref Product Total Value Remarks

20 10001008 98AB AC Str 384 1566720 Armature shaft Constrain

20 10001020 835X AC Str 192 844800 Armature shaft Constrain

20 10001022 2S7T DC Str 1731 7616400 Armature shaft Constrain

20 10001044 6G9N EC Str 90 388800 Alert to be raised for Flange

20 10001050 YC1U AF Str 158 758400 Armature shaft Constrain

20 15001001 2S6T FC Alt 45 187200 Slip ring Constrain

20 15001002 3S6T AD Alt 810 3823200 B+ Insulator Constrain

20 15001004 1S7T CF Alt 296 1704960 Slip ring Constrain

20 15001005 1S7T BE Alt 12 81600 Slip ring Constrain

20 15001007 YC1U EA Alt 147 1140720 Slip ring Constrain

20 15001008 2T1U BE Alt 50 428000 Slip ring Constrain

20 15001034 2S6T AC Alt 220 1372800 B+ Insulator Constrain

Grand Total 4135 19913600

9

Customer Support, ECC & ICA Aftermarket pending orders – Aging

Customer Item Number Quantity Open Due Date Age

ARTEC 20 10001050 8.0 1/12/2015 52

BOSCH 20 15001004 96.0 1/28/2015 36

BOSCH 20 10001022 96.0 1/28/2015 36

CASCO 20 15001002 360.0 1/31/2015 33

CASCO 20 15001008 90.0 1/31/2015 33

CASCO 20 10001020 96.0 1/31/2015 33

CASCO 20 10001022 384.0 1/31/2015 33

AEE01 20 10001022 120.0 2/2/2015 31AEE01 20 15001007 12.0 2/2/2015 31AEE01 20 15001005 12.0 2/2/2015 31AEE01 20 10001010 108.0 2/2/2015 31PSHCV 20 10001008 384.0 2/2/2015 31PSHCV 20 15001004 90.0 2/2/2015 31PSHCV 20 15001034 90.0 2/2/2015 31PSHCV 20 10001020 96.0 2/2/2015 31PSHCV 20 10001022 576.0 2/2/2015 31BIGOT 20 10001022 75.0 2/9/2015 24HCA01 20 15001002 45.0 2/9/2015 24ARTEC 20 15001034 40.0 2/16/201

5 17ARTEC 20 10001050 150.0 2/16/201

5 17HCA01 20 15001002 45.0 2/16/201

5 17HCA01 20 15001001 45.0 2/16/201

5 17PSHCV 20 15001034 90.0 2/16/201

5 17VALEO 20 10001044 90.0 2/16/201

5 17CASCO 20 15001004 90.0 2/28/201

5 5CASCO 20 15001002 360.0 2/28/201

5 5CASCO 20 15001007 90.0 2/28/201

5 5CASCO 20 10001022 480.0 2/28/201

5 5CASCO 20 10001029 128.0 2/28/201

5 5CASCO 20 10001010 128.0 2/28/201

5 5

10

AFTER MARKET PARTS SALES HIGH LIGHTS

• Sales Value for week 9 (23rd Feb to 1st Mar’15) – INR 4,267,387

• Sales Value for the Month to Date (Feb’15) - INR 18,386,547

• Sales Value Year to date (YTD) – INR 22,882,448 (INR 22 Million)

Aftermarket Orders availability Status

ProductOpen Orders

as on 23rd Feb'15

Fresh Orders received

Quantity produced last

week

Quantity Shipped last

week

Additional Qty on Hand @ Comstar

Total Balance Open Quantity as on 02nd Mar’15

Min. Required by

this week

Starters 18899 225 616 1159 1100 16865 1680Alternators 6749 0 413 190 675 5884 420Total 25648 225 1029 1349 1775 22749 2100

EI - INVENTORY REDUCTION TRENDCurrent Value Total Value Feb-15 Mar-15

Total Consumption

Balance on Hand

Alternator A&S 19,06,469 28,69,630 3,02,459 5,23,080 8,25,539 20,44,091 Starter A&S 15,96,892 17,07,537 86,524 6,67,001 7,53,524 9,54,013 Starter Bay 5,72,204 5,72,204 - - - 5,72,204 Starter SML 14,64,156 41,74,162 2,03,324 33,04,449 35,07,773 6,66,389

55,39,722 93,23,534 5,92,307 44,94,530 50,86,837 42,36,697

Current Value Total Value Feb-15 Mar-15Alternator A&S 19,06,469 28,69,630 25,67,171 20,44,091

Starter A&S 15,96,892 17,07,537 16,21,014 9,54,013

Starter Bay 5,72,204 5,72,204 5,72,204 5,72,204

Starter SML 14,64,156 41,74,162 39,70,838 6,66,389

Total All 55,39,722 93,23,534 87,31,227 42,36,697

Oct’14 – 17.2Lakhs.Nov’14 – 9.7Lakhs Actual.Dec’14–12.7Lakhs Actual.Jan’15 – 24Lakhs ActualFeb’15 - 5.92Lakhs planned and 10.48Lakhs Achieved so far.

12

Customer Support, ECC & ICA

Total Pending – 93.2Lakhs

FCSD Sale Planned in Feb’15 & Mar’15 – 17.4Lakhs To Bring Back to Comstar – 33.5Lakhs ( In Transit to Comstar)

31419002 – 2114pcs (29.6Lakhs) 6G9N 11000EC – 63pcs (1.0Lakhs) BG9T 11000AA – 125Pcs (1.5Lakhs) 30795405 – 123pcs (1.4Lakhs)

Total Pending stock as on 1St Apr’15 – 42.4Lakhs Awaiting Ford NA FCSD order – 5.70Lakhs – Ford Buyer Confirmed 100pcs per month pull from Dec’15 BB5Z 11002C – 488pcs (5.70Lakhs) Remaining – 36.7 Lakhs ( 3.5months FCSD Sales value) retained for future order

• CYCLE COUNT ACTUAL – WEEK 09

Starter Housing \ Alternator Housing ,Pulley , Regulator ,Stator line

Classification Parts counted Week -09 FEB-15 Total Plan FEB-15 So far

Class 'A' 17 26 25

Class 'B' 7 44 52

Class 'C' 33 66 82

Total 57 136 159

• Variance details:

Gross Variance 93,105

Net Variance 19,449

Starter Housing Variance Booked. All Alternator Parts Variance booked by this week.

Cycle Count Variance –MIS WEEK - 09

Sl # Item Number Description Item type Class Cost ACVA '14

VarianceLast

Audit sys stock Variance Qty

Variance Value

12 XS6U 10336AA StatorR ASY - ALT PP C 211.5 158

(48)

3,395

(43)

(9,095)

1 CPBV5U 11055AA BRSH ASY-STR MTR INS CS A 119.3 (112)

(14)

4,635

(67)

(7,996)

21 VP2C1U 10A352AA HB ASY-ALT PLY PP A 2095.6 (2) - 1,209

(3)

(6,287)

16 VP3S7U 10505AA RegulatorLATOR - PCM PP B 581.8 131

29

10

(10)

(5,818)

13 VP3S7U 10A303AA BRG - ALT FRT PP C 70.7 226

(52)

1,918

(28)

(1,979)

20 1S7U 10336AA StatorR ASY - ALT PP B 204.7 18

(34)

2,239

(5)

(1,024)

14 XS6U 10A352A1A HB - ALT PLY(MACHINED) PP C 57.4 105

(46)

820

(16)

(918)

9 F75U 11A192AACONNECTING ROD - STR ASY PP B 1.5

2,113 891

10,300

1,134

1,758

8 VP6G9U 11A183AA CONT-STR MTR Solenoid PP B 2.0 3,394

61

9,056

1,015

2,030

7 VP1S7U 11131AAHSG-STR MTR MTR DRIVE EN PP A 136.7

(24) - 2,115 15 2,051

56 VPXS6U 10A351CA HOUSING - ALT FRONT W.O PP A 233.6 53

(68)

1,204 35

8,176

55 VP3S7U 10316BA REINF RR FLR S/M @ BMPR AS A 665.0 - - 27,152 16 10,640

57 R1425 M2L46ANAT ENAMELLED COPPER WIRE RM A 516.9 (73)

(46)

2,117 54

27,778

15

Engineering Change Control Status

ECC

TOTAL OPEN CHANGES DEPT WISE

Dept No. Pending activities

TOTAL OPEN CHANGES 87

Changes Implemented

119

Changed on Hold 1

Changes Closed/Dropped

86

PD 25

Purchase 11

SPE 43

MFG 6

Quality/IQ 4

CBG 1

MPL 6

ECC 0

TOTA

L OPEN

CHANGES

Change

s Implem

ented

Change

d on Hold

Change

s Closed

/Dro

pped PD

Purchase SP

EMFG

Quality/

IQ CBGMPL

ECC

0

20

40

60

80

100

120

140

87

119

1

86

2511

43

6 4 16

0

ECC - CMCs OPEN & PENDING

TOTAL OPEN CHANGESChanges ImplementedChanged on HoldChanges Closed/DroppedPDPurchaseSPEMFGQuality/IQCBGMPLECC

16

Pending CMCs Stratification

ECCDESCRIPTION NO OF CMCs

Number of CMCs open since 2012 4Number of CMCs open since 2013 3Number of CMCs open since 2014 78Number of CMCs open since 2015 1

2012 & 2013- CMCs- SUPPORT REQUIRED

CMCNumber

Requestor

Requestor Dept

CMC Raised date

Change Description Part numberCurrent supplier

proposed supplier

Current Status Dept SUPPORT REQUIRED

CMC00384 garunkum Purchase 23-Feb-12Additional sourcing of F7RU

11448CA Bush to SSPL(Panther, V227, ESM)

F7RU 11448CA(F7RU 11448CA1)

GKN India SSPL FCR Status MFGFCR feedback from Mfg.

Sudar-MFg

CMC00407 rsaravan Purchase 11-Apr-12Alternate source for VP6G9U 11051AA End plate to JAEIL

Metals

VP6G9U 11051AA to AB

Sunbeam/ Gencor

Jaeil

Gencor die modification

FCR Rejected

PPAP lot & Alert for available lot

SPEPPAP Lot & Alert for available

5000nos- Durai-SPE.

CMC00414 rsathies Purchase 26-Apr-12Fully finished VP6G9U

11010CA Armature shaft from SRIMUKHA

VP6G9U 11010CA(new part no:

CP6G9U 11010EA)TKP + Inhouse Srimukha

FCR Rejected

RE-PPAP inspection rejected

MFG trial, SCR & PPAP

SPEMfg trial, SCR & PPAP

Durai-SPE.

CMC00441 kmariapp SPE 18-Oct-12Drill depth added CPBV5U

11131AA-Gencor(also SCR00798)

CPBV5U 11131AA Gencor Gencor SPE/PD to clarify IQ/SPE Thilawar-SPE

CMC00534 ranand Purchase 30-Oct-13

Additional sourcing for VP6G9U 11390AA Solenoid

assy Huanfang automobile(China)

VP6G9U 11390AA In_houseHuanfang

automobile(China)Re-PPAP SPE Durai-SPE

CMC00611 rharish PD 1-Nov-13Fiber band instead of 1C3U

11A163AB steel band in ESM & F series models

1C3U 11A163AB(CPBV5

U 11A163AA)

Necco AnguPV Testing & Cust

approvalPD Ser-FTest--Parameswari-PD

ESM Build-- Meenakshi-Mfg

CMC00614 rharish PD 1-Nov-13Fiber band instead of F7RU 11A163AA steel band in All

LXD models

F7RU 11A163AA (CP6G9U

11A163AA)Necco Angu

Cust. Approval requirement for FCSD(FA Model)

PD FA obsolete, FCSD approval requirement- Veera-PD.

17

ECC

BUILD STATUS FOR THIS WEEK

S.No DESCRIPTION NUMBER OF CHILD PARTS IN THIS BUILD MODEL NO OF MOTORS

REQUIREDBUILD REQUEST

DATEBUILD

COMPLETION DATE

BUILD AGING

(in days)REMARKS

1

Chunk-23A 530659805

(CPCV3S 11000AA)Sigma SID

17

24-Feb-15 TBD 7 PendingChunk-23B 1 8G1T 11000BA 2

Chunk-23C 6 30659314(CPBV5U 11000AA) 20

Chunk-23D 5 6G9N 11000FA 2

2YS4U 11A209AB INITIAL

SUBMISSION NEW CAVITY #3,4 FROM HTP

1 AV6N 11000CA 9 24-Feb-15 27-Feb-15 4 Completed

18

ECCTEST STATUS IN PROGRESS

DESCRIPTION MODELNO OF

MOTORS REQUIRED

BUILD COMPLETION

DATETEST START

DATE

TEST COMPLETIONTARGET TEST AGING

(in days)

TEST AGING

(in Months)

Status

INITIAL REVISED

CHUNK - 22A 6G9N 11000FA 29 4-Nov-14 5-Nov-14 8-Jan-15 16-Mar-15 0 0.0 Testing in progress

CHUNK - 22B 30644972DV6SS 24 4-Nov-14 5-Nov-14 8-Jan-15 16-Mar-15 0 0.0 Testing in

progress

CHUNK - 22C 6G9N 11000AB 28 9-Oct-14 10-Oct-14 13-Dec-14 16-Mar-15 0 0.0 Testing in progress

Retainer New tool & China Drive new

Grease8G1T 11000BA 13 10-Nov-14 11-Nov-14 14-Jan-15 TBD 49 1.6

Target exceeded, need

disposition

F81U 11A171AA Seal form TEKLIGHT & 3mm

Tube frame8G43 11000AA 2 11-Dec-14 12-Dec-14 14-Feb-15 TBD 18 0.6 Testing in

progress

CHUNK-21B Additional test 2834 15100110 3 10-Feb-15 11-Feb-15 20-Feb-15 TBD 19 0.6 Testing in

progress

CHUNK-21B Additional test

2834 15100110 & CPAT2C 11390CA 2 + 4 20-Feb-15 21-Feb 7-Mar-15 TBD 0 0.0 Testing in

progress

YS4U 11A209AB INITIAL SUBMISSION

NEW CAVITY #3,4 FROM HTP

AV6N 11000CA 9 27-Feb-15 2-Mar-15 12-Mar-15 TBD 0 0 Testing in progress

19

THANK YOU