2013-14 ACMA Awards Company Name : Plant Location : Category : Large Excellence in Quality & Productivity PM_44_F8 Rev. No. : 00, Specimen Format*

2013-14

ACMA Awards

Company Name : Plant Location :

Category : Large

Excellence in Quality & Productivity

PM_44_F8 Rev. No. : 00 , Specimen Format*

Index( For office use only except page no. )

S.N. Section Page No.

Max. Marks Actual Marks

1 Work Environment & Employee Involvement.

150

2 Customer Assessment 100

3 Quality Performance. 350

4 Productivity Performance. 300

5 Cost Performance. 100

Total 1000

For Administrative Queries:Mr. Uday Harite Email- [email protected] Mobile – 08149099959

Mr. Jitender Rana Email – [email protected] Mobile – 09873369699

Ms. Sakshi Karkamkar Email – [email protected] - 07387002181

For Technical Queries:Mr. Dinesh VedpathakEmail – [email protected] – 09545887799

Mr. K. ChandrasekharEmail – [email protected] Mobile – 09822911139

Mr. V K Sharma Email : [email protected] : 09811392068

Ms. Sapana Baravkar Email : [email protected] : 07350703339

ACMA Centre for Technology (ACT)( A Division of ACMA )

Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C, Old Mumbai

Pune Highway Wakdewadi, Shivaji Nagar , Pune – 411005, India .www.acma-act.in


mailto:[email protected]







http://www.acma-act.in/

ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)

PM_44_F4 Rev. No. : 00, Specimen Format*

3

Letter for Submission of Award application for 2013-14

Company letterhead details ( Logo , Address )

To ,

The Secretariat ( ACMA Awards ) ,ACMA Centre for TechnologyOffice No. C, , 10th Floor, Godrej Eternia, ”B” Wing ,Old Mumbai –Pune Highway, Wakdewadi , Shivaji Nagar Pune – 411005, India We are pleased to submit the application for ACMA Award 2013-14 for Excellence in Quality & Productivity in Large category .

All data submitted is duly verified and true to the best of our knowledge .

With regards

( Name & Designation of the Plant CEO )

Group Company Name

Turnover in INR Cr. For 2013-14

ACMA Awards Category ( For ACMA Award Process Team )

Small Upto INR 50 Cr

Large Between INR 50 to 150 Cr.

Not Applicable

Large

Criteria for Small and Large Category :Small Category- Company Group Annual Sales Turnover Up to INR 50 CrLarge Category- Company Group Annual Sales Turnover Between INR 50 to 150 Cr



4

1. Name of the corporate group (if company is part of a corporate group): -

( Underline the plant for which application is sent )

Plant Address :

2. Name of the Chief executive of the corporate group-

3 Chief Executive (Site) details :

Name : Designation :

Mobile : E-mail :

Land line with extension : Fax No.

4. Plant Head ( Next to Chief Executive (Site)) details :

Name : Designation :

Mobile : E-mail :

Land line with extension : Fax No.

( If Sr. No. 3 & 4 are same , then provide next level person details at Sr. No. 4 )

Company’s Details



5

Company’s Details

5. Company turnover ( in Rs. Crore ) for Year 2013-14 :

6. Plant turnover ( in Rs, Crore ) for Year 2013-14 :

7. Year of Establishment : Company _______ , Plant ___________

8. Total Employees : Company ___________ , Plant _____________

9. Do you have a Joint Venture : ( If Yes , Mention the partner name )

10. Company’s Key products :

11. Plant’s Key products :

12. Plant’s key manufacturing processes :

13. Plant’s Key competitors :

14. Plant’s Major Certifications :



6

As a part of ACMA Award process , feedback from your major customers will be opted directly and will be provided to Jury as a part of Site diagnosis .The same will be provided to you as a part of Site diagnosis feedback report

Kindly provide 2 names per Key Customers for the plant for which application is send

Customer Details

S. No Customer Location

% Business share ( from the plant )

Key person name & Designation

Mobile Number & E mail

1

2

Note- In addition to application , site diagnosis , Customer feedback scores will be also considered for final scores.



7

Use this slide to brief about your company / Plant .

It includes Product names / photos , Plant facility photographs ,

Company / Plant Information



8

Route Map to reach your plant

Contact person name & Designation:

Name :

Designation :

E-Mail :

Mobile :

Landline : ( STD Code ) ( Number ) : Ext. ( if any )

Provide here route map to your company for site diagnosis ( Site diagnosis is carried out if your application is shortlisted )



9

S.N.

Area Total Marks Actual Marks ( for Office

Use only )

%

1 Work Environment & Employee Involvement.

150

2 Customer Assessment 100

3 Quality Performance. 350

4 Productivity Performance. 300

5 Cost Performance. 100

Total 1000

( For office use only )

Company performance at a glance ( Following radar chart shows the scores for each main area as per

questionnaire , scores are converted to % )

RADAR Chart



10

Section 1

Work Environment & Employee Involvement

Total Marks = 150

S.N. Sub topic Total Marks

Actual Marks ( for office use )

%

1.A Work Place Management 40

1.B Suggestions / Kaizens Per Employee

20

1.C Absenteeism 10

1.D Training 10

1.E Small Group Activities 10

1.F Safety 30

1.G Environment Management

30

TOTAL 150




11

(i) Specify status in below mentioned checklist for “Must be facilities” for all company employees ? Illustrate with photographs some examples (25)

Must be facilities for all company employees

Sr. No. Description Status

1 Jogging track inside shop floor, along walls OK / Not OK

2 Trees in plant campus OK / Not OK

3 No earth should be visible in entire company area. There should be concrete, tar roads or green lawns.

OK / Not OK

4 No truck / fork-lift inside shop floor OK / Not OK

5 Clean toilet blocks inside shop floor, dry & smell free OK / Not OK

6 No nails to be used anywhere in the factory premises. OK / Not OK

7 All employees to wear uniform, shoes and necessary safety gadgets.

OK / Not OK

8 Noise free DG sets & compressor OK / Not OK

9 Clean change room and rest room facilities OK / Not OK

10 Hygienic kitchen, washroom, dinning hall. OK / Not OK

11 Good recreational facilities OK / Not OK

12 Appropriate fire fighting equipments should be placed at accessible locations

OK / Not OK

13 Central display board ( 80 % Digital ) OK / Not OK

Photo Photo

1. Work Environment and employee engagement

(1.A) Work Place Management Total= 40



12


(ii) illustrate how concept of 5S/house keeping has been deployed in your plant?(5)


50

60

70

60

7475

76 77 77 78 79 80

0

10

20

30

40

50

60

70

80

90

% s

core

s

Target Actual

(iii) What methods are adopted to assess 5S levels/scores? (show last one year trend in line graph , illustrate it with your internal Target line.). (5)

Formula 5 S Score = Lowest zone / area score of that month in %



13

(iv) illustrate with photographs examples of good Visual Factory- Before and after. (5)

Before After


Before After




14

(1.B) Suggestions / Kaizens Per Employee Total= 20

(i) Is there a suggestion scheme in the company and How company encourages employees to give suggestions? ? Pls Describe: (5)

(ii) How company ensures the suggestions are implemented? Pls describe: (5)




15


(1.B) Suggestions / Kaizens Per Employee Total= 20

(iv) ) Is there a forum (as well as escalation process) for employees to raise issues / concerns etc.--- shop floor / HR / personal etc. If yes, please elaborate. . (5)

(iii) Trends of number of suggestions implemented / employee / month? (show last one year trend in line graph , illustrate it with your internal Target line.). (5)

Formula Total suggestions + Kaizen Implemented in that month Suggestions / Employee =---------------------------------- -------------------------------- X 100 Total direct employees ( Operatives ) for the month



16

(1.C) Absenteeism Total= 10

(i) What is absenteeism data ( Average) for the year 2013-14 ? What are the trends in regards to total absenteeism? (Three year trend in bar graph , illustrate it with your internal Target line.) ( 5 ) Authorized = % Unauthorized = %Total = %

(ii) What efforts organization takes to reduce absenteeism? ( 5 )

98

5

0

1

2

3

4

5

6

7

8

9

10

2011-12 2012-13 2013-14

Tota

l % a

bsen

teei

sm


Formula Total absent man-hours for the month ( Authorized + Unauthorized ) Absenteeism =-------------------------------------------------------- -------------------------------- X 100 Total man hours for the month



17

(1.D) TRAINING Total= 10

(i) In which areas do you provide training to your employees ? List some benefits achieved by trainings in recent past. What is the trend of the training hours / employee over the years? (show last three year trend in bar graph , illustrate it with your internal Target line.) ( 5 )

Training Areas : • • • • •

25

40

55

0

10

20

30

40

50

60

2011-12 2012-13 2013-14

Trai

ning

hrs

/em

p/ye

ar


(ii) How training effectiveness is measured and Benefits of Training : Tangible ( in Rs. Lacs ) & Intangible : (Give details for TWO shining examples) : ( 5 )

Formula Total training man-hours for all employees for year Training hours/employee / year =---------------------------------------- --------------------- Total employees



18

(1.E) Small Group Activities Total= 10

(i) Explain how company encourages small group activities :

(ii) Do small group participate in the Quality Conventions-Group/State level/National. Show certificates / trophy photographs :

(iii) How many active groups are present in the current year? % employee involvement In QC Activity? (show last three year trend in bar graph.

15

20

25

50

70

100

0

25

50

75

100

0

5

10

15

20

25

30

2011-12 2012-13 2013-14

active groups% of emp involvement


No

. o

f A

ctiv

e

gro

up

s

%

Em

plo

yee

s I

nvo

lve

me

nt



19

(1.F) SAFETY Total= 30

Pls describe: with text / Photos (i)How company ensures Safe work practices? (5)

(ii) Proactive measures taken by company to reduce accidents (5)

(iii) Number of accident free days ( Cumulative ) (5) :




20


(1.F) SAFETY Total= 30

Formula No. of accidents

Frequency rate =------------------------ X 106

Total man hoursFormula

Total man-days lost Severity rate =------------------------------- X 106

Total man hours

(iv) What are the current accident levels? (Show last one year data in line graph) (15)

A) Frequency (nos.) Minor + Major both

B) Severity (man hrs. lost)



21

(1.G) Environment Management Total= 30

(i) What is the frequency of scarp disposal? (5) : (Pl explain is it Daily / Weekly … )

(ii) Does company have resources conservation strategy? List some recent achievements of company to conserve resource -electricity, water, material , etc ? (10)




22

(iii) Please describe the practices of the company to reduce pollution? (10)

(1.G) ENVIRONMENT MANAGEMENT Total= 30


(iv) Does the company have a do’s and don’ts policy for employees especially with regard to safety / quality / manufacturing practices / environment care etc? (5)



23

Section 2

Customer Assessment

Total Marks = 100



%

2.A Awards by Key Customers 10

2.B Customer audit of Quality system

20

2.C Customer rating for Quality & Delivery

30

2.D Feedback from Customer & analysis

40

TOTAL 100




24

(i) Awards by Key Customers (trend of last 3 years) (10)

0

2

4

6

8

10

2011-12 2012-13 2013-14

89

10

56

8

Nos

No. of Key-Customers Awards by key customer

45

55

85

0

25

50

75

100

2011-12 2012-13 2013-14

QCD

aud

it %

sco

re

Actual

Target

(2.A ) Awards by Key Customers Total= 10

2. Customer diagnosis

(i) Does your key customers audit your quality system regularly? Has the audit results improved over the years? What is the trend over last three years? % , illustrate it with your internal Target line. (20)

Award photo

Note : If your Customer does not have a system of Awards , Mention what kind of supplier recognition is followed by Customer .

(2.B ) Customer audit of Quality system Total= 20

Note : If your Customer does not have a audit system , Mention what kind of supplier audit system and scoring is followed by Customer .



25

(i) Does your key customers rate your performance on quality and delivery regularly? If yes, what is the trend over last three years? , illustrate it with your internal Target line. (30)

85 8690

0

25

50

75

100

2011-12 2012-13 2013-14

(2.C ) Customer rating for Quality & Delivery Total= 30


Mention here major improvements done by your company to improve above performance :



26

(i) Please describe system of getting feedback from the customers? (10)

(2.D ) Feedback from Customer & analysis Total= 40


(ii) If yes, how do you analyze this feedback and take actions in weak areas? Explain with two shining examples. (30)



27

Section 3

Quality Performance

Total Marks = 350



%

3.A Customer Complaints 50

3.B In-House Rejection & Rework

90

3.C Supplier Rejection 40

3.D Warranty Rejection 50

3.E Cost of Poor Quality 30

3.F Process Improvement 40

3.G Quality Management 50

TOTAL 350




28

(i) Please describe method of capturing customer complaints? (5)

1112

1110

98

76

54

0 00

2

4

6

8

10

12

14Target Actual

(ii) What is the trend of the customer complaints in nos? (Show last one year data in line graph , illustrate it with your internal Target line.) (20)

(3.A) Customer Complaints Total= 50

3. Quality Performance



29

(iii) Is the Customer complaint data analysis done? (E.g.—Product wise, Customer wise, Process wise, etc). Explain with an example. (5)

(iv) Is analysis of repeated Customer complaints carried out? Explain with an example ? (5)





30

(v) Explain the efforts to reduce customer complaints? (10)

(vi) Enclose examples of countermeasure report on Customer complaints. (5)





31

(3.B) In-House Rejection & Rework Total= 90


(ii) What are the trends of the Total in-house rejection in PPM ? (show last 3 year data in bar graph , illustrate it with your internal Target line.) (20)

(iii) Please describe the actions taken to reduce the in- house rejection (10)

(i) Does the company follow the APQP process? If not, please specify the alternate methodology followed for component development? (10 )

6000

4000

1200

5000

3000

1000

01000200030004000500060007000

2011-12 2012-13 2013-14

PPM

Target

In-houserejection PPM



32


S.N. Defect Before PPM After PPM Actions Taken

1

2

3

4

Before – After Photos

Before After

(iv) Provide example of actions by which you are able to achieve zero defect at In-house rejection (10)




33

(vi) Explain efforts taken to reduce rework : (10)


(v) What is the current level of the rework in PPM ? (show trend for last 3 year in bar graph , illustrate it with your internal Target line.) (20)

13000

100009000

02000400060008000

100001200014000

2011-12 2012-13 2013-14

PPM




34

(vii) Please give details of action taken to reduce rework? (10)


S.N. Rework Before PPM After PPM Actions Taken

1

2

3

4

Before – After Photo

Before After




35

(3.C) Supplier Rejection Total= 40


(i) What are the trends of the supplier rejection in PPM ? (show last 1 year data in bar Graph , illustrate it with your internal Target line.) (20)

1500

1200

15001600

1456

12351124

840

640540

440

230

0

200

400

600

800

1000

1200

1400

1600

1800

Supp

lier

Rej i

n PP

M

Target Actual

(ii) Please describe the efforts to reduce the supplier rejection? (10)



36

(3.C) Supplier Rejection Total= 40


S.N. Defect from Supplier

Before PPM After PPM Actions Taken

1

2

3

4


Before After

(iii) Provide example of actions by which you are able to achieve zero defect at Supplier end (10)



37

(ii) Please describe the efforts to reduce the warranty rejection (10)

(3.D) Warranty Rejection Total= 50


(i) What are the trends of the warranty ? (show last 3 year data in bar Graph , illustrate it with your internal Target line.) (30)

10001100

300

0

200

400

600

800

1000

1200

2011-12 2012-13 2013-14

PPM

Note : If warranty is Not applicable for your products , Mention in place of Graph



38

(3.D) Warranty Rejection Total= 50


S.N. Warranty Defect

Before PPM After PPM Actions Taken

1

2

3

4


Before After

(iii) Provide example of actions by which you are able to achieve Zero warranty defect (10)



39

(i) What is the trend for this data/current status? (show last 3 year data in bar graph , illustrate it with your internal Target line. (10) Cost of Poor Quality ( COPQ ) as a % of Sales

1.2

0.4

0.1

0

0.2

0.4

0.6

0.8

1

1.2

1.4

2011-12 2012-13 2013-14

%(3.E) Cost of Poor Quality ( COPQ) Total= 30


(ii) Show elements of Cost of poor quality and improvements for the year 2013-14 . ( 10 )

S.N. COPQ Element

Before % After % Actions Taken

1

2

3

4

5

6



40

(3.E) Cost of Poor Quality ( COPQ ) Total= 30


(iii) Provide example of actions by which you are able to reduce COPQ ( 10 )


Before After

Before After



41

(i) How company identifies Critical to Quality characteristics (CTQ) ? (10)

(3.F) Process Improvement Total= 40




42

(iii) What steps are taken to improve process capability greater than 1.67? ( 5 )



S.N.

CTQ Parameter

Customer Complaints for 2013-14

Not Monitored

CPk < 1.33

CPk>1.33<1.67

CPk>1.67

Present Control

1

2

3

4

5

6

(ii) Does the company insist on CpK performance for CTQ characteristics? What is the present level of Process capability (Cpk) for CTQ’s identified and controls ? (15)



43

(iv) Show Shining examples of process improvements ( 10 )Explain with text and Photographs .



Before After

Before After




44


(i) How is the quality of safety critical parts ensured on periodic basis? (5 )

(ii) Are process / engineering changes also validated and documented? (5 )

(3.G) Quality Management Total= 50

(iii) How company identifies need for Poka-Yoke ? ( 10 )



45

(iv) What % of CTQs are controlled by Poka Yoke? (5)

% =


(vi) How do you ensure effectiveness of Poka yoke? (5 )

(v) What % of Customer complaints are closed by Poka Yoke in 2013-14 ? (5)

% =




46

(vii) Show innovative examples of poka-yokes & Effect on overall Rejection of that Product ( 15 )


S.N. Product Before Rejection PPM

After Rejection PPM

Poka-yokes done

1

2

3

4


Before After




47

Section 4

Productivity Performance

Total Marks = 300



%

4.A Manpower Productivity 100

4.B Manufacturing Process Improvement

75

4.C Inventory Management 75

4.D Loss of production Hours 50

TOTAL 300




48

(ii) What are the tools used to improve manpower productivity ? (10)

(4.A) Manpower productivity Total= 100

4. Productivity Performance

2024

35

0

10

20

30

40

2011-12 2012-13 2013-14

No.

of p

rodu

cts

/man

/yea

r (i) What is the productivity trend. Show for your key business line ? (show last 3 year data in Bar graph , illustrate it with your internal Target line.) (20)



49

(4.A) Manpower Productivity Total= 100

4 Productivity Performance

(iii) Show innovative examples of Manpower productivity improvements ( 20 )

S.N. Operation Before ( Production / day )

After ( production / Day )

Actions Taken

1

2

3

4


Before After



50

(i) What % of operators are handling more than one machine? Illustrate it with your internal Target line. (30)


56

76

100

0

20

40

60

80

100

120

2011-12 2012-13 2013-14

% o

f op

erat

ors

oper

ating

m

ore

than

one

mac

hine

(ii) How Company encourages employees for operating multi-machines ? (20)

(4.A) Manpower Productivity Total= 100



51

(4.B) Manufacturing Process Total= 75


Before

After

(i) Do you follow Single piece flow or batch flow layout or a mixture of both? Show present material flow for your key business line ? (15)

(ii) Show improvements in layouts done last year , Show benefits of layouts change ( 25 )

Single piece flow = % , Batch Flow =

Before : Material Travel = Meters ; Manufacturing Lead time = Mins ; WIP = Nos.

After : Material Travel = Meters ; Manufacturing Lead time = Mins ; WIP = Nos.



52

(iii) How process cycle times are reduced ? Share examples (20)



S.N. Operation Before Cycle Time

After Cycle Time

Actions Taken

1

2

3

4


Before After



53



(iv) Is planning for safety / quality an integral part of the overall production planning process? Is FMEA carried out during planning stage? (15)



54

(i) Show the trend of ITR (Inventory Turn Ratio) last three years , illustrate it with your internal Target line. (50)

(4.C) Inventory Management Total= 75


2024

35

0

10

20

30

40

2011-12 2012-13 2013-14

Inve

ntor

y T

urns

(ii) Show actions taken to reduce inventory . (25)

S.N. Products Before Inventory in days

After Inventory in days

Actions Taken

1

2

3

4

Formula Material cost of sales for the month x 12 ITR = ----------------------------------------------------------- (RM + WIP + FG ) on last day of the month



55

(i) How much is machine breakdown loss in % of total available time? (Bar graph, illustrate it with your internal Target line ) (20)

(ii) Show Actions taken to reduce break downs (10)

(4.D) Loss of Production Hours Total= 50


2.1

0.40.1

0

0.5

1

1.5

2

2.5

2011-12 2012-13 2013-14

% B

reak

dow

ns

S.N. Breakdown Before Breakdown in a month

After Breakdown in a month

Actions Taken

1

2

3

4



56

(4.D) Loss of Production Hours Total= 50


(iii) How much is the Setup loss in % of total available time? (Bar graph, illustrate it with your internal Target line ) (10)

(iv) Show Actions taken to reduce Setup time (10)

0.1

0.07

0.03

0

0.02

0.04

0.06

0.08

0.1

0.12

2011-12 2012-13 2013-14

% S

et u

p T

ime

S.N. Set up Before

After

Actions Taken

1

2

3

4



57

Section 5

Cost Performance

Total Marks = 100



%

5.A Energy Saving 10

5.B Value Addition / Net Sales 30

5.C Value Addition / Fixed Assets

30

5.D Value Addition / Employee Cost

30

TOTAL 100




58

(5.A) Energy Savings Total= 10

5. Cost Performance

(i) Show energy consumption as % Sales, illustrate it with your internal Target line. (5)

1.21.1

0.7

0

0.2

0.4

0.6

0.8

1

1.2

1.4

2011-12 2012-13 2013-14

% E

nerg

y of

sal

es

S.N. Item Before After

Actions Taken

1

2

3

4

(ii) Show examples to reduce energy consumption (5)



59

(i) Show the trend of last three years in bar graph, illustrate it with your internal Target line. (15)

(5.B) Value Additions / Net Sales Total= 30

5. Cost Performance

1011

13

0

2

4

6

8

10

12

14

2011-12 2012-13 2013-14

Valu

e Ad

ditio

n to

N

et sa

les

Formula Net Sales – Variable Cost

Value Addition to Net Sales = ----------------------------------------------------

Net Sales

(ii) What is the benchmark & efforts to improve value addition / Net sales? (15)



60

(i) Show the trend of last three years in bar graph, illustrate it with your internal Target line. ( 15 )

(5.C) Value Additions / Fixed Assets Total= 30

5. Cost Performance

78

9

0

2

4

6

8

10

2011-12 2012-13 2013-14

Valu

e Ad

ditio

n to

fixe

d

asse

ts

Formula Net Sales - Variable Cost Value Addition to Fixed Assets = ---------------------------------------------------------

Total Cost of Fixed Assets

(ii) What is the benchmark & efforts to improve value addition / Fixed assets ? (15)



61

(i) Show the trend of last three years in bar graph, illustrate it with your internal Target line. ( 15 )

(5.D) Value Additions to Employee cost Total= 30

5. Cost Performance

4

5

6

0

1

2

3

4

5

6

7

2011-12 2012-13 2013-14Valu

e Ad

ditio

n to

Em

ploy

ee

Cost

(ii) What is the benchmark & efforts to improve value addition to Employee Cost ? (15)

Formula Sales –Variable Cost Value Addition to Employee Cost = -------------------------------------------------------

Total Employee Cost ( CTC )



Summary of Achievements for the year 2013-14

( Company has to fill up )




For Company:Show your companies excellent photos


Documents

2013-14 ACMA Awards Company Name : Plant Location : Category : Large Excellence in Quality & Productivity PM_44_F8 Rev. No. : 00, Specimen Format*