ACMA Awards 2012-13 : Excellence in Quality & Productivity For Jury / Assessor / Remarks : 1 Letter for Submission of Award application for 2012-13 Company

ACMA Awards 2012-13 : Excellence in Quality & Productivity

For Jury / Assessor /

Remarks :

1

Letter for Submission of Award application for 2012-13

Company letterhead details ( Logo , Address )

To ,

The Secretariat ( ACMA Awards ) ,ACMA Centre for TechnologyGodrej Eternia-C, ‘B’ Wing, '10th Floor, Office No. - C Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar Pune – 411005,Tel No. 07387002181 ( Ms. Sakshi ) We are pleased to submit the application for ACMA Award 2012-13 for Excellence in Quality & Productivity in Small / Large ( Delete not required ) category

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

With regards

( Sign on all copies ) ( Name & Designation of the Plant CEO )

Paste good photo of ACMA Membership Certificate for the year 2013-14



Remarks :

2

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

( Underline the plant for which application is sent )

1. Plant 12. Plant 23. Plant 3

Plant Address for which application is sent :

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

3 Chief Executive (Applicant Plant) 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



Remarks :

3

Company’s Details

5. Company turnover ( in Rs. Crore ) for Year 2012-13 :

6. Plant turnover ( in Rs, Crore ) for Year 2012-13 :

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. Key competitors :

14. Key Suppliers :

15. Major Certifications :



Remarks :

4

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

Kindly provide 2 names per Key Customers for the plant for which application is being sent.

Customer Details

S. No Customer Location

% Business share ( from the plant )

Key person name & Designation

Mobile Number & E mail

1

2



Remarks :

5

Use slide no. 5 and 6 to brief about your company / Plant .

It includes Product names / photos , Plant facility photographs ,

Company / Plant Information ( page 1 of 2 )



Remarks :

6

Use slide no. 5 and 6 to brief about your company / Plant .

It includes Product names / photos , Plant facility photographs ,

Company / Plant Information ( page 2 of 2 )



Remarks :

7

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 assessment ( Site assessment is carried out if your application is shortlisted by Jury )



Remarks :

8

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. 250

5 Cost Performance. 150

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



Remarks :

9

Section 1

Work Environment & Employee Involvement.

Total Marks = 150

S.N. Sub topic Total Marks

Actual Marks ( for office use )

%

1.A 5 S 40

1.B Suggestions / Kaizens Per Employee

10

1.C Absenteeism 10

1.D Training 10

1.E Small Group Activities 10

1.F Safety 40

1.G Environment Management

30

TOTAL 150




Remarks :

10

1. Work Environment and employee engagement

(i)illustrate how concept of 5S/house keeping has been deployed in your plant?(10 )

(1.A) 5S Total= 40

50

60

70

60

7475

76 77 77 78 79 80

0

10

20

30

40

50

60

70

80

90

% sc

ores

Target Actual

(ii) What methods are adopted to assess 5S levels/scores? (show last one year trend in line graph). (20)

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

30



Remarks :

11

(iii) illustrate with photographs examples of good Visual Factory- Before and after. (10)

/

Before After


(1.A) 5S Total= 40

Before After

10



Remarks :

12

(1.B) Suggestions / Kaizens Per Employee Total= 10

/

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

(iii) Trends of number of suggestions implemented / employee / month? (show last one year trend in line graph).

0.30.4

0.50.6

0.4

0.80.9

0.10.2

0.10.2

0.3

0

0.2

0.4

0.6

0.8

1

1.2

No

of s

ugg

impl

emen

ted

/ em

ploy

ee

Target Actual

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


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

10



Remarks :

13

(1.C) Absenteeism Total= 10

(i) What is absenteeism data ( Average) for the year 2012-13 ? What are the trends in regards to total absenteeism? (Three year trend in bar graph) ( 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

2010-11 2011-12 2012-13

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

10



Remarks :

14

(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) ( 5 )

Training Areas : • • • • •

25

40

55

0

10

20

30

40

50

60

2010-11 2011-12 2012-13

Trai

ning

hrs

/em

p/ye

ar


(ii) Benefits of Training : Tangible ( in Rs. Lacs ) & Intangible ( 5 )

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

10



Remarks :

15

(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

2025

50

70

100

0

25

50

75

100

0

5

10

15

20

25

30

2010-11 2011-12 2012-13

active groups% of emp involvement


No

. o

f A

ctiv

e

gro

up

s

%

Em

plo

yee

s I

nvo

lve

me

nt

10



Remarks :

16

(1.F) SAFETY Total= 40

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

(ii)Proactive measures taken by company to reduce accidents (10)

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


20



Remarks :

17

0.3 0.3

0.50.6

0.4

0.80.9

0.10.2

0.10.2

0.3

0

0.2

0.4

0.6

0.8

1

Adci

dent

freq

uenc

y

Target Actual


(1.F) SAFETY Total= 40

0.30.4

0.50.6

0.4

0.80.9

0.10.2

0.10.2

0.3

0

0.2

0.4

0.6

0.8

1

Ad

cid

en

t S

ev

eri

ty

Target Actual

Formula No. of accidents

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

Total man hours

Formula

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

Total man hours

20

(iii) What are the current accident levels? (Show last one year data in line graph)A) Frequency (rate.) (Minor + Major Accidents) (10)

B) Severity (rate) (10)



Remarks :

18

(1.G) Environment Management Total= 30

(i) What is the frequency of scarp disposal? (10) : (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? (10)


20



Remarks :

19

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

(1.G) ENVIRONMENT MANAGEMENT Total= 30


10



Remarks :

20

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




Remarks :

21

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

0

2

4

6

8

10

2010-11 2011-12 2012-13

89

10

56

8

Nos

No. of Key-Customers Awards by key customer

45

55

85

0

25

50

75

100

2010-11 2011-12 2012-13

QCD

aud

it %

sco

re

Actual Target

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

2. Customer Assessment

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? % (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 .

30



Remarks :

22

Does your key customers rate your performance on quality and delivery regularly? If yes, what is the trend over last three years? (30)

85 86 90

0

25

50

75

100

2010-11 2011-12 2012-13

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


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

30



Remarks :

23

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

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


10



Remarks :

24

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


30

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



Remarks :

25

Section 3

Quality Performance

Total Marks = 350



%

3.A Customer Complaints 50

3.B In-House Rejection 50

3.C Supplier Rejection 40

3.D Warranty Rejection 50

3.E Cost of Poor Quality 40

3.F Process Improvement 40

3.G Rework 40

3.H Poka-Yokes 40

TOTAL 350




Remarks :

26

(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. (20)

(3.A) Customer Complaints Total= 50

3. Quality Performance

25



Remarks :

27

(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)



10



Remarks :

28

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

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



15



Remarks :

29

(3.B) In-House Rejection Total= 50


(i) What are the trends of the Total in-house rejection in PPM ? (show last 3 year data in bar graph) (25)

(ii) Please describe the actions taken to reduce the in- house rejection (15)

40



Remarks :

30

(3.B) In-House Rejection Total= 50


S.N. Defect Before PPM After PPM Actions Taken

1

2

3

4

Before – After Photos

Before After

10

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



Remarks :

31

(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) (20)

1500

1200

15001600

1456

12351124

840

640540

440

230

0

200

400

600

800

1000

1200

1400

1600

1800

Supp

lier R

ej in

PPM

Target Actual

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

30



Remarks :

32

(3.C) Supplier Rejection Total= 40


S.N. Defect from Supplier

Before PPM After PPM Actions Taken

1

2

3

4


Before After

10

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



Remarks :

33

(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) (30)

40

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



Remarks :

34

(3.D) Warranty Rejection Total= 50


S.N. Warranty Defect

Before PPM After PPM Actions Taken

1

2

3

4


Before After

10

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



Remarks :

35

(i) What is the trend for this data/current status? (show last 3 year data in bar graph (20) Cost of Poor Quality ( COPQ ) as a % of Sales

1.2

0.4

0.1

00.20.40.60.8

11.21.4

2010-11 2011-12 2012-13

%(3.E) Cost of Poor Quality ( COPQ) Total= 40


(iii) Show elements of Cost of poor quality and improvements for the year 2012-13 . ( 10 )

S.N. COPQ Element

Before % After % Actions Taken

1

2

3

4

5

6

30



Remarks :

36

(3.E) Cost of Poor Quality ( COPQ ) Total= 40


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


Before After

Before After

10



Remarks :

37

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

(3.F) Process Improvement Total= 40


10



Remarks :

38

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



S.N.

CTQ Parameter

Customer Complaints for 2012-13

Not Monitored

CPk < 1.33

CPk>1.33<1.67

CPk>1.67

Present Control

1 Hole 10 mm dia

0 100 % Inspection

2 Bore 25 mm dia

1 Sampling done

3

4

5

6

20

(ii) What is the present level of Process capability (Cpk) for CTQ’s identified and controls ? (15)



Remarks :

39

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



Manual Clamping

Before After

10

Auto Clamping

Offline checking

Before After

Online checking

Before – After Photo



Remarks :

40

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

(3.G) Rework Total= 40


(i) What is the current level of the rework in PPM ? (show trend for last 3 year in bar graph) (20)

30



Remarks :

41

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

(3.G) Rework Total= 40


S.N. Rework Before PPM After PPM Actions Taken

1

2

3

4


Before After

10



Remarks :

42

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

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

% =

(3.H) Poka-yoke Total= 40


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

(iii) What % of Customer complaints are closed by Poka Yoke in 2012-13 ? (5)

% =

25



Remarks :

43

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

(3.H) Poka-yokes Total= 40


S.N. Product Before Rejection PPM

After Rejection PPM

Poka-yokes done

1

2

3

4


Before After

15



Remarks :

44

Section 4

Productivity Performance

Total Marks = 250



%

4.A Manpower Productivity 50

4.B Manufacturing Process Improvement

50

4.C Inventory Management 50

4.D Utilization of Operators 50

4.E Loss of production Hours 50

TOTAL 250




Remarks :

45

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

(4.A) Manpower productivity Total= 50

4. Productivity Performance

30

(i) What is the productivity trend. Show for your key business line ? (show last 3 year data in Bar graph) (20)



Remarks :

46

(4.A) Manpower Productivity Total= 50

4 Productivity Performance

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

S.N. Operation Before ( Production / day )

After ( production / Day )

Actions Taken

1 Drilling 20 40 Layout Changed

2

3

4


Before After

20



Remarks :

47

(4.B) Manufacturing Process Total= 50


Before

After

30

(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 ? (10)

(ii) Show improvements in layouts done last year , Show benefits of layouts change ( 20 )

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.



Remarks :

48

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

(4.B) Manufacturing Process Total= 50


S.N. Operation Before Cycle Time

After Cycle Time

Actions Taken

1 Milling 25 Seconds 18 Seconds Manual to auto feed

2

3

4


Before After

20



Remarks :

49

(i) Show the trend of ITR (Inventory Turn Ratio) last three years . (30)

(4.C) Inventory Management Total= 50


(ii) Show actions taken to reduce inventory . (20)

S.N. Products Before Inventory

After Inventory

Actions Taken

1 Springs 20 days 3 Days Shared transport

2

3

4

50

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



Remarks :

50

(i) what % of operators are handling more than one machine? (30)

(4.D) Utilization of Operators Total= 50


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

50



Remarks :

51

(i) How much is machine breakdown loss in % of total available time? (Bar graph ) (20)

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

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


S.N. Breakdown Before Breakdown

After Breakdown

Actions Taken

1 Pressure Variation

2 Times / month

0 Hyd oil heating avoided by replacing Solenoid valve type E to G

2

3

4

30



Remarks :

52

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


20

(iii) How much is the Setup loss in % of total available time? (Bar graph ) (10)

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

S.N. Set up Before

After

Actions Taken

1 Mold Change

30 Minutes 1 Minute Only Sub-assembly Changed

2

3

4



Remarks :

53

Section 5

Cost Performance

Total Marks = 150



%

5.A Energy Saving 30

5.B Value Addition / Net Sales 40

5.C Value Addition / Fixed Assets

40

5.D Value Addition / Employee Cost

40

TOTAL 150




Remarks :

54

(5.A) Energy Savings Total= 30

5. Cost Performance

(i) Show energy consumption as % Sales . (20)

S.N. Item Before After

Actions Taken

1 Tube Light 28 Watts 8 Watts Replaced with lower watts with more Lux levels

2 Electrical Panel AC

1500 watts 100 Watts Replaced with fan cooling

3

4

30

(ii) Show examples to reduce energy consumption ( 10 )



Remarks :

55

(i) Show the trend of last three years in bar graph. ( 20 )

(5.B) Value Additions / Net Sales Total= 40

5. Cost Performance

Formula Net Sales – Variable Cost

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

Net Sales (ii) What is the benchmark & efforts to improve value addition / Net sales? (20)

40



Remarks :

56


(5.C) Value Additions / Fixed Assets Total= 40

5. Cost Performance

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 ? (20)

40



Remarks :

57


(5.D) Value Additions to Employee cost Total= 40

5. Cost Performance

(ii) What is the benchmark & efforts to improve value addition to Employee Cost ?(20)

40

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

Total Employee Cost ( CTC )



Remarks :

58

( Assessors have to prepare a summary with bullet points highlighting companies Major strengths and Areas for

improvements )

1 .Work Environment and Employee Involvement: Major Strengths : 1.

2.

3.

4.

Areas for improvements :1.

2.

3.

4.

2. Customer Assessment Major Strengths : 1.

2.

3.

4.


2.

3.

4.

( For office use only )Executive Summary



Remarks :

59


improvements )

3. Quality Performance : Major Strengths : 1.

2.

3.

4.


2.

3.

4.

4. Productivity Performance Major Strengths : 1.

2.

3.

4.


2.

3.

4.




Remarks :

60


improvements )

5. Cost Performance : Major Strengths : 1.

2.

3.

4.


2.

3.

4.


Documents

ACMA Awards 2012-13 : Excellence in Quality & Productivity For Jury / Assessor / Remarks : 1 Letter for Submission of Award application for 2012-13 Company