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2018-19

ACMA Awards Year of Inception: 1966. Excellence in HSE (Health, Safety & Environment) 1000 Marks. Company Name: Plant Location:. Award Category: Tick mark in appropriate box as per your ‘Company Group Turnover for 2017-18’. Small > INR 50 (NA) Medium > INR 50 to 150 Cr (NA)

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2018-19

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  1. ACMA Awards Year of Inception: 1966 Excellence in HSE (Health, Safety & Environment) 1000 Marks Company Name: Plant Location: Award Category: • Tick mark in appropriate box as per your ‘Company Group Turnover for 2017-18’. • Small > INR 50 (NA) • Medium > INR 50 to 150 Cr (NA) • Large > INR 150 to 500 Cr • Very Large > INR 500 Cr (NA) Tick mark in appropriate box: ACMA Member All Past & Present ACT Cluster/ ACMA UNIDO Cluster Companies are eligible without becoming ACMA member 2018-19

  2. Company / Plant Information Use this slide to brief about your company / Plant. It includes Product names / photos , Plant facility photographs.

  3. For Administrative Queries: • Ms. Sakshi Karkamkar • Email –sakshi.karkamkar@acma.in • Mobile – 7387002181 • Ms. Smita Kulkarni • Email – smita.kulkarni@acma.in • Mobile –9922922500 • Mr. Sanket Jadhav • Email- sanket.jadhav@acma.in • Mobile- 7768046868 • Ms. Surekha Deshmukh • Email- S.DESHMUKH@unido.org • Mobile- 9552599463 For Technical Queries: Mr. Arun Bage Email – arun.bage@acma.in Mobile – 9552532184 Mr. Atul Gupta Email – atul.gupta@acma.in Mobile – 9971888751 Mr. Vishal Saxena Email – vishal.saxena@acma.in Mobile – 9650988154 Ms. Tanu Ahuja Email – tanu.ahuja@acma.in Mobile – 09899237770 ACMA – Skilling and Mentoring Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C, Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar , Pune – 411005, India, Desk phone – 020 66061219 act@acma.inwww.acma.in , www.digitalact.in

  4. Letter for Submission of Award application Company letterhead details ( Logo , Address ) To , The Secretariat (ACMA Awards) , ACMA – Skilling and Mentoring Godrej Eternia, ”B” Wing ,, 10th Floor, Office No. C, ,Old Mumbai –Pune Highway, Wakdewadi , Shivaji Nagar Pune – 411005, India We are pleased to submit the application for ACMA Award 2018-19 for Excellence in HSE Large Category. All data submitted is duly verified and true to the best of our knowledge. With regards ( Name & Designation of the Plant CEO ) Note – 1) If you have applied & won multiple awards in one year, please mention accordingly. 2) If a plant has won Gold trophy in the year 2016-17 or 2017-18 in any of the above categories, then that particular plant will not be eligible to apply in the same category. But they can apply for any other categories.

  5. Automotive Component Manufacturers Association of India 6th  Floor, The Capital Court Olof Palme Marg, Munirka New Delhi - 110 067,  India To, Applicant Company CONFIDENTIALITY STATEMENT As a part of the ACMA Awards Process, applicant companies provide business, market, technical, financial information/documents and top customers details in the application. Such information could also be related to intellectual property i. e. patents, product development etc. ACMA take reasonable care to keep the above information confidential and shall not divulge it to third party and/or not use it for their own purpose, any part of this information in the course of assessment and thereafter. I agree. On behalf of ACMA  Sd/- Director General

  6. Company’s Details • Name of the corporate group (if company is part of a corporate group): - • ( Underline the plant for which application is sent ) • 2. Plant Address : • 3. Invoicing Details (Applicable only for shortlisted companies for site diagnosis): • a) GST Number- • b) Invoicing Address (write complete address with pin code)- • 4. Chief Executive Officer details : • Name : Designation : • Mobile : E-mail : • Website: • 5. Plant Head details : • Name : Designation : • Mobile : E-mail : • 6. HR Head details : • Name : Designation : • Mobile : E-mail :

  7. Company’s Details 7. Company Group Annual Sales Turnover (in INR Cr.) for Year 2018-19: 8. Plant ( for which application is submitted) turnover ( in INR Cr.) for Year 2018-19 : 9. Year of Establishment : Group Company _______ , Plant ___________ 10. Total Employees : Group Company ___________ , Plant _____________ 11. Do you have a Joint Venture for the plant applied: ( If Yes , Mention the partner name ) 12. Plant’s Key products : 13. Plant’s major manufacturing processes : 14. Plant’s Key competitors : 15. Plant’s Major Certifications :

  8. Company’s Details 16. Contact Person 1 Information : ( Need to contact thru out the process of ACMA Award ) Name : Designation : E-Mail : Mobile : 17. Contact Person 2 Information : ( Need to Contact if above person is not reachable) Name : Designation : E-Mail : Mobile : Route Map to reach your plant Provide here route map to your company for site diagnosis (Site diagnosis is carried out if your application is shortlisted)

  9. Customer Details Mandatory requirement (not applicable for Excellence in Supplier Development category) • Kindly provide details of your top 3 business customers in below table. • ACMA Award online application software automatically sends a link to all above email addresses to get feedback about your plant. • Kindly inform above persons from your side to respond ASAP & ensure that we receive this before you submit the application online.( Your application will not processed without these feedback). Note: • These feedbacks will be considered by Jury for evaluation & the same will be provided to you as a part of feedback report.

  10. Status of  actions  taken by your company based  on previous ACMA Awards feedback report. (Mention top 5 only)  (Not applicable- for 1st time applicants)

  11. Summary of Achievements for the year 2018-19 1. Did you receive any awards other than Customers? 2. What are your biggest achievements in the last year? 3. What are challenges for you in the future and how are you preparing for it? Example Industry 4.0 , IOT (Internet of things) etc

  12. 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

  13. OFFICE USE ONLY Section 1 Hygiene Factors Total marks =200

  14. 1. Hygiene Factors (1.A) 5S & Plant Upkeep Total = 30 Mention in following chart status of Must be Facilities. (10 ) Questions are applicable for plant for which you have applied for ACMA Awards. In Status kindly mention % . E.g You have jogging track for 50 % areas , then write 50 %

  15. 1. HygieneFactors (1.A) 5S & Plant Upkeep Total = 30 (ii) How you drive 5S Process (10) Explain whether sub areas formed, Sub-Area Owners identified, 5S Audit schedule & mechanism, NC clearance, Award for Best, Cross Audits or any other activities done. ( You may use Photos / Images to support this ) (iii) How you drive Workplace Ownership concept (4) Explain responsibilities of operating people to keep workplace surrounding Clean & Safe

  16. 1. Hygiene Factors (1.A) 5S & Plant Upkeep Total = 30 (iv) Shining examples of 5S Improvements (3) Show 4 Photographs, Assessor may interview few operators for checking effectiveness (v) Share few sample audit findings & actions taken (3)

  17. 1. Hygiene Factors (1.B) Leadership Focus Total = 20 (i) When was your VMV ( Vision , Mission & Values ) Statement was formed ? Have you revisited it afterwards ? When? (2) (ii) How you Communicate VMV to your Stakeholders like Suppliers, Employees etc. (3)

  18. 1. Hygiene Factors (1.B) Leadership Focus Total = 20 (iii) What Process is followed for forming Annual Business Plan i.e. Organizational Targets ? (6) Specify Process time schedule, inputs considered, competitors performance and Benchmarks, who all participate in the Process, whether the Targets are based on last year performance or market oriented, giving some examples of market oriented targets. Also specify, how the Stretched factor is considered during this process. Show KPI (Key Performance Indicators) of any one employee and explain how it is linked to Organizational target

  19. 1. Hygiene Factors (1.B) Leadership Focus Total = 20 (iv) How frequently the Organizational Targets are reviewed ? and show action plans for any two Targets, which were below the expected level - few months prior to year end (5)

  20. 1. Hygiene Factors (1.B ) Leadership Focus Total = 20 Please give information about all types of communication meetings taking place in your organization indicating frequency, major participants and major issues during these meetings (4) ( Assessor may verify with few employees about such meetings)

  21. 1. Hygiene Factors (1.C) Quality Management Total = 30 Explain What actions have been taken in your organization to sensitize employees about Quality Culture (Defects should not go outside company – to - Defects should not get produced) (5) Specify Quality tool training, control gates, empowerment, problem solving training , next station is your customer etc. You may also show photographs of posters for awareness creation

  22. 1. Hygiene Factors (1.C) Quality Management Total = 30 (ii) How you identify CTQs and show some examples of Process capability improvement for two identified CTQs (10)

  23. 1. Hygiene Factors (1.C) Quality Management Total = 30 (iii) Show examples of use of Quality Tools like Six Sigma Project, Poka-yoke, DoE, Why-Why Analysis, 8D etc. (15)

  24. 1. Hygiene Factors (1.D) Stakeholders Happiness Total = 30 (i) Show top 3 concern areas each from your Stakeholders like Customer / Suppliers / Employees and actions taken / planned for these concerns (10 ) Specify major dissatisfaction points received as feedback from these stakeholders

  25. 1. Hygiene Factors (1.D) Stakeholders Happiness Total = 30 (ii) Show score of Supplier Satisfaction for 3 years (10) • (iii) What are the actions initiated during last year? (10 ) • (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text.)

  26. 1. Hygiene Factors (1.E) Safety Total = 20 (i) Give details of One Accident Investigation analysis and corrective actions (4) ( if there are no accidents , mention as ZERO Accidents ) (ii) Give details of One Near Miss Accident and corrective actions (4)

  27. 1. Hygiene Factors (1.E) Safety Total = 20 (iii) At what frequency your Plant Head / CEO take round for Safety purpose only ? Give details of Unsafe Behaviour and Unsafe Condition observed during such round and how you take corrective actions (4) (iv) Indicate 3 identified Accident Prone areas in your factory and actions planned / taken (4)

  28. 1. Hygiene Factors (1.E) Safety Total = 20 (v) Do you conduct Mock Drills, Share one Report (2) (vi) Are you aware about any Fatal Accident happened in any factory (either in your group companies / competitor / customer / supplier etc.) and what preventive actions have you planned / implemented in your organization (2)

  29. 1. Hygiene Factors (1.F) Employee Engagement Total = 15 (I) Whether any of your Teams, participate in External Contests held by various agencies ? Give details indicating where they have participated / Topic of Presentation and level of Team members (Operatives / Supervisory / Managerial etc). Mention about the Awards won by your Team ( 10). (ii) Whether you have Cross Functional Teams working in your organization ? Give details. Whether these Teams, gets an opportunity to make presentation to CEO / Plant Head ? CEO / Plant Head Give one example, where such a cross functional Team has contributed handsomely (5)

  30. 1. Hygiene Factors (1.G) Environment Protection Total = 5 (i) List some of the recent achievements of your organization, regarding Resource Conservation like Energy / Water / Air / Oil (5). (1. H ) Poka-yoke / KAIZEN Total = 10 What % of CTQs (Critical to Quality) are being addressed through poka- yoke ? (3) Show some recent customer complaints, which are addressed through poka-yoke (2)

  31. 1. Hygiene Factors (iii) Show some shining examples of Poka-yoke / KAIZEN (3 ) (iv) Show your mechanism for sustenance of poka-yoke / KAIZEN (2).

  32. 1. Hygiene Factors Total = 5 (1. I) Legal / Statutory Compliance (i) How do you ensure compliance of Statutory issues (5), Give few shining examples

  33. 1. Hygiene Factors (1 J ) Wastage Reduction / Non Value adding activity reduction Total = 5 (i) Show some shining examples of Wastage Reduction / Non Value Adding Activity Reduction (3) (ii) Give shining examples where you have made improvements based on Benchmarking Best Practices Sharing from Industry or Knowledge sharing within Group organizations (2)

  34. 1. Hygiene Factors (1 K) Automation / Digitization of various activities Total = 10 (i) Give shining examples of Automation / Digitization in different areas (6) (ii) What is your strategy for Industry 4.0 (4) Specify actions taken / Planned

  35. 1. Hygiene Factors (1 L) Contribution towards Society & Nation Building Total = 20

  36. 1. Hygiene Factors 1 L Contribution towards Society & Nation Building Total = 20

  37. OFFICE USE ONLY Section 2 Health, Safety & Environmental Systems & Approach Total Marks = 150

  38. 2. Health, safety & Environmental System & Approach 2A. Senior Leadership CommitmentTotal = 55 How does the Senior leadership create a focus on Health, Safety & Environment across the organization? What are the guiding principles, policies, objectives & targets put in place for ensuring Safety in the organization? {Give details of, Safety policy, Environment policy , Review of policies, Specific targets for the organization at various levels etc} (10) (ii) Has a specific management representative been appointed with clear role, responsibilities and authorities for ensuring rigorous implementation of safety policy and activities decided in line with the safety requirements? (Give details of, Role, Responsibility, Authority , of the representative along with the reporting structure and forums in which he can flag issues if any and arrange for resources) ( 10 )

  39. 2. Health, safety & Environmental System & Approach 2A. Senior Leadership CommitmentTotal = 55 (iii) How does the strategic planning process address the impacts due to unsafe incidents/conditions/acts which could result in loss of life , damage to assets, environment and corporate image? How does the planning process address the needs of internal as well as external customers of HSE function. {Explain the objectives and guidelines to be followed during setting up of new facilities, shops units etc Explain how the needs of the HSE customers (Employees, Society, Safety and Environment authorities of the govt etc are addressed during the planning stage.} (15) (iv) How does the Senior Leadership review the Health safety & Environment performance across key stakeholders? (Give details of, Periodic review , Safety & Environment KPI’s identified for key functions, Countermeasures for non achievements etc) (10)

  40. 2. Health, safety & Environmental System & Approach 2A. Senior Leadership CommitmentTotal = 55 (v) Which external certifications are sought by & secured by the organization in the subject of Safety, Health & Environment? {Give details of all external audits including e.g OHSAS 18000, ISO 14000, British Safety, Dupont, any other third party audits conducted by Competent or Statutory authorities} (10)

  41. 2. Health, safety & Environmental System & Approach 2B. Identification & Mitigation of Risks in Operations Total = 40 (i) How are the key Hazards/Risks in the companies operations Identified & Evaluated ? What is the system, used by your company in managing safety? List out the Hazards risks so identified. {Explain how safety & environment thinking is injected in to at planning stage. Explain the methodology used, e.g Subjective evaluation by experts, Techniques like FMEA,, Process ,HAZOP Reviews,(Hazard operational study) RULA for ergonomics (Rapid Upper Limb Assessment) etc. .} (20) (ii) How do you ensure that reasonable risk mitigation actions and plans are in place for the issues identified above ? {Give details of list of actions taken/equipment installed or process modified to mitigate the risks identified How is the remainder of the risk addressed? } (20)

  42. 2. Health, safety & Environmental System & Approach 2C. Statutory and legal RequirementsTotal = 25 (i) How does the organization identify the various statutory and legal requirements applicable to its operations on the safety, health and environments subjects? { Requirements of factories act, hazardous material processing requirements, Electrical safety requirements, Any other specific requirements applicable?} (15) (ii) How are these requirements under various laws met ? What are the arrangements made for the same? (10)

  43. 2. Health, safety & Environmental System & Approach 2D. Safety Culture & communications Total = 30 (i) How is the safety Policy and senior leadership’s objectives for safety, communicated to employees at all levels? What actions are taken to periodically and continuously reinforce the communication? { Give details of Training programs, displays, Banners , discussions held, Monthly /periodic Safety meetings with leadership etc/} (15) (ii) What resources are available at present for training purposes? Are these sufficient for the industry? How many manhours are utilized in training per employee per year? How are training records maintained? How is the effectiveness of training measured? (15)

  44. OFFICE USE ONLY Section 3 HSE : Deployment and Compliance Total Marks = 350

  45. 3. HSE Deployment & Compliance 3A. Training & Awareness. Of HSE requirements Total = 50 (i) Describe in detail , what trainings were given in the past year? Who were the trainers? List what trainings are essential in your industry and how it is linked with the work processes and does it include the lessons learnt from past accidents/incidents? What is the safety documents, guidelines, handbook, or similar available to employees (20) (ii) How do you encourage and motivate the employees to participate actively in matters of Safety, Environment & Health? {Give details of Rewards & Recognitions, Safety/ Environment week celebrations, various drives for safety, tree plantation, other environment activities , water saving drives, kaizens done for safety or fatigue, other improvements, poka-yoke encouraged } (30)

  46. 3. HSE Deployment & Compliance 3B. Activities, Equipment & Facilities for Safety. Total = 100 (i) What are the means , measures and equipment put in place to improve the safety in the processes, Machinery and the Facilities.? { Give details of activities carried out to ensure that the equipment is safe for use, Machine Guarding, electrical safety, LOTO, safety poka-yoke, other devices to improve safety of man/machine interface or any learnings from past incidents/accidents Attach photographs .} (25) (ii) What arrangements are made for safety of personnel working at heights, enclosed spaces, or at other unusual spots ?. {Give details of facilities provided like safety belts, ladders, railings cherry pickers etc.} (15)

  47. 3. HSE Deployment & Compliance 3B. Activities, Equipment & Facilities for Safety. Total = 100 (iii) How does the organization ensure safety of personnel during non-routine works and holiday work that may be undertaken in the premises? How do you ensure safety of contractors and their employees who carry out such non-routine work? { Give details of work permit systems, additional facilities or care taken, barricading provided etc during installations, expansions work or any other civil work that may be carried out. What are the roles and responsibilities of persons organizing out such work ? Give details of methods used like barricading, Loto, work permit system etc .} (20) (iv) How do you ensure safety in material handling? What facilities/ equipment is made available for safety during material handling activities ?. { what is the arrangement available for max weight to lift, safer posture to protect backbone etc? Facilities like forklift, hoists, cranes pallet trucks etc and their conditions} (10)

  48. 3. HSE Deployment & Compliance 3B. Activities, Equipment & Facilities for Safety. Total = 100 (v) How do you ensure driving and road safety within and outside your premises? { Explain the Traffic managements/organization within premises , Rules Regulations, barricading , traffic signs dividers etc. May add photographs} (7) (vi) Explain with examples how do you ensure safety of personnel during development, testing, or use of new product etc (Design safety, physical, chemical, electrical safety of new product activities) { Explain any special actins defined , facilities provided during new product or process introductions} (8)

  49. 3. HSE Deployment & Compliance 3B. Activities, Equipment & Facilities for Safety. Total = 100 (vii) List out Hazardous processes special processes, hazardous material storages etc if any , in the premises and actions /equipment lined up to handle the same in a safe manner. { Explain how safety of processes like Heat treatment, surface treatment, Painting, any other chemical processes, or storage of gases like lpg, liquid nitrogen etc is handled? } (15)

  50. 3. HSE Deployment & Compliance 3C. Safety of Stakeholders (Transporters, Suppliers, Customers) Total = 20 (i) How do you ensure the safety of outsiders, like employees of suppliers, transporters, etc entering your premises ? {Explain the facilities/ppe’s etc that is provided to contractors /transporters employees. Explain other mechanisms like permits, restrictions of entry to safety critical areas etc}} (10) (ii) How do you ensure safety of persons handing your product at customer end and the safety of end customer using your product ? { Explain any special actins taken for product safety, deburring, removal of sharp edges, other operational safety features of the product. Care taken in packaging to prevent injuries to handlers etc.} (10)

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