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2013-14

PM_44_F8 Rev. No. : 00 , Specimen Format*. ACMA Awards. Excellence in Quality & Productivity. Company Name : Plant Location : Category : Large. 2013-14. PM_44_F8 Rev. No. : 00 , Specimen Format*. ( For office use only except page no. ). Index. For Technical Queries:

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2013-14

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

  2. PM_44_F8 Rev. No. : 00 , Specimen Format* ( For office use only except page no. ) Index For Technical Queries: Mr. Dinesh Vedpathak Email –dinesh.vedpathak@acma.in Mobile – 09545887799 Mr. K. Chandrasekhar Email –k.chandrasekhar@acma.in Mobile – 09822911139 Mr. V K Sharma Email : vk.sharma@acma.in Mobile : 09811392068 Ms. Sapana Baravkar Email : sapana.baravkar@acma.in Mobile : 07350703339 For Administrative Queries: Mr. Uday Harite Email- usharite@acma.in Mobile – 08149099959 Mr. Jitender Rana Email –Jitender.rana@acma.in Mobile – 09873369699 Ms. Sakshi Karkamkar Email –sakshi.karkamkar@acma.in Mobile - 07387002181 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

  3. Letter for Submission of Award application for 2013-14 Company letterhead details ( Logo , Address ) To , The Secretariat ( ACMA Awards ) , ACMA Centre for Technology Office 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 ) Criteria for Small and Large Category : Small Category- Company Group Annual Sales Turnover Up to INR 50 Cr Large Category- Company Group Annual Sales Turnover Between INR 50 to 150 Cr

  4. Company’s Details • 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- • 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 )

  5. Company’s Details • Company turnover ( in Rs. Crore ) for Year 2013-14 : • Plant turnover ( in Rs, Crore ) for Year 2013-14 : • Year of Establishment : Company _______ , Plant ___________ • Total Employees : Company ___________ , Plant _____________ • Do you have a Joint Venture : ( If Yes , Mention the partner name ) • Company’s Key products : 11. Plant’s Key products : • Plant’s key manufacturing processes : • Plant’s Key competitors : 14. Plant’s Major Certifications :

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

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

  8. 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 ) Contact person name & Designation: Name : Designation : E-Mail : Mobile : Landline : ( STD Code ) ( Number ) : Ext. ( if any )

  9. ( 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. ( For office use only ) Section 1 Work Environment & Employee Involvement Total Marks = 150

  11. Work Environment and employee engagement (1.A) Work Place Management Total= 40 (i) Specify status in below mentioned checklist for “Must be facilities” for all company employees ? Illustrate with photographs some examples (25) Photo Photo

  12. Work Environment and employee engagement (1.A) Work Place Management Total= 40 (ii) illustrate how concept of 5S/house keeping has been deployed in your plant?(5) (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. Work Environment and employee engagement (1.A) Work Place Management Total= 40 (iv) illustrate with photographs examples of good Visual Factory- Before and after. (5) Before After Before After

  14. Work Environment and employee engagement (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. Work Environment and employee engagement (1.B) Suggestions / Kaizens Per Employee Total= 20 (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 (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)

  16. Work Environment and employee engagement (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 = % Formula Total absent man-hours for the month ( Authorized + Unauthorized ) Absenteeism =-------------------------------------------------------- -------------------------------- X 100 Total man hours for the month (ii) What efforts organization takes to reduce absenteeism? ( 5 )

  17. Work Environment and employee engagement (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 : Formula Total training man-hours for all employees for year Training hours/employee / year =---------------------------------------- --------------------- Total employees (ii) How training effectiveness is measured and Benefits of Training : Tangible ( in Rs. Lacs ) & Intangible : (Give details for TWO shining examples) : ( 5 )

  18. Work Environment and employee engagement (1.E) Small Group Activities Total= 10 • 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. % Employees Involvement No. of Active groups

  19. Work Environment and employee engagement (1.F) SAFETY Total= 30 • Pls describe: with text / Photos • 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. Work Environment and employee engagement (1.F) SAFETY Total= 30 (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) Formula No. of accidents Frequency rate =------------------------ X 106 Total man hours Formula Total man-days lost Severity rate =------------------------------- X 106 Total man hours

  21. Work Environment and employee engagement (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. Work Environment and employee engagement (1.G) ENVIRONMENT MANAGEMENT Total= 30 (iii) Please describe the practices of the company to reduce pollution? (10) (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. ( For office use only ) Section 2 Customer Assessment Total Marks = 100

  24. 2. Customer diagnosis (2.A ) Awards by Key Customers Total= 10 (i) Awards by Key Customers (trend of last 3 years) (10) 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 (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) Note : If your Customer does not have a audit system , Mention what kind of supplier audit system and scoring is followed by Customer .

  25. 2. Customer diagnosis (2.C ) Customer rating for Quality & Delivery Total= 30 (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) Mention here major improvements done by your company to improve above performance :

  26. 2. Customer diagnosis (2.D ) Feedback from Customer & analysis Total= 40 (i) Please describe system of getting feedback from the customers? (10) (ii) If yes, how do you analyze this feedback and take actions in weak areas? Explain with two shining examples. (30)

  27. ( For office use only ) Section 3 Quality Performance Total Marks = 350

  28. 3. Quality Performance (3.A) Customer Complaints Total= 50 (i) Please describe method of capturing customer complaints? (5) (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)

  29. 3. Quality Performance (3.A) Customer Complaints Total= 50 (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. 3. Quality Performance (3.A) Customer Complaints Total= 50 (v) Explain the efforts to reduce customer complaints? (10) (vi) Enclose examples of countermeasure report on Customer complaints. (5)

  31. 3. Quality Performance (3.B) In-House Rejection & Rework Total= 90 (i) Does the company follow the APQP process? If not, please specify the alternate methodology followed for component development? (10 ) (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)

  32. 3. Quality Performance (3.B) In-House Rejection & Rework Total= 90 (iv) Provide example of actions by which you are able to achieve zero defect at In-house rejection (10) Before – After Photos Before After

  33. 3. Quality Performance (3.B) In-House Rejection & Rework Total= 90 (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) (vi) Explain efforts taken to reduce rework : (10)

  34. 3. Quality Performance (3.B) In-House Rejection & Rework Total= 90 (vii) Please give details of action taken to reduce rework? (10) Before – After Photo Before After

  35. 3. Quality Performance (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) (ii) Please describe the efforts to reduce the supplier rejection? (10)

  36. 3. Quality Performance (3.C) Supplier Rejection Total= 40 (iii) Provide example of actions by which you are able to achieve zero defect at Supplier end (10) Before – After Photos Before After

  37. 3. Quality Performance (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) Note : If warranty is Not applicable for your products , Mention in place of Graph (ii) Please describe the efforts to reduce the warranty rejection (10)

  38. 3. Quality Performance (3.D) Warranty Rejection Total= 50 (iii) Provide example of actions by which you are able to achieve Zero warranty defect (10) Before – After Photos Before After

  39. 3. Quality Performance (3.E) Cost of Poor Quality ( COPQ) Total= 30 (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 (ii) Show elements of Cost of poor quality and improvements for the year 2013-14 . ( 10 )

  40. 3. Quality Performance (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 Photos Before After Before After

  41. 3. Quality Performance (3.F) Process Improvement Total= 40 (i) How company identifies Critical to Quality characteristics (CTQ) ? (10)

  42. 3. Quality Performance (3.F) Process Improvement Total= 40 (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) (iii) What steps are taken to improve process capability greater than 1.67? ( 5 )

  43. 3. Quality Performance (3.F) Process Improvement Total= 40 (iv) Show Shining examples of process improvements ( 10 ) Explain with text and Photographs . Before – After Photo Before After Before After

  44. 3. Quality Performance (3.G) Quality Management Total= 50 (i) How is the quality of safety critical parts ensured on periodic basis? (5 ) (ii) Are process / engineering changes also validated and documented? (5 ) (iii) How company identifies need for Poka-Yoke ? ( 10 )

  45. 3. Quality Performance (3.G) Quality Management Total= 50 (iv) What % of CTQs are controlled by Poka Yoke? (5) % = (v) What % of Customer complaints are closed by Poka Yoke in 2013-14 ? (5) % = (vi) How do you ensure effectiveness of Poka yoke? (5 )

  46. 3. Quality Performance (3.G) Quality Management Total= 50 (vii) Show innovative examples of poka-yokes & Effect on overall Rejection of that Product ( 15 ) Before – After Photo Before After

  47. ( For office use only ) Section 4 Productivity Performance Total Marks = 300

  48. 4. Productivity Performance (4.A) Manpower productivity Total= 100 (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) (ii) What are the tools used to improve manpower productivity ? (10)

  49. 4 Productivity Performance (4.A) Manpower Productivity Total= 100 (iii) Show innovative examples of Manpower productivity improvements ( 20 ) Before – After Photo Before After

  50. 4. Productivity Performance (4.A) Manpower Productivity Total= 100 (i) What % of operators are handling more than one machine? Illustrate it with your internal Target line. (30) (ii) How Company encourages employees for operating multi-machines ? (20)

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