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2017-18

ACMA Awards Year of Inception: 1966. Excellence in HSE (Health, Safety & Environment). Company Name: Plant Location:. Award Category: Tick mark in appropriate box as per your ‘Company Group Turnover for 2017-18’. Medium > INR 30 to 100 Cr Large > INR 100 to 500 Cr

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2017-18

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  1. ACMA Awards Year of Inception: 1966 Excellence in HSE (Health, Safety & Environment) Company Name: Plant Location: Award Category: • Tick mark in appropriate box as per your ‘Company Group Turnover for 2017-18’. • Medium > INR 30 to 100 Cr • Large > INR 100 to 500 Cr • Very Large > INR 500 Cr Tick mark in appropriate box: ACMA Member All Past & Present ACT Cluster/ ACMA UNIDO Cluster Companies are eligible without becoming ACMA member for all categories as per Turnover criteria 2017-18

  2. For Administrative Queries: Mr. Rupesh Somania Email – rupesh.somania@acma.in Mobile – 9992603010 • Ms. Sakshi Karkamkar • Email –sakshi.karkamkar@acma.in • Mobile – 7387002181 • Mr. Binny Tomy • Email- binny.tomy@acma.in • Mobile- 9711138869 • Ms. Smita Kulkarni • Email – smita.kulkarni@acma.in • Mobile –9922922500 For Technical Queries: Mr. Uday Harite Email – uday.harite@acma.in Mobile – 8149099959 Mr. Atul Gupta Email – atul.Gupta@acma.in Mobile - 9971888751 Mr. Vishal Saxena Email – Vishal.saxena@acma.in Mobile – 9650988154 Ms. Ekta Agrawal Email- ekta.agrawal@acma.in Mobile - 9657657258 ACMA Centre for Technology (ACT) 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

  3. Letter for Submission of Award application Company letterhead details ( Logo , Address ) To , The Secretariat ( ACMA Awards ) , ACMA Centre for Technology 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 2017-18 for Excellence in HSE (Health, Safety & Environment) in Medium / Large / Very 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- If you have applied & won multiple awards in one year, please mention accordingly.

  4. 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

  5. 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 : • Chief Executive (Site) details : Name : Designation : Mobile : E-mail : Website: 4. Plant Head ( Next to Chief Executive (Site)) details : Name : Designation : Mobile : E-mail : 5. HR Head details : Name : Designation : Mobile : E-mail : 6. Training Head details : Name : Designation : Mobile : E-mail : (If Sr. No. 3 & 4 are same , then provide next level person details at Sr. No. 4 )

  6. Company’s Details 7. Company Group Annual Sales Turnover (in INR Cr.) for Year 2017-18: 8. Plant (for which application is submitted) turnover ( in INR Cr.) for Year 2017-18 : 9. Year of Establishment : Company _______ , Plant ___________ 10. Total Employees : Company ___________ , Plant _____________ On Contract for Company _______ , Plant_______ 11. Do you have a Joint Venture : ( If Yes , Mention the partner name ) 12. Company’s Key products & Key Raw Materials : 13. Plant’s Key products : 14. Plant’s key manufacturing processes : 15. Plant’s Key competitors : 16. Plant’s Major Certifications :

  7. 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 Information: ( Need to contact thru out the process of ACMA Award ) Name : Designation : E-Mail : Mobile : Contact Person Information: ( Need to Contact if above person is not available) Name : Designation : E-Mail : Mobile :

  8. Customer Details Mandatory requirement As a part of ACMA Award process, feedback from your major Customers to be obtained by Applicant companies & to be send by your customer directly to ekta.agrawal@acma.in as per format. This feedback will be shared to Juries directly & the same will be provided to you as a part of feedback report. When you register online, you will receive Customer Feedback format. Kindly send to your top 3 Business Customers & ensure that we receive this before you submit the application online. ( Your application will not be processed without this feedback) Kindly furnish your top 3 Business customer details from whom you will be obtaining feedback. Note- In addition to application & your site diagnosis , Supplier feedback scores will be also considered for final scores.

  9. Key Performance Indicators (KPIs)

  10. Executive Summary

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

  12. Sharing of Best Practices of your company Best Practices along with photos shown here will be compiled and shared by ACMA to all applicants / members / non-members for learning purpose. (This is OPTIONAL and there are no marks for this) By tick mark hereby I agree to allow ACMA to use this information for sharing with others (From above topic only) • Please mention your best practices here Photo Photo Photo Photo

  13. ( 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

  14. ( For office use only ) Section 1 LEADERSHIP FOCUS & COMMITMENT Total Marks = 200

  15. 1. LEADERSHIP FOCUS & COMMITMENT 1A. HSE Policy, Strategy & Communication (20) (i) Has organization defined its HSE management policy, Vision, Mission & Strategy statements? Does it includes commitment for continuous improvement, prevention of accident & pollution, compliance under applicable legal and other requirements which relates to HSE aspects and a framework for setting and reviewing HSE objectives and targets periodically? (10) (ii) What procedures been developed to ensure that all staff, contractors staff or on its behalf are aware of HSE aspects, the importance of conforming with HSE policy, procedures and requirements for the potential consequences for not following procedures? (5) (iii) What procedures been developed for internal communication , documenting and responding to receiving communication from internal & external interested parties? (5)

  16. 1. LEADERSHIP FOCUS & COMMITMENT 1B. HSE Management Role & Responsibility (20) • (i) Have specific management representative(s) been appointed with the clear role, responsibilities and authorities for ensuring that the HSE is implemented and maintained and reporting on the performance of the HSE for review? (10) (ii) Has the organizations identified training needs & appropriate facility for the staff and contractors associated with its HSE aspects and provided training to meet these needs? Are competence, training and awareness records available? (5) • (iii) Has top management reviewed performance of the HSE at planned intervals to ensure its continued suitability, improvements, adequacy & preventive actions and to give recommendations for its improvement? (5)

  17. 1. LEADERSHIP FOCUS & COMMITMENT 1C. HSE Performance Reporting (20) (i) Have ‘Health Safety & Environment ‘(HSE) systems been developed and documented & does it define its scope of Performance Reporting? Mention KPIs monitored with its weightage out of 100 %. (10) (ii) Have procedures been developed to establish and maintain records and necessary to determine conformity to the requirements of its HSE,( ISO 14001, 18001 ) and the results achieved? Mention how you monitor effectiveness of actions ? (5) (iii) Are internal HSE audits scheduled at defined intervals to determine whether the HSE practices conforms to the requirements of ISO 14001, 18001, & is being properly maintained? (5)

  18. 1. LEADERSHIP FOCUS & COMMITMENT 1D. Accident, Incident, Illness & Near miss Management (20) • (i) Have operations that are associated with significant HSE aspects been identified and planned by preparing procedures to ensure that they are carried out under specified conditions to control situations where their absence could lead to Incident or deviation from the HSE policy, objectives and targets? Are these frequently reviewed and revised ? If yes, provide few examples (20)

  19. 1. LEADERSHIP FOCUS & COMMITMENT 1E. Incident investigation & Emergency Preparedness (20) (i) Has the procedures been developed and implemented with designated persons to investigate minor, major & serious incidents & near misses? Are these procedures reviewed with after serious incident or certain period of time? (10) (ii) Have all Emergency scenarios been identified in your plant ? Are the procedures been developed accordingly and implemented and reviewed periodically or after serious incident for continual improvement? (5) (iii) When was the last mock drill held? Was it effective? Please list all the identified areas which are subjected to a mock drill? Do you have the yearly schedule of Mock drill? ( 5 )

  20. 1. LEADERSHIP FOCUS & COMMITMENT 1F. Incorporation of Safety KPIs (20) (i) What are the KPIs related to Health , Safety and Environment are monitored in your company ? Kindly provide list and monitoring frequencies and responsibilities e.g. Medicine consumption, Noise, Heat, etc. (10) (ii) At what frequencies TOP Management reviews the above KPIs and what actions are initiated after this review? Elaborate with 2 examples. (10)

  21. 1. LEADERSHIP FOCUS & COMMITMENT 1G. Rewards & recognitions (20) (i) What are rewards and recognitions provided in year 2017-18 for your employees under HSE? (10) (ii) How these rewards / Recognitions help to IMPROVE HSE at your company ? Elaborate with 2 examples. (10)

  22. 1. LEADERSHIP FOCUS & COMMITMENT 1H. Motivation (20) (i) How do you motivate your employees to come forward and get involved in HSE activities? Do you have Kaizen, Suggestion Scheme, etc. for motivating the employees? ( 10 ) (ii) What is the effect of motivation for improving HSE areas? Elaborate with 2 examples. (10)

  23. 1. LEADERSHIP FOCUS & COMMITMENT 1I. Consequence Management (20) Have you listed the disasters which will affect the working of the Company? (05) How company manages consequences in case of disaster to restore essential services? e.g. natural / man made incidents. (05) (iii) Have you been able to resolve such incidences in recent past ? Elaborate with 2 examples. (10)

  24. 1. LEADERSHIP FOCUS & COMMITMENT 1J. Expectations / role modelling (10) (i) How your company ensures that expectations in HSE are met? e.g. Leading by examples, Meeting statutory regulations etc. ( 5 ) (ii) Elaborate with examples where employees follow HSE inspired by the role Model. ( 5 )

  25. 1. LEADERSHIP FOCUS & COMMITMENT (1.K)Contribution of Company towards Nation building (10) Please describe the practices of the company to support the implementation of the issues of national importance with respect to the following – but not limited to this. ( 1 mark each )

  26. 1. LEADERSHIP FOCUS & COMMITMENT (1.K) Contribution of Company towards Nation building (10) Please describe the practices of the company to support the implementation of the issues of national importance with respect to the following – but not limited to this. ( 1 mark each )

  27. ( For office use only ) Section 2 General Health, Safety & Environmental Requirements Total Marks = 230

  28. 2. General Health, safety & Environmental Requirements 2A. Safety Policy and Strategy Total = 20 Please describe your safety policy & describe how it is achieved, maintained & improved continuously. (10) (ii) Are Cardinal Rules exist? How are they implemented ? (Life saving rules ) (10)

  29. 2. General Health, safety & Environmental Requirements 2B. Housekeeping (Implementation of 5S) Total = 20 (Note:- Add photos where necessary to show good practices) (i) Describe what aspects involved in housekeeping and how it is achieved and maintained all time up to date How is the 5Sscore for the year 2017-18? (10) (ii) Describe how all employees involved in housekeeping (5) (iii) Mention role & responsibilities of responsible persons to achieve and maintain Housekeeping. (5)

  30. 2. General Health, safety & Environmental Requirements 2C. Safety Training Excellence Total = 20 (i) Describe in details all Safety training strategies & development plan adopted in your industry to eliminate or reduce accidents, incidents & Near misses in the Industry. (5) (ii) Describe in details what trainings were in in the past year ? Who were / are the trainers ? How are training delivered ( Either at classroom or at shop floor ) ? List what trainings are essential in your industry and how it is linked with the work process and accident lesson learned. (5) (iii) Is there a competency matrix available for trainers ? How do you measure effectiveness of training ? Do you need field demonstration for proving trainer’s competency? How do you increase the training competency of the trainer? (3)

  31. 2. General Health, safety & Environmental Requirements 2C. Safety Training Excellence Total = 20 (iv) What resources are available at present and are those adequate for the size of the industry? How many training hours utilized per employee in a year? What is your internal target? Do you have qualified and experienced safety trainers? and How do you maintain all training records? (5) (v) How do you ensure the understanding & knowledge retention after training is imparted? Do you have safety training handbook relevant to your industry ? What are the content in it? Is the hand book issued to each & every employee during Induction process? (2)

  32. 2. General Health, safety & Environmental Requirements 2D. Safety Communication Total = 20 (i) What are the different means being used in industry for efficient safety communication to your employees and contractors? And should not be restricted to safety day only. (5) (ii) How do you ensure that all safety information communicated to all employees and contractors in time & that understood by all? (5)

  33. 2. General Health, safety & Environmental Requirements 2D. Safety Communication Total = 20 (iii) Do you have feedback system from employees and contractors regards to HSE & how this system work? (5) (iv) Describe the process of accident / Incident / Near-miss reporting in your industry. Are there any targets for Near Miss cases? How do you ensure that all NMC ( Near Miss cases ) are reported ? (5)

  34. 2. General Health, safety & Environmental Requirements 2E. Safety Assessment Total = 20 (i) Describe in detail how unsafe conditions and unsafe acts are noticed or what systems are implemented for safety assessment. (e.g.. Safety Audit, Safety Inspection, Safety management personnel tour, Safety Survey etc..) (5) (ii) How do you ensure immediate corrective and preventive measures taken are for all serious safety noncompliance reported? (10) (iii) Provide the data for last years of findings of noncompliance and closed items within specified time duration, including overdue . (5)

  35. 2. General Health, safety & Environmental Requirements 2F. Safety Processes Total = 20 (i) Describe in brief what safety tools being used for “process safety” for hazard identification in your industry. Elaborate one of the process with example. e.g.: Process Hazards Analysis (PHA), Failure mode and effect analysis (FMEA), Hazard and Operability Review (HAZOP) Human Error Analysis, (HEA), Fault tree analysis.(FTA) Risk analysis, (RA) Job security Analysis (JSA ) etc. (20)

  36. 2. General Health, safety & Environmental Requirements 2G. Safety Motivation Total = 15 (i) Describe in detail about safety motivation processes are in places & how effective are they. What are the responses & feedback received from employees for further improvement? (15)

  37. 2. General Health, safety & Environmental Requirements 2H. Machine Guarding Total = 20 (i) Describe in details principles of safeguarding of machines being used in your industry. What safe guarding measures have been adopted? (10) (ii) Mention how many incidents or near misses reported during last 3 years and corrective & preventive actions taken, explain with the help of Bar Chart. Were these repeat incidences?(5) (iii) Describe safe practices for working near unprotected running machines, live electrical appliances / panel boards, Crane / hoisting , PTW ( Permit to Work ) , LOTO , etc., (5)

  38. 2. General Health, safety & Environmental Requirements 2I. Safe Use of Ladder and trolleys (by persons) & Working at Heights Total = 15 (i) Describe in details about system / safe practices in place for safe use of ladders and trolleys (used for working at heights by people) in your industry. (5) (ii) What type of ladders and trolleys being used in the industry? & how do you ensure that all ladders and trolleys are safe? & employees will follow safe practices all time? (5) (iii) Mention about ladder / trolley incidents happened during last 3 years and corrective & preventive actions (CAPA) implemented. (5)

  39. 2. General Health, safety & Environmental Requirements 2J. Material handling & Ergonomics in work place Total = 20 (i) How do you ensure safety in manual handling? (eg- Maximum weight to lift, safe posture to protect backbone,) (5) (ii) How do you ensure safety in material handling with the aid of power tools, power equipment? (e.g.- fork lift, hoist, cranes, pallet truck, trolleys, wheel barrow, etc.) How do you carry out statutory checking of cranes, hoists, forklifts, lifting tackles, etc. (5) (iii) Explain areas you have considered for Ergonomics aspects at workplace (10)

  40. 2. General Health, safety & Environmental Requirements 2K. Slip –Trip –Fall (on same level ) Total = 20 (i) Explain in details what safety aspects are considered & implemented to eliminate slip-trip & fall in the work place. (10) (ii) Explain in details what is strategy / systems implemented in the workplace to eliminate fall from 1.5m height above. Explain the use of Safety belt with double lanyard (Full body harness with double lanyard). Working at height permits are obtained in advance.(5) (iii) List the incident if any happened due to fall from height , above 1.5m (from ladder / trolley / platform) & corrective and preventive action taken for last 3 years. (5)

  41. 2. General Health, safety & Environmental Requirements 2L. New Product / innovation Safety Total = 20 (i) Explain with examples how do you ensure safety of personnel and work place during development, testing or use of new product ( Design , physical Chemical safety ). (20)

  42. ( For office use only ) Section 3 Regulatory safety Requirements Total Marks = 200

  43. 3. Regulatory safety Requirements 3A. Mandatory regulatory requirement according to manufacturing processes Total = 40 (i) List & describe in brief the mandatory regulatory requirements has to be implemented in your industry according to activities and safety of personnel associated with it. (40)

  44. 3. Regulatory safety Requirements 3B. Welfare and other mandatory facilities for employees Total = 40 (i) List & explain in brief what welfare facilities are provided for employees & How all those maintained up to date all time. (15)

  45. 3. Regulatory safety Requirements 3B. Welfare and other mandatory facilities for employees Total =40 (ii) Specify status in below mentioned checklist for “Must be facilities” for all company employees ? Illustrate with photographs of some examples (25) Photo Photo YOU CAN ADD MORE PHOTOS

  46. 3. Regulatory safety Requirements 3C. Hazardous process & safety Total = 40 (i) List hazardous process & Explain Provisions & mandatory safety requirements in relation to any two hazardous process in your industry. (40)

  47. 3. Regulatory safety Requirements 3D. Emergency preparedness Total = 40 (i) List & explain in brief what types of emergencies could possible in your industry & how industry has prepared to face it. How emergency preparedness systems are maintained & updated regularly. Give one example of outcome of (Mock Drill) and action taken. (40)

  48. 3. Regulatory safety Requirements 3E. Fire prevention measures Total = 40 (i) Explain in detail preventive and post actions for safety measures implemented to eliminate / reduce risk of fire in your industry. What are mandatory and proactive measures implemented in your industry. (40)

  49. ( For office use only ) Section 4 Industry Specific Safety Requirements Total Marks 220

  50. 4. Industry Specific Safety Requirements 4A. Mandatory HSE regulatory requirements Total = 30 (i) List the regulatory safety requirements according to manufacturing processes of your industry & how are those requirements maintained on day to day practice? (30)

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