2013-14

1. PM_44_F8 Rev. No. : 00 , Specimen Format* ACMA Awards Excellence in Quality & Productivity Company Name : Plant Location : Category : Small 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 Small 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 to150 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 = 75

11. Work Environment and employee involvement (1.A) Safety Total= 20 (i) Does system exists for Safety monitoring / review ? (10) (ii) Show last one year trend in line graph for number of accidents. (10)

12. Work Environment and employee involvement (1.B) Upkeep of the plant Inside Total= 20 (i) Is there a plan for must be facilities? (5) (ii) What is your system to maintain upkeep of the plant Inside? (5) (iii) Show photographs of production line, raw material stores, finished goods store and employees wash room. (10) Production Line Raw Material Stores Employees Wash Room Finished Goods Stores

13. Work Environment and employee involvement (1.C) Upkeep of the plant Outside Total= 20 (i) What is your system to maintain upkeep of the plant Outside? (5) (ii) Show photographs of plant entrance, scrap yard, plant rear (back) side, canteen / dining area. (15) Plant Entrance Scrap Yard Canteen / Dining Area Plant Rear (Back) Side

14. Work Environment and employee involvement (1.D) Employee Involvement Total= 15 (i) How company involves employees (mention areas like QCC, Kaizen, Quality Improvement, Cost reduction etc)? (5) (ii) How company motivates employees (rewards / suggestions schemes etc.)? (5) (iii) What is your employee involvement in improvement activities? (Mention %) (5)

15. ( For office use only ) Section 2 Customer Expectations & Feedback Total Marks = 50

16. 2. Customer Expectations & Feedback (2.A) Understanding of Customer Need Total= 20 (i) Are the customer defined technical specifications clearly understood? (20)

17. 2. Customer Expectations & Feedback (2.B) Customer Complaints- Exports Total= 20 (i) Show last one year trend in line graph for number of customer complaints. (20) (2.C) Customer Complaints- Analysis Total= 10 (i) Mention actions taken to eliminate exports customer complaints if any. (10)

18. ( For office use only ) Section 3 Quality Performance Total Marks = 165

19. 3. Quality Performance (3.A) Customer Complaints Total= 25 (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. (10)

20. 3. Quality Performance (3.A) Customer Complaints Total= 25 (iii) Is the Customer complaint data analysis done? (E.g.—Product wise, Customer wise, Process wise, etc). Explain with an example. (5) (iv) Enclose examples of countermeasure report on Customer complaints. (5)

21. 3. Quality Performance (3.B) In-House Rejection & Rework Total= 50 (i) 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) (15) (ii) Please describe the actions taken to reduce the in- house rejection (10)

22. 3. Quality Performance ((3.B) In-House Rejection & Rework Total= 50 (iii) 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) (15) (iv) Explain efforts taken to reduce rework : (10)

23. 3. Quality Performance (3.C) Supplier Rejection Total= 20 (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) (15) (ii) Please describe the efforts to reduce the supplier rejection? (5)

24. 3. Quality Performance (3.D) Warranty Rejection Total= 20 (i) What are the trends of the warranty ? (show last 3 year data in bar Graph, illustrate it with your internal Target line) (15) Note : If warranty is Not applicable for your products , Mention in place of Graph (ii) Please describe the efforts to reduce the warranty rejection (5)

25. 3. Quality Performance (3.E) Process Improvement Total= 25 (i) How company identifies Critical to Quality characteristics ( CTQ ) ? (5) (ii) What is the present level of Process capability (Cpk) for CTQ’s identified and controls ? (5)

26. 3. Quality Performance (3.E) Process Improvement Total= 25 (iii) What steps are taken to improve process capability greater than 1.67? Show Shining examples of process improvements ( 5 ) Explain with text and Photographs . Before – After Photo Before After Manual Clamping Auto Clamping Before After Offline checking Online checking

27. 3. Quality Performance (3.E) Process Improvement Total= 25 (iv) After the start of serial production, is there a system for conformity check (system level and part level) as done during the initial PPAP submission? (5) (v) Are process changes / engg changes validated and documented? (5)

28. 3. Quality Performance (3.F) Poka-yokes Total= 25 (i) How company identifies need for Poka-Yoke ? ( 7) (ii) What % of CTQs are controlled by Poka Yoke? (5) % = (iii) What % of Customer complaints are closed by Poka Yoke in 2013-14 ? (5) % =

29. 3. Quality Performance (3.F) Poka-yokes Total= 25 (iv) Show innovative examples of poka-yokes & Effect on overall Rejection of that Product ( 8) Before – After Photo Before After

30. ( For office use only ) Section 4 Productivity Performance Total Marks = 160

31. 4. Productivity Performance (4.A) Manpower productivity Total= 25 (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) (10)

32. 4 Productivity Performance (4.A) Manpower Productivity Total= 25 (ii) Show innovative examples of Manpower productivity improvements ( 15 ) Before – After Photo Before After

33. 4. Productivity Performance (4.B) Manufacturing Process Total= 20 (i) Show improvements related to manpower productivity done last year , Show benefits of layouts change ( 10 ) Before Before : Material Travel = Meters ; Manufacturing Lead time = Mins ; WIP = Nos. After After : Material Travel = Meters ; Manufacturing Lead time = Mins ; WIP = Nos.

34. 4. Productivity Performance (4.B) Manufacturing Process Total= 20 (ii) How process cycle times are reduced ? Share examples (10) Before – After Photo Before After

35. 4. Productivity Performance (4.C) Inventory Management Total= 30 (i) Show the trend of ITR (Inventory Turn Ratio) last three years, illustrate it with your internal Target line . (20) • Formula • Material cost of sales for the month x 12 • ITR = ----------------------------------------------------------- • (RM + WIP + FG ) on last day of the month (ii) Show actions taken to reduce inventory . (10)

36. 4. Productivity Performance (4.D) Utilization of Operators Total= 30 (i) what % of operators are handling more than one machine, illustrate it with your internal Target line? (20) (ii) How Company encourages employees for operating multi-machines ? (10)

37. 4. Productivity Performance (4.E) Machine Break down Total= 20 (i) What is the status of machine break downs? (10) (ii) Share innovative examples for machine break down reduction? (10)

38. 4. Productivity Performance (4.F) Loss of Production Hours Total= 35 (i) How much is machine breakdown loss in % of total available time? (Bar graph, illustrate it with your internal Target line ) (11) (ii)  Show Actions taken to reduce break downs (8)

39. 4. Productivity Performance (4.F) Loss of Production Hours Total= 35 (iii) How much is the Setup loss in % of total available time? (Bar graph, illustrate it with your internal Target line ) (8) (iv)  Show Actions taken to reduce Setup time (8)

40. ( For office use only ) Section 5 Cost Performance Total Marks = 50

41. 5. Cost Performance (5.A) Energy Savings Total= 10 (i) Show energy consumption as % Sales, illustrate it with your internal Target line . (5) (ii) Show examples to reduce energy consumption ( 5 )

42. 5. Cost Performance (5.B) Value Additions / Net Sales Total= 20 (i) Show the trend of last three years in bar graph, illustrate it with your internal Target line. ( 10 ) • Formula • Net Sales – Variable Cost • Value Addition to Net Sales = ---------------------------------------------------- • Net Sales (ii) What is the benchmark & efforts to improve value addition / Net sales? (10)

43. 5. Cost Performance (5.C) Value Additions to Employee cost Total= 20 (i) Show the trend of last three years in bar graph, illustrate it with your internal Target line. ( 10 ) • Formula • Sales –Variable Cost • Value Addition to Employee Cost = ------------------------------------------------------- • Total Employee Cost ( CTC ) (ii) What is the benchmark & efforts to improve value addition to Employee Cost ? (10)

44. PM_44_F8 Rev. No. : 00 , Specimen Format* Summary of Achievements for the year 2013-14 ( Company has to fill up )

45. PM_44_F8 Rev. No. : 00 , Specimen Format* For Company: Show your companies excellent photos