2014-15 ACMA Awards Company Name : Plant Location : Category : Small Excellence in Quality & Productivity

2014-15

ACMA Awards

Company Name : Plant Location :

Category : Small

Excellence in Quality & Productivity

Index( For office use only except page no. )

S.N. Section Page No.

Max. Marks Actual Marks

1 Work Environment & Employee Involvement.

75

2 Customer Expectations & Feedback

50

3 Quality Performance. 165

4 Productivity Performance. 160

5 Cost Performance. 50

Total 500

For Administrative Queries:

Mr. Jitender Rana Email – [email protected] Mobile – 09873369699

Ms. Sakshi Karkamkar Email – [email protected] – 07387002181Mr. Binny TomyEmail- [email protected] Mobile- 9711138869

For Technical Queries:

Mr. V K Sharma Email : [email protected] : 09811392068

Ms. Sapana Baravkar Email : [email protected] : 07350703339

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 .www.acma-act.in

mailto:[email protected]





http://www.acma-act.in/

ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small)

3

Letter for Submission of Award application for 2014 - 15

Company letterhead details ( Logo , Address )

To ,

The Secretariat ( ACMA Awards ) ,ACMA Centre for TechnologyOffice 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 2014-15 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 )

Group Company Name

Group Company Turnover in INR Cr. For 2014-15

ACMA Awards Category ( For ACMA Award Process Team )

Small Between INR 20 to 50 Cr

Large Between INR 50 to 150 Cr

Small Not Applicable

Criteria for Small and Large Category :Small Category- Company Group Annual Sales Turnover Between INR 20 to 50 CrLarge Category- Company Group Annual Sales Turnover Between INR 50 to150 Cr


4

1. 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-

3 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 )

Company’s Details


5

Company’s Details

5. Company turnover ( in Rs. Crore ) for Year 2014-15 :

6. Plant turnover ( in Rs, Crore ) for Year 2014-15 :

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. Plant’s Key competitors :

14. Plant’s Major Certifications :


6

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

Customer Details

S. No Customer Location

% Business share ( from the plant )

Key person name & Designation

Mobile Number & E mail

1

2

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


7

Use this slide to brief about your company / Plant .

It includes Product names / photos , Plant facility photographs ,

Company / Plant Information


8

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 diagnosis ( Site diagnosis is carried out if your application is shortlisted )


9

S.N.

Area Total Marks

Actual Marks ( for Office

Use only )

%

1 Work Environment & Employee Involvement.

75

2 Customer Expectations & Feedback

50

3 Quality Performance. 165

4 Productivity Performance. 160

5 Cost Performance. 50

Total 500

( 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

0

20

40

60

80

100

Work Environment &Employee Involvement

Customer Expectations &Feedback

Quality PerformanceProdcutivity Perfromance

Cost Performance


10

Section 1

Work Environment & Employee Involvement.

Total Marks = 75

S.N. Sub topic Total Marks

Actual Marks ( for office use )

%

1.A Safety 20

1.B Plant Upkeep- Inside 20

1.C Plant Upkeep- Outside 20

1.D Employee Involvement 15

TOTAL 75



11

1. Work Environment and employee involvement

(i) Does system exists for Safety monitoring / review ? (10)

(1.A) Safety Total= 20

(ii) Show last one year trend in line graph for number of accidents. (10)

5

4

3

2

1

0 0 0 0 0 0 00

1

2

3

4

5

6

Numb

er of

Adcid

ents

Target Actual


12

(1.F) SAFETY Total= 20

1. Work Environment and employee engagement

(i)How do you do incident investigation? Do you track Near Miss Incidences? Do you have system of Office staff's round in shop floor for observing Unsafe Acts / Conditions, How this system works?. Indicate the Top 3 Incident prone areas in your Factory and Preventive actions planned. (10)

(ii) What you have learnt from others / shared with others on Safety. (5)

(ii) Show last one year trend in line graph for number of accidents. (5)

5

4

3

2

1

0 0 0 0 0 0 00

1

2

3

4

5

6

Num

ber o

f Adc

iden

ts

Target Actual


13


(iii) Show photographs of production line, raw material stores, finished goods store and employees wash room. (10)

(1.B) Upkeep of the plant Inside Total= 20

(ii) What is your system to maintain upkeep of the plant Inside? What is the plan to take all the areas taken for must be facilities. ?(5)

Production Line

Employees Wash RoomFinished Goods Stores

Raw Material Stores

(i) Is there a plan for must be facilities ? Which are the areas which are taken for plant upkeep ? (5)


14


(ii) Show photographs of plant entrance, scrap yard, plant rear (back) side, canteen / dining area. (10)

(1.C) Upkeep of the plant Outside Total= 20

(i) What is your system to maintain upkeep of the plant Outside? What is the plan to cover entire area for upkeep ? Have you done any bench marking to maintain the area. (10)

Plant Entrance

Canteen / Dining AreaPlant Rear (Back) Side

Scrap Yard


15


(1.D) Employee Involvement Total= 15

(i) How company involves employees (mention areas like QCC, Kaizen, Quality Improvement, Cost reduction etc)? What forums are available for employees to share their ideas ?(5)

(iii) What is your employee involvement in improvement activities? Provide employee satisfaction results (5)

(ii) How do you take inputs from your employees for Process improvements / Quality improvements ? How company motivates employees (rewards / suggestions schemes etc.)? (5)


16

Section 2

Customer Expectations & Feedback

Total Marks = 50




%

2.A Understanding of Customer need

20

2.B Customer Complaints- Exports

20

2.C Customer Complaints- Analysis

10

TOTAL 50


17

(i) How do you listen to customer ? How customer issues are communicated and action taken ? (10)

(2.A) Understanding of Customer Need Total= 20

2. Customer Expectations & Feedback

(ii)Are the customer defined technical specifications clearly understood? How do you sensitise employees towards customer issues and how do you motivate them for faster response?(10)


18

(i ) Show last one year trend in line graph for number of customer complaints. (20)

15

12

10

5

10 0 0 0 0 0 00

2

4

6

8

10

12

14

16

Num

ber o

f Com

plai

nts-

Target Actual

(i) Mention actions taken to eliminate customer complaints if any. How do you ensure proactive corrective measures in future applications (10)

(2.B) Customer Complaints Total= 20

(2.C) Customer Complaints- Analysis Total= 10

2. Customer Expectations & Feedback


19

Section 3

Quality Performance

Total Marks = 165



%

3.A Customer Complaints 25

3.B In-House Rejection & Rework

50

3.C Supplier Rejection 20

3.D Warranty Rejection 20

3.E Process Improvement 25

3.F Poka-Yokes 25

TOTAL 165



20

(i) Please describe method of capturing customer complaints? (5)

11

12

11

10

9

8

7

6

5

4

0 002468

101214 Target Actual

(ii) What is the trend of the customer complaints in nos? (Show last one year data in line graph. (10)

(3.A) Customer Complaints Total= 25

3. Quality Performance


21

(iii) Is the Customer complaint data analysis done? (E.g.—Product wise, Customer wise, Process wise, etc). Explain with an example. (5)

(3.A) Customer Complaints Total= 25


(iv) Provide key complaint management results [internal as well as external] (5)


22

(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 . How do you train employees to meet product quality ? Provide key product quality results(10)

6000

4000

1200

5000

3000

1000

01000200030004000500060007000

2012-13 2013-14 2014-15

PPM

Target

In-houserejection PPM


23

(iv) Explain efforts taken to reduce rework . Provide key process matrices results : (10)

((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)

13000

100009000

02000400060008000

100001200014000

2012-13 2013-14 2014-15

PPM


24


(3.C) Supplier Rejection Total = 20

(i) How do you measure supplier quality [quality of everything about supplier]

how do you give feedback to your vendor provide key vendor related results (10)

1500

1200

1500

1600

1456

1235

1124

840

640

540

440

230

0

200

400

600

800

1000

1200

1400

1600

1800

Supp

lier R

ej in

PPM

Target Actual

(ii) How do you align vendor with your strategic objectives. Explain your ongoing vendor audit process Please describe the efforts to reduce the supplier rejection? (10 )


25

(ii) How do you ensure outgoing product quality ? How do you compare your quality with that of your competition ? Please describe the efforts to reduce the warranty rejection (10)

(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) (10)

10001100

300

0

200

400

600

800

1000

1200

2012-13 2013-14 2014-15

PPM

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


26

(3.E) Process Improvement Total= 25


S.N.

CTQ Parameter

Customer Complaints for 2014 - 15

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

(ii) What are your process control metrics ? What is the present level of Process capability (Cpk) for CTQ’s identified and controls ? (5)

(i) How company identifies Critical to Quality characteristics ( CTQ ) ? How do decide on your process control measures(5)


27

(iii) How do you update or upgrade your process for improvement ? What steps are taken to improve process capability greater than 1.67? Provide key process metrics results( 5 )Explain with text and Photographs .



Before After

Before After

Before – After Photo


28



(v) Are process changes / engg changes validated and documented? (5)

(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)


29

(i) How company identifies need for Poka-Yoke ? ( 7)

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

% =

(3.F) Poka-yokes Total= 25


(ii) What % of Customer complaints are closed by Poka Yoke in 2014-15 ? (5)

% =


30

(iii) Show innovative examples of poka-yokes & Effect on overall Rejection of that Product ( 8)

(3.F) Poka-yokes Total= 25


S.N. Product Before Rejection PPM

After Rejection PPM

Poka-yokes done

1

2

3

4


Before After


31

Section 4

Productivity Performance

Total Marks = 160



%

4.A Manpower Productivity 25

4.B Manufacturing Process Improvement

20

4.C Inventory Management 30

4.D Utilization of Operators 30

4.E Machine Break Down 20

4.F Loss of production Hours 35

TOTAL 160



32

(4.A) Manpower productivity Total= 25

4. Productivity Performance

2024

35

0

10

20

30

40

2012-13 2013-14 2014-15

No.

of p

rodu

cts

/m

an/y

ear

(i) How do you measure productivity ? How do you decide on Productivity targets ? (5)

(ii) 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)


33

(4.A) Manpower Productivity Total= 25

4 Productivity Performance

(iii) What is the roll of QC/SG in productivity improvement ? How do you motivate employees for improving productivity ? Show innovative examples of Manpower productivity improvements ( 10 )

S.N. Operation Before ( Production / day )

After ( production / Day )

Actions Taken

1

2

3

4


Before After


34

(4.B) Manufacturing Process Total= 20


Before

After

(i) Show improvements related to manpower productivity done last year , Show benefits of layouts change ( 10 )

Before : Material Travel = Meters ; Manufacturing Lead time = Mins ; WIP = Nos.

After : Material Travel = Meters ; Manufacturing Lead time = Mins ; WIP = Nos.


35

(ii) How process cycle times are reduced ? Share examples (10)

(4.B) Manufacturing Process Total= 20


S.N. Operation Before Cycle Time

After Cycle Time

Actions Taken

1

2

3

4


Before After


36

(i) Show the trend of ITR (Inventory Turn Ratio) last three years, illustrate it with your internal Target line . (20)

(4.C) Inventory Management Total= 30


2024

35

0

10

20

30

40

2012-13 2013-14 2014-15

Inve

ntor

y Tu

rns

(ii) Show actions taken to reduce inventory . (10)

S.N. Products Before Inventory

After Inventory

Actions Taken

1

2

3

4

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


37

(i) what % of operators are handling more than one machine, illustrate it with your internal Target line? (20)

(4.D) Utilization of Operators Total= 30


56

76

100

0

20

40

60

80

100

120

2012-13 2013-14 2014-15

% of

ope

rato

rs o

pera

ting

mor

e tha

n one

mac

hine

(ii) How Company encourages employees for operating multi-machines ? (10)


38

(i) Provide your equipment maintenance plan ? What are the measures tracked for equipment up time ? What is the status of machine break downs? (10)

(4.E) Machine Break down Total= 20


(ii) How your maintenance team participate in achievement of strategic goals ? Share innovative examples for machine break down reduction? provide key maintenance related results (10)


39

(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)

(4.F) Loss of Production Hours Total= 35


2.1

0.40.1

0

0.5

1

1.5

2

2.5

2012-13 2013-14 2014-15

% B

reak

dow

ns

S.N. Breakdown Before Breakdown

After Breakdown

Actions Taken

1

2

3

4


40

(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)

0.1

0.07

0.03

0

0.02

0.04

0.06

0.08

0.1

0.12

2012-13 2013-14 2014-15

% S

et u

p T

ime

S.N. Set up Before

After

Actions Taken

1

2

3

4


41

Section 5

Cost Performance

Total Marks = 50



%

5.A Energy Saving 10

5.B Value Addition / Net Sales 20

5.C Value Addition / Employee Cost

20

TOTAL 50



42

(5.A) Energy Savings Total= 10

5. Cost Performance

(i) Show energy consumption as % Sales, illustrate it with your internal Target line . (5)

1.21.1

0.7

0

0.2

0.4

0.6

0.8

1

1.2

1.4

2012-13 2013-14 2014-15

% En

ergy

of

sale

s

S.N. Item Before After Actions Taken

1

2

3

4

(ii) Show examples to reduce energy consumption ( 5 )


43

(i) How do you track various cost ? Show the trend of last three years in bar graph, illustrate it with your internal Target line. ( 10 )

(5.B) Value Additions / Net Sales Total= 20

5. Cost Performance

1011

13

0

2

4

6

8

10

12

14

2012-13 2013-14 2014-15

Valu

e A

dditi

on to

N

et sa

les

Formula Net Sales – Variable Cost

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

Net Sales

(ii) How do you sensitise employees for costs and motivate them to participate in cost reduction drives ? What is the benchmark & efforts to improve value addition / Net sales? (10)


44

(i) Show the trend of last three years in bar graph, illustrate it with your internal Target line. ( 10 )

(5.C) Value Additions to Employee cost Total= 20

5. Cost Performance

4

5

6

0

1

2

3

4

5

6

7

2012-13 2013-14 2014-15Valu

e Ad

ditio

n to

Em

ploy

ee

Cost

(ii) What is the benchmark & efforts to improve value addition to Employee Cost ? (10)

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

Total Employee Cost ( CTC )


Summary of Achievements for the year 2014-15

( Company has to fill up )


For Company:Show your companies excellent photos

Documents

2014-15 ACMA Awards Company Name : Plant Location : Category : Small Excellence in Quality & Productivity