ACMA Awards 2013-14 : Excellence in Export (Large) PM_44_F2 Rev No:00, Specimen Format 2013-14 ACMA Awards Company Name : Plant Location : Category : LARGE

ACMA Awards 2013-14 : Excellence in Export (Large)PM_44_F2 Rev No:00 , Specimen Format

2013-14

ACMA Awards

Company Name : Plant Location :

Category : LARGE

Excellence in Export

PM_44_F6 Rev No: 0 Specimen Format*


Index( For office use only except page no. )

S.N. Section Page No.

Max. Marks Actual Marks

1 Work Environment & Employee Involvement.

150

2 Customer Assessment 150

3 Export Operation Performance. 300

4 Export Market Performance. 250

5 Quality Performance. 150

Total 1000

For Administrative Queries:Mr. Uday Harite Email- [email protected] Mobile – 08149099959

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

Ms. Sakshi Karkamkar Email – [email protected] - 07387002181

For Technical Queries:Mr. Dinesh VedpathakEmail – [email protected] – 09545887799

Mr. K. ChandrasekharEmail – [email protected] Mobile – 09822911139

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

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

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

PM_44_F6 Rev No: 0 Specimen Format*


3

Letter for Submission of Award application for 2013-14

Company letterhead details ( Logo , Address )

To ,

The Secretariat ( ACMA Awards ) ,ACMA Centre for TechnologyGodrej Eternia, ”B” Wing ,, 10th Floor, Office No. C, ,Old Mumbai –Pune Highway, Wakdewadi , Shivaji Nagar Pune – 411005, India Tel No. 07387002181 ( Ms. Sakshi ) We are pleased to submit the application for ACMA Award 2013-14 for Excellence in Export 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 )

Group Company Name

Group Company Turnover in INR Cr. For 2013-14

ACMA Awards Category ( For ACMA Award Process Team )

Small Upto INR 50 Cr

Large > INR 50 Cr.

Not Applicable

Large

Criteria for Small and Large Category :Small Category- Company Group Annual Sales Turnover Up to INR 50 CrLarge Category- Company Group Annual Sales Turnover > INR 50 Cr


4

Company’s Details

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 )


5

Company’s Details

5. Company turnover ( in Rs. Crore ) for Year 2013-14 :

6. Plant turnover ( in Rs, Crore ) for Year 2013-14 :

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 obtained 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.

150

2 Customer Assessment 150

3 Export Operation Performance.

300

4 Export Market Performance.

250

5 Quality Performance. 150

Total 1000

( 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

25

50

75

100

Work Environment &Employee Involvement

Customer Assessment

Export OperationPerformance

Export MarketPerformance

Quality Performance


10

Section 1

Work Environment & Employee Involvement.

Total Marks = 150

S.N. Sub topic Total Marks

Actual Marks ( for office use )

%

1.A Work Place Management 40

1.B Suggestions / Kaizens Per Employee

10

1.C Absenteeism 10

1.D Training 10

1.E Small Group Activities 10

1.F Safety 40

1.G Environment Management

30

TOTAL 150



11

(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)

Must be facilities for all company employees

Sr. No. Description Status

1 Jogging track inside shop floor, along walls OK / Not OK

2 Trees in plant campus OK / Not OK

3 No earth should be visible in entire company area. There should be concrete, tar roads or green lawns.

OK / Not OK

4 No truck / fork-lift inside shop floor OK / Not OK

5 Clean toilet blocks inside shop floor, dry & smell free OK / Not OK

6 No nails to be used anywhere in the factory premises. OK / Not OK

7 All employees to wear uniform, shoes and necessary safety gadgets.

OK / Not OK

8 Noise free DG sets & compressor OK / Not OK

9 Clean change room and rest room facilities OK / Not OK

10 Hygienic kitchen, washroom, dinning hall. OK / Not OK

11 Good recreational facilities OK / Not OK

12 Appropriate fire fighting equipments should be placed at accessible locations

OK / Not OK

13 Central display board ( 80 % Digital ) OK / Not OK

Photo Photo

1. Work Environment and employee involvement


12


(i) Illustrate how concept of 5S/house keeping has been deployed in your plant? (5 )

(ii) 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


(iii) illustrate with photographs examples of good Visual Factory- Before and after. (5)

Before After

Before After



14


(1.B) Suggestions / Kaizens Per Employee Total= 10

(i) Is there a suggestion scheme in the company and How company encourages employees to give suggestions? ? Pls Describe:

(iii) Trends of number of suggestions implemented / employee / month? (show last one year trend in line graph, illustrate it with your internal Target line.).

(ii) How company ensures the suggestions are implemented? Pls describe:

Formula Total suggestions + Kaizen Implemented in that month Suggestions / Employee =---------------------------------- -------------------------------- X 100 Total direct employees ( Operatives ) for the month


15


(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 = %

(ii) What efforts organization takes to reduce absenteeism? ( 5 )

Formula Total absent man-hours for the month ( Authorized + Unauthorized ) Absenteeism =-------------------------------------------------------- -------------------------------- X 100 Total man hours for the month


16


(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 : • • • • •

(ii) How training effectiveness is measured and Benefits of Training : Tangible ( in Rs. Lacs ) & Intangible : (Give details for TWO shining examples) : ( 5 )

Formula Total training man-hours for all employees for year Training hours/employee / year =---------------------------------------- --------------------- Total employees


17


(1.E) Small Group Activities Total= 10

(i) 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, illustrate it with your internal Target line.)

No

. o

f A

ctiv

e

gro

up

s

%

Em

plo

yee

s I

nvo

lve

me

nt


18


(1.F) SAFETY Total= 40

Pls describe: with text / Photos (i)How company ensures Safe work practices? (5)

(ii)Proactive measures taken by company to reduce accidents (10)

(iii)Number of accident free days ( Cumulative ) (5) : Days


19


(1.F) SAFETY Total= 40

Formula No. of accidents

Frequency rate =------------------------ X 106

Total man hoursFormula

Total man-days lost Severity rate =------------------------------- X 106

Total man hours

(iii) What are the current accident levels? (Show last one year data in line graph)

A) Frequency (nos.) Minor + Major both (10)

B) Severity (man hrs. lost) (10)


20


(1.G) Environment Management Total= 30 (i) What is the frequency of scrap disposal? (10) : (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? (10)


21


(iii) Please describe the practices of the company to reduce pollution ? (10)

(1.G) ENVIRONMENT MANAGEMENT Total= 30


22

Section 2

Customer Assessment

Total Marks = 150



%

2.A SOB with 3 Major Customers

30

2.B Customer Feedback 40

2.C Feedback Analysis 60

2.D Customer Awards 20

TOTAL 150



23

(i)% SOB with Major 3 Export Customers (show last 3 yr trend) , illustrate it with your internal Target line. (20)

(2.A ) Share Of Business with 3 Major Export Customers

Total= 30

(ii) Why business has reduced or Improved ? Explain with case to case (10)

2. Customer Assessment


24

(ii) Please describe system of getting feedback from the customers? (20)

(2.B ) Customer Feedback Total= 40

(i) Does the company have an organization structure to address customer needs in a proactive way and also respond quickly to queries / issues etc? (10)

(iii) Is there a warranty involved in supplies? If yes, is there a system to address the same? (10 )



25

(i) How do you analyze this feedback and take actions in weak areas? Explain with a case study. (30)

(2.C ) Feedback Analysis Total= 60



26

(2.C ) Feedback Analysis Total= 60

(ii) Is there a data monitoring system in place to review field performance in export markets? (15)

(iii) Is there a system to address the need of Service parts requirements in export market? (15)



27

(2.D ) Customer Awards Total= 20

(i) Awards / Recognition by Key Customers from Domestic and Export Customers (trend of last 3 years) (20)

Award photo

Note : If your Customer does not have a system of Awards , Mention what kind of supplier recognition is followed by Customer .

Award photo



28

Section 3

Export Operation Performance

Total Marks = 300



%

3.A Export Sales 80

3.B Export OEM / Tier 1 Sales 50

3.C Foreign Exchange Earned 50

3.D New Product added in Export

50

3.E Royalty Payments 20

3.F General 50

TOTAL 300



29

3. Export Operation Performance (3.A ) Sales Growth Total= 80

(ii) How Total sales improved ? If not improved , what are the reasons ? (20)

(I) Total sales in Rs. Crore and % of total Sales Growth ( Last 3 years Trend, illustrate it with your internal Target line.) – (20)


30

3. Export Operation Performance (3.A ) Export Sales Total= 80

(iv) How export sales improved ? If not improved , what are the reasons ? (20)

(iii) Total Export Sales , In Rs. Crore and % growth in Export Sales ( Last 3 years Trend, illustrate it with your internal Target line.) – (20)


31

3. Export Operation Performance

(i) OEM/Tier 1 Export Sales and % of Total Exports (In Rs Crore ) ( last 3 years Trend, illustrate it with your internal Target line.) – (15)

(3.B ) OEM / Tier 1 Export Sales Total= 50

(ii) How has OEM / Tier 1 sales improved ? If not improved , what are the reasons ? (15)


32

3. Export Operation Performance (3.B ) OEM / Tier 1 Export Sales Total=

50

(iv) How has Aftermarket sales improved ? If not improved , what are the reasons ? (10)

(iii) Total aftermarket Export Sales , In Rs. Crore and % growth in After Market Export Sales ( Last 3 years Trend, illustrate it with your internal Target line.) – (10)


33


(i) Net foreign exchange earned in Rs. Crore ? Net foreign exchange earned through Reduction in Imports (Rs. Crore ) , illustrate it with your internal Target line. (30)

(3.C ) Foreign Exchange Earned Total= 50

(ii) What are the efforts taken to improve Net foreign exchange ? (20)


34

3. Export Operation Performance (3.D) New Product added for Export Total=

50 (i) Number of new products added from existing product portfolio for export market and % of sales contribution from these new products to Exports in last three years –show 3 years trend graph. , illustrate it with your internal Target line.(10)

(ii) Number of entirely new products added and % of sales contribution from these new products to Exports in last three years –show 3 years trend graph, illustrate it with your internal Target line. (10)


35


(iii) Show process / roadmap for development of new products for export and its achievement status (10)

(3.D) New Product added for Export Total= 50


36

3. Export Operation Performance (3.D) New Product added for Export Total=

50 (iv) Is there a method to communicate design changes to export markets customers to address supply conditions as well as stocked material at warehouses / service outlets etc? (10)

(v) How is the engineering change implementation effected for OE export customers? What is the system for aftermarket supplies? (10)


37

3. Export Operation Performance (3.E) Royalty Payments Total= 20

(i) Royalty payments over last 3 years in Rs.. Crore ) , illustrate it with your internal Target line.(10)

(ii) How have royalty payments reduced ? (10)


38

3. Export Operation Performance (3.D) General Total= 50

(i) Is there a risk management system in place to address export market litigations / law suits etc particulars with reference to safety part supplies? (10)

(ii) Is the document retention period for exports clearly defined? (10)

(iii) Does the above address the statutory requirements of the country of export as well as customer requirements? (10)


39

3. Export Operation Performance (3.D) General Total= 50

(iv) Are process changes / engineering changes also validated and documented? (10)

(v) How is the quality of safety critical parts ensured on periodic basis? (10)


40

Section 4

Export Market Performance

Total Marks = 250



%

4.A Export growth in Established Market

150

4.B Breakthrough Achievements for Capturing Markets

100

TOTAL 250



41

4. Export Market Performance

(i) Export destinations (Names) – (20)

(ii) Principal OEMs / Tier 1 customers – (20)

(4.A) Export Growth in Established Market Total= 150


42

4. Export Market Performance (4.A) Export Growth in Established Market Total=

150 (iii) Export Growth in established Market (Rs. Crore ) Last 3 years Trend for Developed Countries ? , illustrate it with your internal Target line. (40) ( You can edit / add your export countries in this graph )

(iv) What are the initiatives to improve growth in developed countries ? ( 20 )


43

4. Export Market Performance (4.A) Export Growth in Established Market Total=

150 (v) Export Growth in developing Market (Rs. Crore ). Last 3 years Trend for Developing countries (30) , illustrate it with your internal Target line. ( You can edit / add your export countries in this graph )

(iv) What are the initiatives to improve growth in developing countries ? ( 20 )


44

4. Export Market Performance (4.B) Breakthrough Achievements for capturing new Markets

Total=

100 (i) Cost competitiveness for capturing new markets (40)

(ii) Use of Technology for capturing new markets (20)


45

4. Export Market Performance

(iii) Quality and Delivery performance for capturing new markets (20)

(iv) Through Innovation (20)

(4.B) Breakthrough Achievements for capturing new Markets

Total= 100


46

Section 5

Quality Performance

Total Marks = 150



%

5.A In-House Rejection 30

5.B Cost of Poor Quality 20

5.C Rework 25

5.D Poka-Yokes 25

5.E Customer Complaints 30

5.F Customer Returns 20

TOTAL 150



47

(5.A) In-House Rejection Total= 30

5. Quality Performance

(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.) (10)

(ii) Please describe the actions taken to reduce the in- house rejection (10)


48

(5.A) In-House Rejection Total= 30


S.N. Defect Before PPM After PPM Actions Taken

1

2

3

4

Before – After Photo

Before After

(iii) Provide example of actions by which you are able to achieve zero defect for In-House rejection (10)


49

(5.B) Cost of poor Quality ( COPQ ) Total= 20


(iii) Show elements of Cost of poor quality and improvements for the year 2013-14 . ( 10 )

S.N. COPQ Element

Before % After % Actions Taken

1

2

3

4

5

6

(i) What is the trend for COPQ ? (show last 3 year data in bar graph, illustrate it with your internal Target line. (5)

Cost of Poor Quality ( COPQ ) as % of Sales


50

(5.B) Cost of poor Quality Total= 20


(iii) Provide example of actions by which you are able to reduce COPQ ( 5 )

Before – After Photos

Before After

Before After


51

(5.C) Rework Total= 25


(ii) Explain efforts taken to reduce rework : (10)

(i) 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.) (5)


52

(5.C) Rework Total= 25


(iii) Please give details of action taken to reduce rework? (10)

S.N. Rework Before PPM After PPM Actions Taken

1

2

3

4


Before After


53

(5.D) Poka-yoke Total= 25


(i) How company identifies need for Poka-Yoke ? ( 5 )

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

% =

(iv) How do you ensure effectiveness of Poka yoke? (5 )

(iii) What % of Customer complaints are closed by Poka Yoke in 2013-14 ? (5)

% =


54

(5.D) Poka-yokes Total= 25


(v) Show innovative examples of poka-yoke & Effect on overall Rejection of that Product ( 5)

S.N. Product Before Poka-Yoke Rejection PPM

After Poka-yoke Rejection PPM

Poka-yokes done

1

2

3

4


Before After


55

(5.E) Customer Complaints Total= 30


S.N. Export Complaints

Root Cause Action Taken

1

2

3

4

(i) Customer complaints for Domestic and export customers (show last 3 yr trend, illustrate it with your internal Target line.) (15)

(ii) What actions are initiated to eliminate export Complaints ? (15 )


56

(5.F) Customer Returns Total= 20


S.N. Export Returns Root Cause Action Taken

1

2

3

4

(i) Customer Returns PPM for Domestic and export customers (show last 3 yr trend, illustrate it with your internal Target line.) (10)

(ii) What actions are initiated to eliminate export Customer Returns ? (10 )


Summary of Achievements for the year 2013-14

( Company has to fill up )

PM_44_F6 Rev No: 0, Specimen Format


For Company:Show your companies excellent photos

PM_44_F6 Rev No: 0, Specimen Format

Documents

ACMA Awards 2013-14 : Excellence in Export (Large) PM_44_F2 Rev No:00, Specimen Format 2013-14 ACMA Awards Company Name : Plant Location : Category : LARGE