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2013-14

ACMA Awards. PM_44_F09 Rev. No. : 00, Specimen Format*. Excellence in Manufacturing. Company Name : Plant Location :. 2013-14. PM_44_F09 Rev. No. : 00, Specimen Format*. ( For office use only except page no. ). Index. For Technical Queries: Mr. Dinesh Vedpathak

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2013-14

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  1. ACMA Awards PM_44_F09 Rev. No. : 00, Specimen Format* Excellence in Manufacturing Company Name : Plant Location : 2013-14

  2. PM_44_F09 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 Godrej 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 Manufacturing. All data submitted is duly verified and true to the best of our knowledge . With regards ( Name & Designation of the Plant CEO ) Criteria for Manufacturing Category : Company Group Annual Sales Turnover > INR150 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 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 sent 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 Leadership Focus Total Marks = 325

  11. Leadership Focus (1.A) Vision, Mission and Strategy Total = 60 • Please enclose your Statements of vision, mission strategies & dates of when these were Formed and Revised . (5) VISION : ( Formed on / / , Revised on : / / ) MISSION : ( Formed on / / , Revised on : / / ) STRATEGIES : ( Formed on / / , Revised on : / / )

  12. Leadership Focus (1.A) Vision, Mission and Strategy Total = 60 (ii) Do you have a planning process for deploying vision, mission, strategies (e.g., Policy Deployment, Management by Objective, etc.)? (5) (iii) Please enclose samples of action plans of people in line and support functions for achieving a common objective. (5)

  13. Leadership Focus (1.A) Vision, Mission and Strategy Total = 60 (iv) What is the vision for New product Development ? ( 5 ) (v) What Strategy is deployed to achieve Vision of New Product Development ? Give evidence if company is using tools like quality function deployment, concurrent or simultaneous engineering, etc. for product development (20 )

  14. Leadership Focus (1.A) Vision, Mission and Strategy Total = 60 (vi) How company improves operational Excellence ? ( 10 ) (vii) Show shining examples of Operational Excellence ( 10 ) photo photo

  15. Leadership Focus (1.B) Communications Total = 20 (i) How often Leadership communicates to employees ? . (10) (ii) Show photographs of above communication . (10) Sr.No. 1 photo Sr.No. 2 photo Sr.No. 3 photo

  16. Leadership Focus (1.C) Social Commitment Total = 20 (i) How do leadership contribute to the society ? What was the budget for last year ? (10) (ii) Share some shining examples of Social commitment, Photos (10) Photo Photo

  17. Leadership Focus (1.D) Training Total = 20 • In which areas do you provide training to your employees ? List some benefits achieved by trainings in recent past. ( 5 ) Training Areas : (ii) 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 ) (10) Formula Total training man-hours for all employees for year Training hours/employee / year =---------------------------------------- --------------------- Total employees (iii) Benefits of Training : Tangible ( in Rs. Lacs ) & Intangible : ( 5 )

  18. Leadership Focus (1.E) Work Environment Total = 55 (i) Specify status in below mentioned checklist for “Must be facilities” for all company employees ? Illustrate with photographs some examples (30) Photo Photo

  19. Leadership Focus (1.E) Work Environment Total = 55 (ii) 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) (iii) Illustrate how concept of 5S/house keeping has been deployed in your plant? (10 ) (iv) What methods are adopted to assess 5S levels/scores? (show last one year trend in line graph). (10) Formula 5 S Score = Lowest zone / area score of that month in %

  20. Leadership Focus (1.F) Motivation, creativity and innovation Total = 50 • What are the methods used for motivating employees at various levels ? ( 5 ) (ii) How company encourages creativity and innovativeness ? ( 5 )

  21. Leadership Focus (1.F) Motivation, creativity and innovation Total = 50 (iii) Show TWO breakthrough achievements as a result of Motivation ? ( 5 ) (iv) Give evidence of benchmarking with competitor’s products and/or services and improvements done in weak areas (15)

  22. Leadership Focus (1.F) Motivation, creativity and innovation Total = 50 (v) What innovations are done to reduce cost of logistics ? (10 ) (vi) What innovations are done to improve packing / packaging ? (10 )

  23. Leadership Focus (1.G) Employee Satisfaction Total = 50 • Explain how company encourages small group activities : ( 5 ) • (ii) Do small group participate in the Quality Conventions-Group/State level/National. Show certificates / trophy photographs : ( 5 ) (iii) How many active groups are present in the current year? % employee involvement In QC Activity? (show last three year trend in bar graph) (10 )

  24. Leadership Focus (1.G) Employee Satisfaction Total = 50 • (iv) What are the parameters considered for measuring Employees Satisfaction (5) (v) What is the trend of Employee Satisfaction over the years? (show last three year trend in bar graph , illustrate it with your internal Target line ) (10)

  25. Leadership Focus (1.G) Employee Satisfaction Total = 50 (vi) What are the areas improved based on Employee Survey (10 ) (vii) 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)

  26. Leadership Focus (1.H) Partnering with Customers / suppliers Total = 50 (i) How company is partnering with Customers/ Suppliers for creating higher value for the customer.(15 ) (ii) Show one shining example of partnering with Customers / Suppliers .( 10 )

  27. Leadership Focus (1.H) Partnering with suppliers/dealers Total = 50 (iii) How company supporting its suppliers for creating higher value for suppliers (15 ) (iv) Show one shining example of Supporting Suppliers .( 10 )

  28. ( For office use only ) Section 2 Manufacturing operations & processes Total Marks = 275

  29. 2. Manufacturing Operations & Processes (2.A) Operations Performance Total = 25 (i) Are the customer defined technical specifications clearly understood and are the same one are translated into Operation Standards? ( 5 ) (ii) Are process changes / engineering changes validated and documented? Elaborate process ( 5 )

  30. 2. Manufacturing Operations & Processes (2.A) Operations Performance Total = 25 (iii) Is process FMEA done during process design? ( 5 ) (iv) Does your company certified for TS 16949, ISO 14001 and similar certifications? ( 5 ) (v) Is FIFO a way of working- from incoming to final supplies? Elaborate ( 5 )

  31. 2. Manufacturing Operations & Processes (2.B) Production Planning Process Total = 15 (i) Is planning for safety / quality an integral part of the overall production planning process? Provide details. (5) (ii) Are the Critical to Quality (CTQ) parameters addressed at the process planning stage? Elaborate. (5) (iii) Is part handling management a part of the planning process? Provide details. (5)

  32. 2. Manufacturing Operations & Processes (2.C) Product Quality Total = 20 (i) Is quality level for customer supplies the same as for spares / service parts? (5) (ii) How is the quality of safety critical parts ensured on periodic basis? (5) (iii) Does the company follow the APQP process? If not, please specify the alternate methodology followed for component development? (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)

  33. 2. Manufacturing Operations & Processes (2. D) Waste Elimination Total = 20 (i) Which techniques are used to find wastes in your company ? How Waste is reduced ? Show one shining example ( 10 ) (ii) What are the Benefits of Waste removal in your company (10 )

  34. 2. Manufacturing Operations & Processes (2. E) Material Handling Total = 20 (i) What are the containers used for material handling ? (10 ) (ii) What % of containers are “ 3 C “ ? Show Shining examples with photographs ( 3C = Count Free, Contact Free, Clean Container) (10 )

  35. 2. Manufacturing Operations & Processes (2. F) Total Productive Maintenance Total = 25 (i) What % of machines / Equipment's are covered under TPM (10 ) (ii) What are the benefits of TPM ? Quantify . ( 10 ) (ii) How company achieves Zero Defect through TPM ? Mention 2 shining examples .( 5 )

  36. 2. Manufacturing Operations & Processes (2. G) Quick Changeovers Total = 20 (i) What is the change over time of Bottleneck Process ? And what is the Total Changeover time as % of Available Time for Bottleneck process?(10 ) (ii) Is there any method to monitor changeover times ? If Yes , then show evidence ? ( 5 ) (ii) Show TWO Shining examples of Changeover time reduction / Elimination ( 5 )

  37. 2. Manufacturing Operations & Processes (2.H) Poka-Yokes Total = 25 (i) What % of CTQs are having Poka-Yoke ? . Total how many Poka-Yoke are implemented and how many are working ? (5) (ii) Is there any method to identify need for Poka-Yoke ? (10) (iii) Show TWO Shining examples of Poka-Yoke ( 10 )

  38. 2. Manufacturing Operations & Processes (2. I) Cellular Manufacturing Total = 25 (i) What % processes are working with cellular manufacturing ? (5 ) (ii) Is there any method to design the cell ? (5 ) (iii) Show 2 Shining examples of Cellular manufacturing , Before / After layout with Benefits (15 )

  39. 2. Manufacturing Operations & Processes (2. J) CAD / CAM & Computer Integrated Manufacturing Total = 20 (i) What are the areas for the use of CAD / CAM in your company (5) (ii) What are the latest software available for Manufacturing Shop with your company ? (5 ) (iii) Show 2 Shining examples for the use of such software to improve Quality , Cost , productivity , Lead time (10 )

  40. 2. Manufacturing Operations & Processes (2. K) Statistical Process Control Total = 20 (i) How many CTQ parameters are tracked with SPC ? And % of total CTQ Parameters under SPC (5) (ii) Show one latest Run chart / SPC Chart filled by operator ( 5 ) (iii) Does the company monitors CpK performance for CTQ characteristics . What % of CTQ parameters where Cpk >1.67. (5 ) (iv) How company eliminates need of 100% inspection? (5 )

  41. 2. Manufacturing Operations & Processes (2. L) Kaizens Linked to Results Total = 20 (i) How many Kaizens done in Year 2013-14 as per following ? (10) (ii) What is the per employee Kaizen for last Year ? ( 5 ) (iii) Share two shining examples ? ( 5 )

  42. 2. Manufacturing Operations & Processes (2. M) Tools of Quality Total = 20 (i) How many basic Quality tools are used and for what purpose & what % of employees are trained for each tool ? (10) (i) How many Management Quality tools are used and for what purpose & what % of employees are trained for each tool ? (10)

  43. ( For office use only ) Section 3 Support Functions Total Marks = 100

  44. 3. Support Functions (3.A) Support Function Strategy Total = 25 (i) What is the policy and strategy for improvements in support functions? ( 10 ) (ii) Please describe the process for implementing this strategy covering all functions.(15)

  45. 3. Support Functions (3.b) Support Department : Goals Vs Actual Total = 25 (i) What is the % achievements of Support function Goals for the year 2013-14 ? ( 15 ) (ii) How Top management ensures that this achievement ratio improve year on year (10)

  46. 3. Support Functions (3.C) Value Adding Improvements Total = 25 (i) What is the shining Value adding improvements done by support departments ( 15 ) (ii) How top management motivates support team ? ( 10 )

  47. 3. Support Functions (3.D) Use of IT Total = 25 (i) How IT Is integrated with Manufacturing ? ( 15 ) (ii) How IT integration helped to improve performance, give two shining examples ? ( 10 )

  48. ( For office use only ) Section 4 Performance Results Total Marks = 200

  49. 4. Performance Results (4.A) Cost of poor Quality ( COPQ) Total = 20 (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. Cost of poor Quality ( COPQ ) as a % of Sales (10) (ii) Show elements of Cost of poor quality and improvements for the year 2013-14 . (10)

  50. 4. Performance Results (4.B) Customer Complaints Total = 20 (i) Please describe method of capturing customer complaints? (10) (ii) What is the trend of the customer complaints in nos? (Show last one year data in line graph. (10)

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