acma awards 2014 - 15 : excellence in technology (large) 2014-15 acma awards company name : plant...

ACMA Awards 2014 - 15 : Excellence in Technology (Large)

2014-15

ACMA Awards

Company Name : Plant Location :

Category : LARGE

Excellence in Technology


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 100

3 Technology & Innovations 400

4 R & D and Product Development 200

5 Quality & Operations Performance

150

Total 1000

For Administrative Queries:

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

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

Mr. 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/


3

Letter for Submission of Award application for 2014- 15

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 2014 - 15 for Excellence in Technology 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

Turnover in INR Cr. For

2014-15

ACMA Awards Category ( For ACMA Award

Process Team )

Small Between INR 20 to 50 CrProduct / Process

Large > INR 50 CrProduct / Process

Not Applicable Large

Not Applicable Product / Process

Criteria for Small and Large Category :Small Category- Company Group Annual Sales Turnover: INR 21 to 50 CrLarge Category- Company Group Annual Sales Turnover: Above INR 50 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 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 Customer for the plant for which application is sent

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 100

3 Technology & Innovations 400

4 R & D and Product Development

200

5 Quality & Operations 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

Technology & InnovationR&D and Product Development

Quality & OperationsPerformance


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 45

1.B Suggestions / Kaizens Per Employee

20

1.C Absenteeism 10

1.D Training 10

1.E Small Group Activities 10

1.F Safety 25

1.G Environment Management

30

TOTAL 150



11

(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 engagement

(1.A) Work Place Management Total= 45


12

1. Leadership Focus

(1.A ) Work Place Management Total = 45

50

60

70

60

7475

76 77 77 78 79 80

0

10

20

30

40

50

60

70

80

90

% s

core

s

Target Actual

Formula 5 S Score = Lowest zone / area score of that month in %

(ii) How do you practice 5s culture ( 5 ) ?

(iii) How employees are motivated to follow 5s (5)

(iv) What is 5s target ( 5 ) ?

(v) Provide 5s results with trends (5)


13

1. Leadership Focus

(1.A) ) Work Place Management Total = 45

Formula 5 S Score = Lowest zone / area score of that month in %

(vi) How you drive 5S in your Organization (making Zones, accountability, checklist, inclusion of all areas, trophy, audits, corrective actions, non conformity points closure, cross audits, negative marking for critical points, time allotted for m/c cleaning) (4)

( vii ) What you feel is your Best Practice in 5S (2)

( viii) How the 5S Results are moving in last 3 years. How the Targets are set (are the targets modified, consistency in targets, improvements etc). Gap between Highest Zonal Score & Lowest Zonal Score (2)

( ix) What corrective actions are planned based on 5S results (2)


14

(1.B) Suggestions / Kaizens Per Employee Total= 20

(i) Is there a suggestion scheme in the company and How company encourages employees to give suggestions? ? Pls Describe: (5)

(ii) How company ensures the suggestions are implemented? Pls describe: (5)



15


(1.B) Suggestions / Kaizens Per Employee Total= 20

(iv) ) 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)

(iii) Trends of number of suggestions implemented / employee / month? (show last one year trend in line graph , illustrate it with your internal Target line.). (5)

0.30.4

0.50.6

0.4

0.80.9

11.1

1.21.3

1.4

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

No

of s

ugg

impl

emen

ted

/ em

ploy

ee

Target Actual

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


16

(1.C) Absenteeism Total= 10

(i) Provide results on absenteeism etc? 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 forums are available for employees to share grievances ? What efforts organization takes to reduce absenteeism? ( 5 )

98

5

0123456789

10

2012-13 2013-14 2014-15

Tota

l % a

bsen

teei

sm


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


17

(1.D) TRAINING Total= 10

(i) Is training and development opportunities available ? ? 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 : • • • • •

25

40

55

0

10

20

30

40

50

60

2012-13 2013-14 2014-15Trai

ning

hrs

/em

p/ye

ar


(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


18

(1.E) Small Group Activities Total= 10

(i) Explain how company encourages small group activities : How do you promote small group activity culture ? How various SGs interact with each other ? 9( 5 )

(ii) Do small group participate in the Quality Conventions-Group/State level/National. Show certificates / trophy photographs : ( 2 )

(iii) How many active groups are present in the current year? % employee involvement In QC Activity? (show last three year trend in bar graph.( 3 )

15

2025

50

70

100

0

25

50

75

100

0

5

10

15

20

25

30

2012-13 2013-14 2014-15

active groups% of emp involvement


No

. o

f A

ctiv

e

gro

up

s

%

Em

plo

yee

s I

nvo

lve

me

nt


19

(1.F) SAFETY Total= 25


(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. (5)

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


20

0.3 0.3

0.50.6

0.4

0.8

0 0 0 0 0 00

0.2

0.4

0.6

0.8

1

Acci

dent

freq

uenc

y

Target Actual


(1.F) SAFETY Total= 25

0.3

0.4

0.5

0.6

0.4

0.8

0 0 0 0 0 00

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Acc

iden

t fr

eque

ncy

Target Actual

Formula No. of accidents

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

Total man hoursFormula

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

Total man hours

(iv) What are the current accident levels? (Show last one year data in line graph) (15)

A) Frequency (nos.) Minor + Major both

B) Severity (man hrs. lost)


21

(1.G) Environment Management Total= 30

(i) What is the frequency of scarp disposal? (5) (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 , etc ? (10)



22

(iii) Please describe the practices of the company to reduce pollution? Do you measure Carbon Foot Print ? How do you measure it ? What is the score ? (10)

(1.G) ENVIRONMENT MANAGEMENT Total= 30


(iv) 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)


23

Section 2

Customer Assessment

Total Marks = 100



%

2.A Awards by Key Customers 10

2.B Customer audit of Quality system

20

2.C Customer rating for Quality & Delivery

30

2.D Feedback from Customer & analysis

40

TOTAL 100



24

2. Customer Assessment

(2.A) Customer Awards Total = 10

(i) How do you listen to customer ( 5 )

(ii ) Awards by Key Customers (5)

0

2

4

6

8

10

2011-12 2012-13 2013-14

89

10

56

8

Nos

No. of Key-Customers Awards by key customer

Award photo

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


25

45

55

85

0

25

50

75

100

2011-12 2012-13 2013-14

QCD

aud

it %

sco

re

Actual

Target


(i) how do you ensure proactive corrective measures in future applications Does your key customers audit your quality system regularly? Has the audit results improved over the years? What is the trend over last three years? % , illustrate it with your internal Target line. (20)

(2.B ) Customer audit of Quality system Total= 20

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


26

(i) Does your key customers rate your performance on quality and delivery regularly? If yes, what is the trend over last three years? , illustrate it with your internal Target line. (20)

85 86 90

0

25

50

75

100

2012-13 2013-14 2014-15

(2.C ) Customer rating for Quality & Delivery Total= 30


( ii ) How do you ensure proactive corrective measures in future applications ? Mention here major improvements done by your company to improve above performance (10)


27

(i) How customer issues are communicated and actions are taken ? Please describe system of getting feedback from the customers? (10)

(2.D ) Feedback from Customer & analysis Total= 40


(ii) How do you sensitise employees towards customer issues and how do you motivate them for faster response? how do you analyze this feedback and take actions in weak areas? Explain with two shining examples. (30)


28

Section 3

Technology & Innovation

Total Marks = 400



%

3.A New Product /Process Applied for award

100

3.B How New product / process is superior

100

3.C Patent Application 75

3.D Motivation Behind Innovation

75

3.E Innovation Awards 50

TOTAL 400



29

(3.A) New Product or Process Applied for Award Total= 100

3. Technology & Innovation

(i) What prompted the change in Product / process ? What methods are adopted for deployment ? (bench marking, in-house, OEM driven, Market driven etc) (20)

(ii) How the product or process has been validated ? Describe validations system of New Product or Process applied for technology / innovation Award . (20)


30

(iii) Describe process of execution of concept. (20)



(iv) Describe benefits of new product / process. (20)


31

(v) Impact of new Product / Process on environment . (20)




32

(3.B) How new product / process is superior than existing

Total= 100


(i) Describe Totally new product / process. (30)

(ii) Describe modification of existing product / process. (20)


33


(3.B) How new product / process is superior than existing

Total= 100 (iii) Describe Performance of new product or process ? How this

change has impacted the business ? (30)

(iv) How do you track the costs of the new product or process ? What methods are used to reduce costs ? Cost competitiveness of new product or process (20)


34

(3.C) Patent Application Total= 75


(i) Has the company applied for patents for the new Product / process developed for which Award application is submitted? (50)

(ii) Describe the patents your company has applied for products / processes in last 3 years (25)


35

(i) Describe the motivation behind innovation. Is it Market ? (20)

(3.D) Motivation behind innovation Total= 75


(ii) Describe the motivation behind innovation. Is it in-house initiative? How do you sensitise employees for this change and motivate them to participate in development drives (20)


36

(iii) Describe the motivation behind innovation. Is it OEM / Customer driven? (15)

(3.D) Motivation behind innovation Total= 75


(iv) Describe the motivation behind innovation. Is it Management push to drive innovation culture? (20)


37

(i) Has your organization achieved any Innovation Awards for the year 2013 – 14 from Govt. or reputed organization? (25)

(3.E) Innovation Awards Total= 50


(ii) Has your organization achieved any Citations / Commendation letters for the year 2013 – 14 from Govt. or reputed organization? (25)


38

Section 4

R & D and Product development

Total Marks = 200



%

4.A Collaboration and Technical Tie-up

30

4.B Dependence or self competence

30

4.C In-house R & D or Collaborators Assistance

30

4.D Investments in R & D 30

4.E Recognitions 30

4.F Interactions with other organizations

20

4.G Bench Marking 30

TOTAL 200



39

(4.A) Collaborations and Technical Tie-ups Total= 30

4. R & D and Product Development

(i) Give details of Collaborations and Technical tie-ups, if any, in Product Technology (15)

(ii) Give details of Collaborations and Technical tie-ups, if any, in Process Technology (15)


40

(4.B) Dependence or Self Competence Total= 30


(i) Have you reduced dependence on Collaborators and Developed internal competence Give short Note on (a) Design Capability Enhancement (10)

(b) Manufacturing Capability Enhancement. How do you ensure skill with your employees to meet product requirements (10)

(c) Sourcing Capability Enhancement How do you align vendor with your strategic objectives ? (10)


41

(4.C) In-house R & D or Collaborator’s Assistance Total= 30


(i) Are Products / Processes developed by in-house R&D or Collaborator’s Assistance? Give information on

(a) Entirely by Collaborator (6)

(b) Entirely in house . How do you sensitise employees towards customer issues and how do you motivate them for faster response? (6)


42



(c) With joint efforts (6)

(d) Alignment of R & D efforts with business plans (6)


43



(ii) Is market scan / QFD / Benchmarking etc. an integral part of R & D efforts (6)


44

(4.D) Investment in R & D Total= 30


(i) Total investment in R & D ( Rs. Crore ) and % of sales turnover, , illustrate it with your internal Target line. ( 10)

(ii) Investments done in different Areas; See table (20)

S.N. Investment Areas Investment in Rs. Crore

% of sales turnover

1 Personnel Recruitment & Training

2 Testing and validation

3 Design Facilities

4 Process Improvements

TOTAL


45

(4.E) Recognitions Total= 30


(i) R & D recognition by Govt. of India, Ministry of science & Technology etc.

(a) NABL accreditation for R & D / Test Laboratories Give Details (15)

(b) Give details of Commendation Certificates / letters for R & D efforts (15)


46

(4.F) Interactions with other Organizations Total= 20


(i) How do you Interact with National Laboratories, Research Organizations, Universities, IITs etc. Give details on

(a) Meeting with above agencies for technology up gradation (5)

(b) Projects identified jointly (5)


47

(4.F) Interactions with other Organizations Total= 20


(c) Projects implemented jointly (5)

(d) Future plans for working together (5)


48

(4.G) Benchmarking Total= 30


(i) Benchmarking exercise during designing. Give details on following

(a) Product Benchmarking (6)

(b) Process Benchmarking (6)

(c) Benchmarking ideas implemented (6)


49

(4.G) Benchmarking Total= 30


(d) Benchmarking process documented (6)

(e) Benchmarking plans for future exercises (6)


50

Section 5

Quality Planning & Operation Performance

Total Marks = 150



%

5.A Environment friendly Product / Process

30

5.B New Product Sales 30

5.C Improvements due to Technology / Innovation

40

5.D Quality Planning & Performance

50

TOTAL 150



51

(5.A) Environment friendly Product / Process Total= 30

5. Quality Planning & Operations Performance

(i) How do you ensure that product / process evolved is environment friendly. What is the review mechanism on :

(a) Energy Management Audit ( fuel, electricity, compressed air) (5)

(b) Water management audit / disposal / treatment system (5)

(c) Recycling of oils, coolants etc. (5)


52

(5.A) Environment friendly Product / Process Total= 30


(d) Use of renewable energy (5)

(e) Pollution trends-noise/ dust / fumes / effluents etc. (5)

(f) End of life diagnosis of products. (5)


53

(5.B) New Product Sales Total= 30


(ii) What is the % of new products against total no. of products produced (10)

(i) New Product sales in Rs. Crore and % of total sales , illustrate it with your internal Target line. (10)


54

(5.B) New Product Sales Total= 30


(iv) Roadmap for new products for 3/5 years and What is the linkage with sales roadmap. Give details (5)

(iii) Are the customer defined technical specifications clearly understood? (5)


55

(5.C) Improvements due to Technology / Innovation Total= 40


(i) Improvement in Productivity (10)

(ii) Improvement in Export Competitiveness (10)


56

(5.C) Improvements due to Technology / Innovation Total= 40


(iii) Improvement in Cost Reduction (10)

(iv) Improvement in Import Substitution (10)


57

(5.D) Quality Performance Total= 50


(ii) What are the trends of the Total in-house rejection in PPM due to new product or process? (show last 3 year data in bar graph, illustrate it with your internal Target line.) (15)

(i) Does the company follow the APQP process? If not, please specify the alternate methodology followed for component development? (10 )

5000

3000

1000

4500

2000

800

0

1000

2000

3000

4000

5000

6000

2012-13 2013-14 2014-15

PPM

Target

In-houserejection PPM


58

(5.D) Quality Performance Total= 50


(iii) Provide key complaint management results [internal as well as external] Please describe the impact of New Product or process implementation on Cost of Poor Quality (10)

(iv) What steps are taken to improve process controls ? ( 15 )Explain with text and Photographs .

Before – After Photos

Before After


Summary of Achievements for the year 2014-15

( Company has to fill up )


For Company:Show your companies excellent photos

acma awards 2014 - 15 : excellence in technology (large) 2014-15 acma awards company name : plant...

Documents

acma awards company

acma awards category

large excellence

technology slide

acma centre

company turnover

technology large index

secretariat acma awards