1. 2015-16 ACMA Awards Company Name : Plant Location : Category : LARGE Excellence in Manufacturing

2. Index ( For office use only except page no. ) S.N.SectionPage No. Max. MarksActual Marks 1 Leadership Focus325 2 Manufacturing Operations & Processes 275 3 Support Functions100 4 Performance Results200 5 Business Results100 Total 1000 For Administrative Queries: Mr. Jitender Rana Email – Jitender.rana@acma.inJitender.rana@acma.in Mobile – 9873369699 Ms. Sakshi Karkamkar Email – sakshi.karkamkar@acma.insakshi.karkamkar@acma.in Mobile – 7387002181 Mr. Binny Tomy Email- binny.tomy@acma.inbinny.tomy@acma.in Mobile- 9711138869 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.inwww.acma-act.in ; act@acma.inact@acma.in For Technical Queries: Mr. V K Sharma Email : vk.sharma@acma.in vk.sharma@acma.in Mobile : 9811392068 Mr. Sunil Mutha Email- sunil.mutha@acma.insunil.mutha@acma.in Mobile- 9881475940 Ms. Sapana Baravkar Email : sapana.baravkar@acma.insapana.baravkar@acma.in Mobile : 7350703339

3. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 3 Letter for Submission of Award application 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 2015-16 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 ) Company History with ACMA Awards (last 3 years) Sr. No.Financial Year (April to March) ACMA Awards Category- Applied Award / Certificate Won 1 2013-14 2 2014-15 3 2015-16 Note- If you have applied & won multiple awards in one year, please mention accordingly.

4. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 4 To, Applicant Company CONFIDENTIALITY STATEMENT As a part of the ACMA Awards Process, applicant companies provide business, market, technical, financial information/documents and top customers details in the application. Such information could also be related to intellectual property i.e, patents, product development etc. ACMA take reasonable care to keep the above information confidential and shall not divulge it to third party and/or not use it for their own purpose, any part of this information in the course of assessment and thereafter. I agree. On behalf of ACMA Sd/- Director General Automotive Component Manufacturers Association of India 6th Floor, The Capital Court Olof Palme Marg, Munirka New Delhi - 110 067, India

5. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 5 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- 3Chief 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

6. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 6 Company’s Details 5.* Company Group Annual Sales Turnover (in INR Cr.) for Year 2015-16: 6.Plant (for which application is submitted) turnover ( in INR Cr.) for Year 2015-16 : 5.Year of Establishment : Company _______, Plant ___________ 6.Total Employees : Company ___________, Plant _____________ 7. Do you have a Joint Venture : ( If Yes, Mention the partner name ) 8. 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 : * Award Criteria for Excellence in Manufacturing (Large Category) - Company Group Annual Sales Turnover for Year 2015-16 > INR 250 Cr

7. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 7 As a part of ACMA Award process, feedback from your major customers will be obtained directly and will be provided to Jury. The same will be provided to you as a part of feedback report. Top 2 Business Customer’s Key person details are required (Without customer details, application will not be processed). Customer Details Mandatory requirement S. NoCustomerLocation% Business share (from the plant ) Customer Key person name & Designation Mobile Number & E mail 1 Manufacturing Head Incoming Quality Head 2 Manufacturing Head Incoming Quality Head Note- In addition to application & site diagnosis, Customer feedback scores will be also considered for final scores.

8. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 8 Use this slide to brief about your company / Plant. It includes Product names / photos, Plant facility photographs, Company / Plant Information

9. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 9 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 )

10. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 10 S.NArea Total Marks Actual Marks ( for Office Use only ) % 1Leadership Focus325 2 Manufacturing Operations & Processes 275 3Support Functions100 4Performance Results200 5Business Results100 Total1000 ( 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

11. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 11 Section 1 Leadership Focus Total Marks = 325 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 1.AVision, Mission and Strategy25 1.BNew Product Development25 1. COperational Excellence20 1.DCommunication20 1.ESocial commitment20 1.FTraining20 1.GMust Be Facilities35 1.H5 S20 1.I Motivation, creativity and innovation 15 1.JCompetitor Study10 1.KLogistics20 1.LSmall Group Activity20 1.MEmployee Satisfaction30 1.N Partnering with suppliers 45 TOTAL325 ( For office use only )

12. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 12 1.Leadership Focus (1.A) Vision, Mission and Strategy Total = 25 (i)Please enclose your Statements of vision & mission (9) VISION : MISSION :

13. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 13 1.Leadership Focus (ii) What process is used to deploy vision & strategies (e.g., Policy Deployment, Management by Objective, etc..)? (8) (ii)How you ensure achievement of set objectives, mention in brief? (8) (1.A) Vision, Mission and Strategy Total = 25

14. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 14 1.Leadership Focus (i)How leadership ensure addition of New products ? (5) (v)Do you have structured road maps & targets to drive the New Product Development ? Mention in brief. (20) (1.B) New Product Development Total =25

15. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 15 1.Leadership Focus (i)How leadership drives Operational Excellence ? (10) (ii)Do you have separate team for this area? What are the key areas focused under operational excellence? ( 10 ) (1.C) Operational Excellence Total =20

16. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 16 1.Leadership Focus (1.D) Communications Total = 20 (i) How often does the top management meet all employees in a year? What points are discussed in that meeting & what is the duration? (20)

17. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 17 1.Leadership Focus (1.E) Social Commitment Total = 20 (i)What are the activities done under corporate social responsibility CSR? (10) (ii) Share / Mention some shining examples of Social commitment (10)

18. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 18 1.Leadership Focus (1.F) Training Total = 20 (i)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) (iii) Benefits of Training : Tangible ( in Rs. Lacs ) & Intangible : ( 5 ) Formula Total training man-hours for all employees for year Training hours/employee / year =---------------------------------------- --------------------- Total employees

19. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 19 1.Leadership Focus (1.G) Must Be Facilities Total = 35 (i) Specify status in below mentioned checklist for “Must be facilities” for all company employees ? Illustrate with photographs (30) Must be facilities for all company employees Sr. No. DescriptionStatus 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 wash room / change room and rest room facilities OK / Not OK 10 Hygienic kitchen, drinking water & 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 (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)

20. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 20 1.Leadership Focus (1.H) 5S Total = 20 Formula 5 S Score = Lowest zone / area score of that month in % (i) How do you practice 5s culture ? How employees are motivated to follow 5s ( 5 ) (ii) What is 5s target ? Provide 5s results with trends, last year data (5)

21. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 21 1.Leadership Focus (1.H) 5S Total = 20 (iii) 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) (10)

22. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 22 1.Leadership Focus (1.I) Motivation, creativity and innovation Total = 15 (i)What are the methods used for motivating employees at various levels ? ( 5 ) (ii) How company encourages creativity and innovativeness ? ( 5 ) S. N. LevelMethods 1 2 3

23. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 23 1.Leadership Focus (I) Give evidence of benchmarking with competitor’s products and/or services and improvements done in weak areas (10) (1.I) Motivation, creativity and innovation Total = 15 (iii) Show TWO breakthrough achievements as a result of Motivation ? ( 5 ) (1.J) Competitors Study Total = 10

24. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 24 1.Leadership Focus (I) What innovations are done to reduce cost of logistics ? (10 ) (Ii) What innovations are done to improve packing / packaging ? (10 ) (1.K) Logistics Total = 20

25. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 25 1.Leadership Focus (iii) How many active groups are present in the current year? (show last three year trend in bar graph) (10) (1.L) Small Group Activity Total = 20 (ii) Do small group participate in the Quality Conventions-Group/State level/National. Show certificates / trophy photographs : (5) (I)How do you promote small group activity culture? How many SG/QC exist ? How do they function? How various SGs interact with each other? What training is imparted to members of SGs provide key SG/QC results? (5)

26. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 26 1.Leadership Focus (1.M) Employee Satisfaction Total = 30 (i) What are the parameters considered for measuring Employees Satisfaction (5) (ii) 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)

27. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 27 1.Leadership Focus (1.M) Employee Satisfaction Total = 30 (iii) What are the areas improved based on Employee Survey (10 ) (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)

28. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 28 1.Leadership Focus (1.N) Partnering with suppliers Total = 45 (I) Give details of your supplier development process. How do you communicate Organisational objectives to supplier? How do you interact with supplier? Provide supplier satisfaction results (15) (ii) Show one shining example of partnering with Suppliers. (10)

29. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 29 1.Leadership Focus (1.N) Partnering with suppliers Total = 45 (iii) How company supporting its suppliers for creating higher value for suppliers (10) (iv) Show one shining example of Supporting Suppliers.( 10 )

30. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 30 Section 2 Manufacturing operations & processes Total Marks = 275 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 2.A Operations Performance 25 2.B Production Planning Process 15 2.C Product Quality 20 2.D Waste Elimination 20 2.E Material Handling 20 2.F Equipment Uptime 25 2.G Quick changeover 20 2.H Poka-Yokes 25 2.I Cellular manufacturing 25 2.J CAD/CAM & computer integrated manufacturing 20 2.KStatistical process control20 2.LKaizen linked to results20 2.MTools of quality20 TOTAL275 ( For office use only )

31. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 31 2. Manufacturing Operations & Processes (2.A) Operations Performance Total = 25 (i)How process improvements are carried out ( Through FMEA Revisions or any other method, Describe ) (5) (ii) Are process changes / engineering changes validated and documented? Elaborate process ( 5 )

32. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 32 2. Manufacturing Operations & Processes (2.A) Operations Performance Total = 25 (iii) Is process FMEA done during process design? ( 5 ) (iv) Is 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 )

33. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 33 2. Manufacturing Operations & Processes (2.B) Production Planning Process Total = 15 (i) How do you plan to meet market/customer requirements? How do you monitor your yearly/monthly/daily production targets? what are your measures to track plan vs actual ( 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)

34. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 34 2. Manufacturing Operations & Processes (2.C) Product Quality Total = 20 (i)How do you ensure conformance to product specifications? how do you communicate product requirements in your organisation? how do you ensure skill with your employees to meet product requirements (5) (ii) What is your quality policy? how do you ensure outgoing product quality? how do you take customer / competitive inputs towards improving quality? provide key product quality results (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)

35. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 35 2. Manufacturing Operations & Processes (2. D) Waste Elimination Total = 20 (i)How do you identify different types of wastes in your organisation? what methods are deployed to eliminate wastes? what are the forums available for employees to share waste elimination success stories? how do you motivate employees to participate in waste elimination provide key results such as no of kaizen, savings accrued etc. ( 10 ) (ii) What are the Benefits of Waste removal in your company? (10 )

36. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 36 2. Manufacturing Operations & Processes (2. E) Material Handling Total = 20 (i)How you design the containers used for material handling, do you have structured process for the same ? (10 ) (ii) How you promote environment friendly / recycling of container, mention in brief? (10 )

37. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 37 2. Manufacturing Operations & Processes (2. F) Equipment Uptime Total = 25 (i)Provide your equipment maintenance plan, what are the measures tracked for equipment up time, how your maintenance team participate in achievement of strategic goals, provide key maintenance related results. (25 )

38. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 38 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) Show TWO Shining examples of Changeover time reduction / Elimination ( 5 ) (ii) Is there any method to monitor changeover times ? If Yes, then show evidence ? ( 5 )

39. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 39 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) (iii) Show TWO Shining examples of Poka-Yoke ( 10 ) (ii) Is there any method to identify need for Poka-Yoke ? (10)

40. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 40 2. Manufacturing Operations & Processes (2. I) Cellular Manufacturing Total = 25 (i) What % processes are working with cellular manufacturing ? (5 ) (iii) Show 2 Shining examples of Cellular manufacturing, Before / After layout with Benefits (15 ) (ii) Is there any method to design the cell ? (5 )

41. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 41 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) (iii) Show 2 Shining examples for the use of such software to improve Quality, Cost, productivity, Lead time (10 ) (ii) What are the latest software available for Manufacturing Shop with your company ? (5 )

42. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 42 2. Manufacturing Operations & Processes (2. K) Statistical Process Control Total = 20 (iv) How company eliminates need of 100% inspection? (5 ) (i) How many CTQ parameters are tracked with SPC ? And % of total CTQ Parameters under SPC (5) (iii) Does the company monitor Cpk performance for CTQ characteristics. What % of CTQ parameters where Cpk >1.67. (5 ) (ii) How is Run chart or SPC Chart utilised / filled by operator? ( 5 )

43. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 43 2. Manufacturing Operations & Processes (2. L) Kaizens Linked to Results Total = 20 (i) How many Kaizens done in Year 2015-16 as per following ? (10) (iii) Share two shining examples ? ( 5 ) (ii) What is the per employee Kaizen for last Year ? ( 5 ) S.N. AreaNo. of Kaizens Done Saving in Rs. Lacs Remarks 1Productivity 2Quality 3Cost 4Delivery 5Safety 6Morale 7Energy 8Environment 9IT Total

44. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 44 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 ? Explain few problems solved by operators. (20) S.N.Quality tools Usage purpose% Employees trained 1 2 3 4 5 6 7

45. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 45 Section 3 Support Functions Total Marks = 100 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 3.A Support Functions Strategy 25 3.B Support Department : Goals Vs Actual 25 3.C Value adding improvements 25 3.D Use of IT 25 TOTAL100 ( For office use only )

46. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 46 3. Support Functions (3.A) Support Function Strategy Total = 25 (i) How support function contribute in improvement activities? (10) (ii) Mention few shining improvements done by each functions. ( 15 )

47. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 47 3. Support Functions (3.b) Support Department : Goals Vs Actual Total = 25 (i) How support functions are motivated to achieve their goals? (15) (ii) What training inputs were provided to them for it ? (10)

48. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 48 3. Support Functions (3.C) Value Adding Improvements Total = 25 (i) How value adding activities captured in non production area? Mention few shinning examples? ( 15 ) (ii) How top management motivates support team ? ( 10 )

49. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 49 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 )

50. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 50 Section 4 Performance Results Total Marks = 200 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 4.A Cost of poor Quality 20 4.B Customer Complaints 20 4.C Customer Returns 15 4.D Warranty Rejection 10 4.E In-House Rejection 10 4.F Supplier Rejection 10 4.G Absenteeism15 4.H Manpower Productivity 15 4.I Energy Saving 20 4.J Breakdowns 10 4.K Delivery Performance 15 4.L Safety 20 4.M Inventory Turns 20 TOTAL200 ( For office use only )

51. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 51 3. Quality Performance (3.E) Cost of poor Quality ( COPQ) Total = 20 (i)Show cost of poor quality trends for last three years (10) (ii) Mention elements of Cost of poor quality and its trend for last 2 years.(10) S.N.COPQ Element Before % 2014-15 After % 2015-16 Remarks 1 2 3 4 5 Insert more rows, total 15 required

52. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 52 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)

53. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 53 4. Performance Results (4.C) Customer Returns Total = 15 (i) Show the trend of last three years of Customer Returns PPM in bar graph. ( 5 ) (ii) What efforts are taken to reduce Customer returns ? (10)

54. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 54 4. Performance Results (4.D) Warranty Rejections Total =10 (i) What are the trends of the warranty ? (show last 3 year data in bar Graph, illustrate it with your internal Target line) (5 ) Note : If warranty is Not applicable for your products, Mention in place of Graph (ii) Please describe the actions taken to reduce warranty rejection ( 5 )

55. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 55 4. Performance Results (ii) Please describe the actions taken to reduce the in- house rejection (5) (4.E) In-House Rejection Total = 10 (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) (5)

56. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 56 3. Quality Performance (3.C) Supplier Rejection Total = 10 (i)Show the trend of your incoming supplier rejection (PPM) ( in last year in bar graph.) (5) (ii) Please describe the efforts to reduce the supplier rejection? (5 )

57. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 57 4. Performance Results (4.G) Absenteeism Total = 15 (iii) What efforts organization takes to reduce absenteeism? (5) (ii) What are the trends in regards to total absenteeism? (Three year trend in bar graph, illustrate it with your internal Target line) (5) Formula Total absent man-hours for the month ( Authorized + Unauthorized ) Absenteeism =-------------------------------------------------------- -------------------------------- X 100 Total man hours for the month (i)What is absenteeism data ( Average) for the year 2015-16 ? (5) Authorized = % Unauthorized = % Total = %

58. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 58 4. Performance Results (4.H) Manpower Productivity Total = 15 (ii) What are the tools used to improve manpower productivity ? (10) (i) What is the productivity trend ? (show last 3 year data in Bar graph, illustrate it with your internal Target line). Show the data for the Major Business Product Line. (5)

59. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 59 4. Performance Results (4.I) Energy Saving Total = 20 (i) Show energy cost as % Sales, Include all energy resources, illustrate it with your internal Target line (electricity / fuel / gas) (10) S.N.ItemBeforeAfterActions Taken 1 2 3 4 (ii) List improvement actions implemented to reduce energy consumption in the year 2015-16 (10)

60. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 60 4. Performance Results (4.J) Breakdowns Total = 10 (i) How much is machine breakdown loss as % of total available time? (Bar graph, illustrate it with your internal Target line ) (5) (ii) Show Actions taken to reduce break downs (5) S.N.BreakdownBefore Breakdown per month After Breakdown per month Actions Taken 1 2 3 4

61. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 61 4. Performance Results (4.K) Delivery Performance Total = 15 (i) What is the Delivery Performance ? (show last 3 year data in Bar graph, illustrate it with your internal Target line) (10)

62. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 62 4. Performance Results (ii) How many times Mis-Shipments happened ? (show last 3 year data in Bar graph, illustrate it with your internal Target line) (5) (4.K) Delivery Performance Total = 15

63. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 63 4. Performance Results (4.L) Safety Total = 20 (i)what is your safety policy? how is safety ensured? How safety incidences are communicated in Organisation? Role of each employee in safety. what best practices have been adopted? provide safety related results with trends (10) Formula No. of accidents Frequency rate =------------------------ X 10 6 Total man hours

64. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 64 4. Performance Results (4.L) Safety Total = 20 (ii) 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 What you feel is your Best Practice in Safety What you have learnt from others / shared with others on Safety Define what you meant by Accident (when you account it in your Record) Whether minor incidences are also accounted. (10) Formula Total man-days lost Severity rate =------------------------------- X 10 6 Total man hours

65. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 65 4. Performance Results (4.M) Inventory Turns Total = 20 (i) Show the trend of ITR (Inventory Turn Ratio) last three years, illustrate it with your internal Target line. (10) Formula Material cost of sales for the month x 12 in Rs. ITR = ----------------------------------------------------------- (RM + WIP + FG ) in Rs. On 1 st of the month (ii) Show actions taken to improve ITR. (10) S.N.ProductsBefore Inventory in days After Inventory in days Actions Taken 1 2 3 4

66. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 66 Section 5 Business Results Total Marks =100 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 5.A Repeat Business 20 5.B Customer Awards 20 5.C Customer Satisfaction 20 5.D Value Additions to Net Sales 20 5.E Value Added to Employee cost 20 TOTAL100 ( For office use only )

67. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 67 5. Business Results (5.A) Repeat Business Total = 20 (i) Show the trend of last 3 years of your business share with top 2 Customer in bar graph, illustrate it with your internal Target line. ( 10 ) Customer 1 Customer 2 (ii) What efforts are taken to Retain / Improve Business share ( 10 )

68. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 68 5. Business Results (5.B) Customer Awards Total = 20 (i)How do you listen to customer How customer issues are communicated and actioned how do you ensure proactive corrective measures in future applications how do you sensitise employees towards customer issues and how do you motivate them for faster response? provide key complaint management results [internal as well as external] Awards by Key Customers (10) Note : If your Customer does not have a system of Awards, Mention what kind of supplier recognition is followed by Customer. (ii) What efforts are taken to improve to meet Customer awards Criteria / Expectations (10)

69. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 69 5. Business Results (5.C) Customer Satisfaction Total = 20 (ii) What efforts taken to improve Customer satisfaction Score ? (10) (i) Show the trend of last three years of Customer Satisfaction in bar graph, illustrate it with your internal Target line. ( 10 )

70. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 70 5. Business Results (5.D) Value Additions to 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 to Net sales? (10)

71. ACMA Awards 2015-16 : Excellence in Manufacturing (Large) PM_44_F5 71 5. Business Results (5.E) Value Added 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 = ------------------------------------------------------- All Employee Cost ( CTC ) (ii) What is the benchmark & efforts to improve value addition to Employee Cost ? (10)