1. 2013-14 ACMA Awards Company Name : Plant Location : Category : Large Excellence in Quality & Productivity PM_44_F8 Rev. No. : 00, Specimen Format*

2. Index ( For office use only except page no. ) S.N.SectionPage No. Max. MarksActual Marks 1 Work Environment & Employee Involvement. 150 2 Customer Assessment100 3 Quality Performance.350 4 Productivity Performance.300 5 Cost Performance.100 Total 1000 For Administrative Queries: Mr. Uday Harite Email- usharite@acma.inusharite@acma.in Mobile – 08149099959 Mr. Jitender Rana Email – Jitender.rana@acma.inJitender.rana@acma.in Mobile – 09873369699 Ms. Sakshi Karkamkar Email – sakshi.karkamkar@acma.insakshi.karkamkar@acma.in Mobile - 07387002181 For Technical Queries: Mr. Dinesh Vedpathak Email – dinesh.vedpathak@acma.indinesh.vedpathak@acma.in Mobile – 09545887799 Mr. K. Chandrasekhar Email – k.chandrasekhar@acma.ink.chandrasekhar@acma.in Mobile – 09822911139 Mr. V K Sharma Email : vk.sharma@acma.in vk.sharma@acma.in Mobile : 09811392068 Ms. Sapana Baravkar Email : sapana.baravkar@acma.insapana.baravkar@acma.in Mobile : 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_F8 Rev. No. : 00, Specimen Format*

3. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, 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 Technology Office 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 2013-14 for Excellence in Quality & Productivity 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 2013-14 ACMA Awards Category( For ACMA Award Process Team ) Small Upto INR 50 Cr Large Between INR 50 to 150 Cr. Not Applicable Large Criteria for Small and Large Category : Small Category- Company Group Annual Sales Turnover Up to INR 50 Cr Large Category- Company Group Annual Sales Turnover Between INR 50 to 150 Cr

4. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 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- 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

5. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 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. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 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. NoCustomerLocatio n % 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. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 7 Use this slide to brief about your company / Plant. It includes Product names / photos, Plant facility photographs, Company / Plant Information

8. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 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. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 9 S. N. AreaTotal Marks Actual Marks ( for Office Use only ) % 1 Work Environment & Employee Involvement. 150 2Customer Assessment100 3Quality Performance.350 4Productivity Performance.300 5Cost Performance.100 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

10. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 10 Section 1 Work Environment & Employee Involvement Total Marks = 150 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 1.AWork Place Management40 1.B Suggestions / Kaizens Per Employee 20 1.CAbsenteeism10 1.DTraining10 1.ESmall Group Activities10 1.FSafety30 1.G Environment Management 30 TOTAL150 ( For office use only )

11. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 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. 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 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 1.Work Environment and employee engagement (1.A) Work Place Management Total= 40

12. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 12 1.Work Environment and employee engagement (ii) illustrate how concept of 5S/house keeping has been deployed in your plant?(5) (1.A) Work Place Management Total= 40 (iii) 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. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 13 (iv) illustrate with photographs examples of good Visual Factory- Before and after. (5) BeforeAfter 1.Work Environment and employee engagement BeforeAfter (1.A) Work Place Management Total= 40

14. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 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) 1.Work Environment and employee engagement

15. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 15 1.Work Environment and employee engagement (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) Formula Total suggestions + Kaizen Implemented in that month Suggestions / Employee =---------------------------------- -------------------------------- X 100 Total direct employees ( Operatives ) for the month

16. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 16 (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 ) 1.Work Environment and employee engagement Formula Total absent man-hours for the month ( Authorized + Unauthorized ) Absenteeism =-------------------------------------------------------- -------------------------------- X 100 Total man hours for the month

17. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 17 (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 : 1.Work Environment and employee engagement (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. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 18 (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. 1.Work Environment and employee engagement No. of Active groups % Employees Involvement

19. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 19 (1.F) SAFETY Total= 30 Pls describe: with text / Photos (i)How company ensures Safe work practices? (5) (ii) Proactive measures taken by company to reduce accidents (5) (iii) Number of accident free days ( Cumulative ) (5) : 1.Work Environment and employee engagement

20. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 20 1.Work Environment and employee engagement (1.F) SAFETY Total= 30 Formula No. of accidents Frequency rate =------------------------ X 10 6 Total man hours Formula Total man-days lost Severity rate =------------------------------- X 10 6 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. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 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) 1.Work Environment and employee engagement

22. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 22 (iii) Please describe the practices of the company to reduce pollution? (10) (1.G) ENVIRONMENT MANAGEMENT Total= 30 1.Work Environment and employee engagement (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. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 23 Section 2 Customer Assessment Total Marks = 100 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 2.AAwards by Key Customers10 2.B Customer audit of Quality system 20 2.C Customer rating for Quality & Delivery 30 2.D Feedback from Customer & analysis 40 TOTAL100 ( For office use only )

24. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 24 (i) Awards by Key Customers (trend of last 3 years) (10) (2.A ) Awards by Key Customers Total= 10 2. Customer diagnosis (i) 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) Award photo Note : If your Customer does not have a system of Awards, Mention what kind of supplier recognition is followed by Customer. (2.B ) Customer audit of Quality system T otal= 20 Note : If your Customer does not have a audit system, Mention what kind of supplier audit system and scoring is followed by Customer.

25. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 25 (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. (30) (2.C ) Customer rating for Quality & Delivery Total= 30 2. Customer diagnosis Mention here major improvements done by your company to improve above performance :

26. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 26 (i) Please describe system of getting feedback from the customers? (10) (2.D ) Feedback from Customer & analysis T otal= 40 2. Customer diagnosis (ii) If yes, how do you analyze this feedback and take actions in weak areas? Explain with two shining examples. (30)

27. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 27 Section 3 Quality Performance Total Marks = 350 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 3.ACustomer Complaints50 3.B In-House Rejection & Rework 90 3.CSupplier Rejection40 3.DWarranty Rejection50 3.ECost of Poor Quality30 3.FProcess Improvement40 3.GQuality Management50 TOTAL350 ( For office use only )

28. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 28 (i) Please describe method of capturing customer complaints? (5) (ii) What is the trend of the customer complaints in nos? (Show last one year data in line graph, illustrate it with your internal Target line.) (20) (3.A) Customer Complaints Total= 50 3. Quality Performance

29. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 29 (iii) Is the Customer complaint data analysis done? (E.g.—Product wise, Customer wise, Process wise, etc). Explain with an example. (5) (iv) Is analysis of repeated Customer complaints carried out? Explain with an example ? (5) (3.A) Customer Complaints Total= 50 3. Quality Performance

30. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 30 (v) Explain the efforts to reduce customer complaints? (10) (vi) Enclose examples of countermeasure report on Customer complaints. (5) (3.A) Customer Complaints Total= 50 3. Quality Performance

31. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 31 (3.B) In-House Rejection & Rework Total= 90 3. Quality Performance (ii) 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.) (20) (iii) Please describe the actions taken to reduce the in- house rejection (10) (i) Does the company follow the APQP process? If not, please specify the alternate methodology followed for component development? (10 )

32. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 32 3. Quality Performance S.N.DefectBefore PPMAfter PPMActions Taken 1 2 3 4 Before – After Photos BeforeAfter (iv) Provide example of actions by which you are able to achieve zero defect at In-house rejection (10) (3.B) In-House Rejection & Rework Total= 90

33. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 33 (vi) Explain efforts taken to reduce rework : (10) 3. Quality Performance (v) 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.) (20) (3.B) In-House Rejection & Rework Total= 90

34. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 34 (vii) Please give details of action taken to reduce rework? (10) 3. Quality Performance S.N.ReworkBefore PPMAfter PPMActions Taken 1 2 3 4 Before – After Photo BeforeAfter (3.B) In-House Rejection & Rework Total= 90

35. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 35 (3.C) Supplier Rejection Total= 40 3. Quality Performance (i) What are the trends of the supplier rejection in PPM ? (show last 1 year data in bar Graph, illustrate it with your internal Target line.) (20) (ii) Please describe the efforts to reduce the supplier rejection? (10)

36. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 36 (3.C) Supplier Rejection Total= 40 3. Quality Performance S.N.Defect from Supplier Before PPMAfter PPMActions Taken 1 2 3 4 Before – After Photos BeforeAfter (iii) Provide example of actions by which you are able to achieve zero defect at Supplier end (10)

37. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 37 (ii) Please describe the efforts to reduce the warranty rejection (10) (3.D) Warranty Rejection Total= 50 3. Quality Performance (i) What are the trends of the warranty ? (show last 3 year data in bar Graph, illustrate it with your internal Target line.) (30) Note : If warranty is Not applicable for your products, Mention in place of Graph

38. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 38 (3.D) Warranty Rejection Total= 50 3. Quality Performance S.N.Warranty Defect Before PPMAfter PPMActions Taken 1 2 3 4 Before – After Photos BeforeAfter (iii) Provide example of actions by which you are able to achieve Zero warranty defect (10)

39. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 39 (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. (10) Cost of Poor Quality ( COPQ ) as a % of Sales (3.E) Cost of Poor Quality ( COPQ) Total= 30 3. Quality Performance (ii) 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

40. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 40 (3.E) Cost of Poor Quality ( COPQ ) Total= 30 3. Quality Performance (iii) Provide example of actions by which you are able to reduce COPQ ( 10 ) Before – After Photos BeforeAfter BeforeAfter

41. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 41 (i) How company identifies Critical to Quality characteristics (CTQ) ? (10) (3.F) Process Improvement Total= 40 3. Quality Performance

42. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 42 (iii) What steps are taken to improve process capability greater than 1.67? ( 5 ) (3.F) Process Improvement Total= 40 3. Quality Performance S.N.S.N. CTQ Param eter C ustomer Complain ts for 2013-14 Not Monit ored CPk < 1.33 CPk>1.33<1. 67 CPk>1. 67 Present Control 1 2 3 4 5 6 (ii) Does the company insist on CpK performance for CTQ characteristics? What is the present level of Process capability (Cpk) for CTQ’s identified and controls ? (15)

43. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 43 (iv) Show Shining examples of process improvements ( 10 ) Explain with text and Photographs. (3.F) Process Improvement Total= 40 3. Quality Performance BeforeAfter BeforeAfter Before – After Photo

44. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 44 3. Quality Performance (i) How is the quality of safety critical parts ensured on periodic basis? (5 ) (ii) Are process / engineering changes also validated and documented? (5 ) (3.G) Quality Management Total= 50 (iii) How company identifies need for Poka-Yoke ? ( 10 )

45. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 45 (iv) What % of CTQs are controlled by Poka Yoke? (5) % = 3. Quality Performance (vi) How do you ensure effectiveness of Poka yoke? (5 ) (v) What % of Customer complaints are closed by Poka Yoke in 2013-14 ? (5) % = (3.G) Quality Management Total= 50

46. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 46 (vii) Show innovative examples of poka-yokes & Effect on overall Rejection of that Product ( 15 ) 3. Quality Performance S.N.ProductBefore Rejection PPM After Rejection PPM Poka-yokes done 1 2 3 4 Before – After Photo Before After (3.G) Quality Management Total= 50

47. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 47 Section 4 Productivity Performance Total Marks = 300 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 4.A Manpower Productivity 100 4.B Manufacturing Process Improvement 75 4.C Inventory Management 75 4.D Loss of production Hours 50 TOTAL300 ( For office use only )

48. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 48 (ii) What are the tools used to improve manpower productivity ? (10) (4.A) Manpower productivity Total= 100 4. Productivity Performance (i) 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.) (20)

49. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 49 (4.A) Manpower Productivity Total= 100 4 Productivity Performance (iii) Show innovative examples of Manpower productivity improvements ( 20 ) S.N.OperationBefore ( Production / day ) After ( production / Day ) Actions Taken 1 2 3 4 Before – After Photo Before After

50. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 50 (i) What % of operators are handling more than one machine? Illustrate it with your internal Target line. (30) 4. Productivity Performance (ii) How Company encourages employees for operating multi- machines ? (20) (4.A) Manpower Productivity Total= 100

51. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 51 (4.B) Manufacturing Process Total= 75 4. Productivity Performance Before After (i) Do you follow Single piece flow or batch flow layout or a mixture of both? Show present material flow for your key business line ? (15) (ii) Show improvements in layouts done last year, Show benefits of layouts change ( 25 ) Single piece flow = %, Batch Flow = Before : Material Travel = Meters ; Manufacturing Lead time = Mins ; WIP = Nos. After : Material Travel = Meters ; Manufacturing Lead time = Mins ; WIP = Nos.

52. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 52 (iii) How process cycle times are reduced ? Share examples (20) (4.B) Manufacturing Process Total= 75 4. Productivity Performance S.N.OperationBefore Cycle Time After Cycle Time Actions Taken 1 2 3 4 Before – After Photo Before After

53. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 53 (4.B) Manufacturing Process Total= 75 4. Productivity Performance (iv) Is planning for safety / quality an integral part of the overall production planning process? Is FMEA carried out during planning stage? (15)

54. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 54 (i) Show the trend of ITR (Inventory Turn Ratio) last three years, illustrate it with your internal Target line. (50) (4.C) Inventory Management Total= 75 4. Productivity Performance (ii) Show actions taken to reduce inventory. (25) S.N.ProductsBefore Inventory in days After Inventory in days 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

55. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 55 (i) How much is machine breakdown loss in % of total available time? (Bar graph, illustrate it with your internal Target line ) (20) (ii) Show Actions taken to reduce break downs (10) (4.D) Loss of Production Hours Total= 50 4. Productivity Performance S.N.BreakdownBefore Breakdown in a month After Breakdown in a month Actions Taken 1 2 3 4

56. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 56 (4.D) Loss of Production Hours Total= 50 4. Productivity Performance (iii) How much is the Setup loss in % of total available time? (Bar graph, illustrate it with your internal Target line ) (10) (iv) Show Actions taken to reduce Setup time (10) S.N.Set upBeforeAfterActions Taken 1 2 3 4

57. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 57 Section 5 Cost Performance Total Marks = 100 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 5.AEnergy Saving10 5.BValue Addition / Net Sales30 5.C Value Addition / Fixed Assets 30 5.D Value Addition / Employee Cost 30 TOTAL100 ( For office use only )

58. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 58 (5.A) Energy Savings Total= 10 5. Cost Performance (i) Show energy consumption as % Sales, illustrate it with your internal Target line. (5) S.N.ItemBeforeAfterActions Taken 1 2 3 4 (ii) Show examples to reduce energy consumption (5)

59. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 59 (i) Show the trend of last three years in bar graph, illustrate it with your internal Target line. (15) (5.B) Value Additions / Net Sales Total= 30 5. Cost Performance Formula Net Sales – Variable Cost Value Addition to Net Sales = ---------------------------------------------------- Net Sales (ii) What is the benchmark & efforts to improve value addition / Net sales? (15)

60. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 60 (i) Show the trend of last three years in bar graph, illustrate it with your internal Target line. ( 15 ) (5.C) Value Additions / Fixed Assets Total= 30 5. Cost Performance Formula Net Sales - Variable Cost Value Addition to Fixed Assets = --------------------------------------------------------- Total Cost of Fixed Assets (ii) What is the benchmark & efforts to improve value addition / Fixed assets ? (15)

61. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* 61 (i) Show the trend of last three years in bar graph, illustrate it with your internal Target line. ( 15 ) (5.D) Value Additions to Employee cost Total= 30 5. Cost Performance (ii) What is the benchmark & efforts to improve value addition to Employee Cost ? (15) Formula Sales –Variable Cost Value Addition to Employee Cost = ------------------------------------------------------- Total Employee Cost ( CTC )

62. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* Summary of Achievements for the year 2013-14 ( Company has to fill up ) PM_44_F8 Rev. No. : 00, Specimen Format*

63. ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large) PM_44_F4 Rev. No. : 00, Specimen Format* For Company: Show your companies excellent photos PM_44_F8 Rev. No. : 00, Specimen Format*