ACMA Awards : Excellence in Export (Large) ACMA Awards Company Name : Plant Location : Category : LARGE Excellence in Export

ACMA Awards : Excellence in Export (Large) Index ( For office use only except page no. ) S.N.SectionPage No. Max. MarksActual Marks 1 Work Environment & Employee Involvement Customer Assessment150 3 Export Operation Performance Export Market Performance Quality Performance.150 Total 1000 For Administrative Queries: Mr. Jitender Rana – Mobile – Ms. Sakshi Karkamkar – Mobile – Mr. Binny Tomy - Mobile For Technical Queries: Mr. V K Sharma Mobile : Ms. Sapana Baravkar Mobile : ACMA Centre for Technology (ACT) Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C, Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar, Pune – , India.

ACMA Awards : Excellence in Export (Large) 3 Letter for Submission of Award application for 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 – , India Tel No ( Ms. Sakshi ) We are pleased to submit the application for ACMA Award for Excellence in Export in Large category. All data submitted is duly verified and true to the best of our knowledge. With regards ( Name & Designation of the Plant CEO ) Group Company Name Group Company Turnover in INR Cr. For ACMA Awards Category( For ACMA Award Process Team ) Small Between INR 20 to 50 Cr Large > INR 50 Cr. Not Applicable Large Criteria for Small and Large Category : Small Category- Company Group Annual Sales Turnover Between INR 20 to 50 Cr Large Category- Company Group Annual Sales Turnover > INR 50 Cr

ACMA Awards : Excellence in Export (Large) 4 Company’s Details 1.Name of the corporate group (if company is part of a corporate group): - ( Underline the plant for which application is sent ) Plant Address : 2. Name of the Chief executive of the corporate group- 3Chief Executive (Site) details : Name : Designation : Mobile : Land line with extension : Fax No. 4. Plant Head ( Next to Chief Executive (Site)) details : Name : Designation : Mobile : Land line with extension : Fax No. ( If Sr. No. 3 & 4 are same, then provide next level person details at Sr. No. 4 )

ACMA Awards : Excellence in Export (Large) 5 Company’s Details 5.Company turnover ( in Rs. Crore ) for Year : 6.Plant turnover ( in Rs, Crore ) for Year : 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 :

ACMA Awards : Excellence in Export (Large) 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. 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.

ACMA Awards : Excellence in Export (Large) 7 Use this slide to brief about your company / Plant. It includes Product names / photos, Plant facility photographs, Company / Plant Information

ACMA Awards : Excellence in Export (Large) 8 Route Map to reach your plant Contact person name & Designation: Name : Designation : 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 )

ACMA Awards : Excellence in Export (Large) 9 S. N. AreaTotal Marks Actual Marks ( for Office Use only ) % 1 Work Environment & Employee Involvement Customer Assessment150 3 Export Operation Performance Export Market Performance Quality Performance.150 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

ACMA Awards : Excellence in Export (Large) 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 )

ACMA Awards : Excellence in Export (Large) 11 (i) Specify status in below mentioned checklist for “Must be facilities” for all company employees ? Illustrate with photographs of 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

ACMA Awards : Excellence in Export (Large) 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 %

ACMA Awards : Excellence in Export (Large) 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

ACMA Awards : Excellence in Export (Large) 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

ACMA Awards : Excellence in Export (Large) 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

ACMA Awards : Excellence in Export (Large) 16 (1.C) Absenteeism Total= 10 (i) What is absenteeism data ( Average) for the year ? 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

ACMA Awards : Excellence in Export (Large) 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

ACMA Awards : Excellence in Export (Large) 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

ACMA Awards : Excellence in Export (Large) 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

ACMA Awards : Excellence in Export (Large) 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)

ACMA Awards : Excellence in Export (Large) 21 (1.G) Environment Management Total= 30 (i) What is the frequency of scarp disposal? (5) : (Pl explain is it Daily / Weekly … ) (5) (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

ACMA Awards : Excellence in Export (Large) 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)

ACMA Awards : Excellence in Export (Large) 23 Section 2 Customer Assessment Total Marks = 150 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 2.A SOB with 3 Major Customers 30 2.BCustomer Feedback40 2.CFeedback Analysis60 2.DCustomer Awards20 TOTAL150 ( For office use only )

ACMA Awards : Excellence in Export (Large) 24 (i)% SOB with Major 3 Export Customers (show last 3 yr trend), illustrate it with your internal Target line. (20) (2.A ) Share Of Business with 3 Major Export Customers Total= 30 (ii) Why business has reduced or Improved ? Explain with case to case (10) 2. Customer Assessment

ACMA Awards : Excellence in Export (Large) 25 (ii) How do you listen to customer ? How customer issues are communicated and actions are taken ? (20) (2.B ) Customer Feedback Total= 40 (i) Does the company have an organization structure to address customer needs in a proactive way and also respond quickly to queries / issues etc? (10) (iii) Is there a warranty involved in supplies? If yes, is there a system to address the same? (10 ) 2. Customer Assessment

ACMA Awards : Excellence in Export (Large) 26 (i) How do you analyze this feedback and take actions in weak areas? Explain with a case study. (30) (2.C ) Feedback Analysis Total= Customer Assessment

ACMA Awards : Excellence in Export (Large) 27 (2.C ) Feedback Analysis Total= 60 (ii) Is there a data monitoring system in place to review field performance in export markets? (15) (iii) Is there a system to address the need of Service parts requirements in export market? (15) 2. Customer Assessment

ACMA Awards : Excellence in Export (Large) 28 (2.D ) Customer Awards Total= 20 (i) Awards / Recognition by Key Customers from Domestic and Export Customers (trend of last 3 years) (20) Award photo Note : If your Customer does not have a system of Awards, Mention what kind of supplier recognition is followed by Customer. Award photo 2. Customer Assessment

ACMA Awards : Excellence in Export (Large) 29 Section 3 Export Operation Performance Total Marks = 300 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 3.AExport Sales80 3.BExport OEM / Tier 1 Sales50 3.CForeign Exchange Earned50 3.D New Product added in Export 50 3.ERoyalty Payments20 3.FGeneral50 TOTAL300 ( For office use only )

ACMA Awards : Excellence in Export (Large) Export Operation Performance (3.A ) Sales Growth Total= 80 (ii) How Total sales improved ? If not improved, what are the reasons ? (20) (I) Total sales in Rs. Crore and % of total Sales Growth ( Last 3 years Trend, illustrate it with your internal Target line.) – (20)

ACMA Awards : Excellence in Export (Large) Export Operation Performance (3.A ) Export Sales Total= 80 (iv) How export sales improved ? If not improved, what are the reasons ? (20) (iii) Total Export Sales, In Rs. Crore and % growth in Export Sales ( Last 3 years Trend, illustrate it with your internal Target line.) – (20)

ACMA Awards : Excellence in Export (Large) Export Operation Performance (i) OEM/Tier 1 Export Sales and % of Total Exports (In Rs Crore ) ( last 3 years Trend, illustrate it with your internal Target line.) – (15) (3.B ) OEM / Tier 1 Export Sales Total= 50 (ii) How has OEM / Tier 1 sales improved ? If not improved, what are the reasons ? (15)

ACMA Awards : Excellence in Export (Large) Export Operation Performance (3.B ) OEM / Tier 1 Export Sales Total= 50 (iv) How has Aftermarket sales improved ? If not improved, what are the reasons ? (10) (iii) Total aftermarket Export Sales, In Rs. Crore and % growth in After Market Export Sales ( Last 3 years Trend, illustrate it with your internal Target line.) – (10)

ACMA Awards : Excellence in Export (Large) Export Operation Performance (i) Net foreign exchange earned in Rs. Crore ? Net foreign exchange earned through Reduction in Imports (Rs. Crore ), illustrate it with your internal Target line. (30) (3.C ) Foreign Exchange Earned Total= 50 (ii) What are the efforts taken to improve Net foreign exchange ? (20)

ACMA Awards : Excellence in Export (Large) Export Operation Performance (3.D) New Product added for Export Total= 50 (i) Number of new products added from existing product portfolio for export market and % of sales contribution from these new products to Exports in last three years –show 3 years trend graph., illustrate it with your internal Target line.(10) (ii) Number of entirely new products added and % of sales contribution from these new products to Exports in last three years –show 3 years trend graph, illustrate it with your internal Target line. (10)

ACMA Awards : Excellence in Export (Large) Export Operation Performance (iii) Show process / roadmap for development of new products for export and its achievement status (10) (3.D) New Product added for Export Total= 50

ACMA Awards : Excellence in Export (Large) Export Operation Performance (3.D) New Product added for Export Total= 50 (iv) Is there a method to communicate design changes to export markets customers to address supply conditions as well as stocked material at warehouses / service outlets etc? (10) (v) How is the engineering change implementation effected for OE export customers? What is the system for aftermarket supplies? (10)

ACMA Awards : Excellence in Export (Large) Export Operation Performance (3.E) Royalty Payments Total= 20 (i) Royalty payments over last 3 years in Rs.. Crore ), illustrate it with your internal Target line.(10) (ii) How have royalty payments reduced ? (10)

ACMA Awards : Excellence in Export (Large) Export Operation Performance (3.F) GeneralTotal= 50 (i) Is there a risk management system in place to address export market litigations / law suits etc particulars with reference to safety part supplies? (10) (ii) Is the document retention period for exports clearly defined? (10) (iii) Does the above address the statutory requirements of the country of export as well as customer requirements? (10)

ACMA Awards : Excellence in Export (Large) Export Operation Performance (3.F) GeneralTotal= 50 (iv) Are process changes / engineering changes also validated and documented? (10) (v) How is the quality of safety critical parts ensured on periodic basis? (10)

ACMA Awards : Excellence in Export (Large) 41 Section 4 Export Market Performance Total Marks = 250 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 4.A Export growth in Established Market B Breakthrough Achievements for Capturing Markets 100 TOTAL250 ( For office use only )

ACMA Awards : Excellence in Export (Large) Export Market Performance (i) Export destinations (Names) – (20) (ii) Principal OEMs / Tier 1 customers – (20) (4.A) Export Growth in Established Market Total= 150

ACMA Awards : Excellence in Export (Large) Export Market Performance (4.A) Export Growth in Established Market Total= 150 (iii) Export Growth in established Market (Rs. Crore ) Last 3 years Trend for Developed Countries ?, illustrate it with your internal Target line. (40) ( You can edit / add your export countries in this graph ) (iv) What are the initiatives to improve growth in developed countries ? ( 20 )

ACMA Awards : Excellence in Export (Large) Export Market Performance (4.A) Export Growth in Established Market Total= 150 (v) Export Growth in developing Market (Rs. Crore ). Last 3 years Trend for Developing countries, illustrate it with your internal Target line. ( You can edit / add your export countries in this graph ) (30) (iv) What are the initiatives to improve growth in developing countries ? ( 20 )

ACMA Awards : Excellence in Export (Large) Export Market Performance (4.B) Breakthrough Achievements for capturing new Markets Total= 100 (i) Cost competitiveness for capturing new markets (40) (ii) Use of Technology for capturing new markets (20)

ACMA Awards : Excellence in Export (Large) Export Market Performance (iii) Quality and Delivery performance for capturing new markets (20) (iv) Through Innovation (20) (4.B) Breakthrough Achievements for capturing new Markets Total= 100

ACMA Awards : Excellence in Export (Large) 47 Section 5 Quality Performance Total Marks = 150 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 5.AIn-House Rejection30 5.BCost of Poor Quality25 5.CRework25 5.DPoka-Yokes25 5.ECustomer Complaints25 5.FCustomer Returns20 TOTAL150 ( For office use only )

ACMA Awards : Excellence in Export (Large) 48 (5.A) In-House Rejection Total= Quality Performance (i) What are the trends of the Total in-house rejection in PPM ? (show last 3 year data in bar graph, illustrate it with your internal Target line.) (10) (ii) Please describe the actions taken to reduce the in- house rejection (10)

ACMA Awards : Excellence in Export (Large) 49 (5.A) In-House Rejection Total= Quality Performance S.N.DefectBefore PPMAfter PPMActions Taken Before – After Photo BeforeAfter (iii) Provide example of actions by which you are able to achieve zero defect for In-House rejection (10)

ACMA Awards : Excellence in Export (Large) Quality Performance (5.B) Cost of poor Quality ( COPQ) Total = 25 (i)what are different elements of Cost of quality what measures are monitors towards cost of quality how do you reduce cost of quality how do you communicate cost of quality to your employees and prepare action plans ? give cost of quality results and trends for last three years (10) (ii) Show elements of Cost of poor quality and improvements for the year (10) Give two action plans for cost of quality reduction S.N.COPQ Element Before %After %Actions Taken 1 2

ACMA Awards : Excellence in Export (Large) 51 (5.B) Cost of poor Quality Total= Quality Performance (iii) Provide example of actions by which you are able to reduce COPQ ( 5 ) Before – After Photos BeforeAfter BeforeAfter

ACMA Awards : Excellence in Export (Large) 52 (5.C) Rework Total= Quality Performance (ii) Explain efforts taken to reduce rework : (10) (i) What is the current level of the rework in PPM ? (show trend for last 3 year in bar graph, illustrate it with your internal Target line.) (5)

ACMA Awards : Excellence in Export (Large) 53 (5.C) Rework Total= Quality Performance (iii) Please give details of action taken to reduce rework? (10) S.N.ReworkBefore PPMAfter PPMActions Taken Before – After Photo BeforeAfter

ACMA Awards : Excellence in Export (Large) 54 (5.D) Poka-yoke Total= Quality Performance (i) How company identifies need for Poka-Yoke ? ( 5 ) (ii) What % of CTQs are controlled by Poka Yoke? (5) % = (iv) How do you ensure effectiveness of Poka yoke? (5 ) (iii) What % of Customer complaints are closed by Poka Yoke in ? (5) % =

ACMA Awards : Excellence in Export (Large) 55 (5.D) Poka-yokes Total= Quality Performance (v) Show innovative examples of poka-yoke & Effect on overall Rejection of that Product ( 5) S.N.ProductBefore Poka-Yoke Rejection PPM After Poka- yoke Rejection PPM Poka-yokes done Before – After Photo Before After

ACMA Awards : Excellence in Export (Large) 56 (5.E) Customer Complaints Total= Quality Performance S.N.Export Complaints Root CauseAction Taken (i) Customer complaints for Domestic and export customers (show last 3 yr trend, illustrate it with your internal Target line.) (15) (ii) What actions are initiated to eliminate export Complaints ? (10 )

ACMA Awards : Excellence in Export (Large) 57 (5.F) Customer Returns Total= Quality Performance S.N.Export ReturnsRoot CauseAction Taken (i) Customer Returns PPM for Domestic and export customers (show last 3 yr trend, illustrate it with your internal Target line.) (10) (ii) What actions are initiated to eliminate export Customer Returns ? (10 )

ACMA Awards : Excellence in Export (Large) Summary of Achievements for the year ( Company has to fill up )

ACMA Awards : Excellence in Export (Large) For Company: Show your companies excellent photos