Excellence in Manufacturing 250 Marks

Excellence in Manufacturing 250 Marks
ACMA Awards Year of Inception: 1966 Excellence in Manufacturing 250 Marks Company Name : Plant Location : Award Category: Tick mark in appropriate box as per your ‘Company Group Turnover for ’. Small < 50 Cr Medium > INR 50 to 150 Cr Large > INR 150 to 500 Cr ( NA ) Very Large > INR 500 Cr ( NA ) Tick mark in appropriate box: ACMA Member All Past & Present ACT Cluster/ ACMA UNIDO Cluster Companies are eligible without becoming ACMA member for all categories as per Turnover criteria

Company / Plant Information
Use this slide to brief about your company / Plant. It includes Product names / photos , Plant facility photographs.

ACMA – Skilling and Mentoring
For Administrative Queries: Ms. Sakshi Karkamkar – Mobile – Ms. Smita Kulkarni – Mobile – Mr. Sanket Jadhav - Mobile Ms. Surekha Deshmukh - Mobile For Technical Queries: Mr. Arun Bage – Mobile – Mr. Atul Gupta – Mobile – Mr. Vishal Saxena – Mobile – Ms. Tanu Ahuja – Mobile – ACMA – Skilling and Mentoring Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C, Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar , Pune – , India, Desk phone – ,

Company History with ACMA Awards (last 3 years)
Letter for Submission of Award application Company letterhead details ( Logo , Address ) To , The Secretariat (ACMA Awards) , ACMA – Skilling and Mentoring Godrej Eternia, ”B” Wing ,, 10th Floor, Office No. C, ,Old Mumbai –Pune Highway, Wakdewadi , Shivaji Nagar Pune – , India We are pleased to submit the application for ACMA Award for Excellence in Manufacturing Small/Medium Category. 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 2 3 Note – 1) If you have applied & won multiple awards in one year, please mention accordingly. 2) If a plant has won Gold trophy in the year or in any of the above categories, then that particular plant will not be eligible to apply in the same category. But they can apply for any other categories.

CONFIDENTIALITY STATEMENT
Automotive Component Manufacturers Association of India 6th Floor, The Capital Court Olof Palme Marg, Munirka New Delhi , India 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

ACMA Awards 2018-19 : Excellence in Supplier Development PM_44_F41, Rev No 00
Company’s Details Name of the corporate group (if company is part of a corporate group): - ( Underline the plant for which application is sent ) 2. Plant Address : 3. Invoicing Details (Applicable only for shortlisted companies for site diagnosis): a) GST Number- b) Invoicing Address (write complete address with pin code)- 4. Chief Executive Officer details : Name : Designation : Mobile : Website: 5. Plant Head details : Name : Designation : 6. HR Head details :

Company’s Details 7. Company Group Annual Sales Turnover (in INR Cr.) for Year : 8. Plant ( for which application is submitted) turnover ( in INR Cr.) for Year : 9. Year of Establishment : Group Company _______ , Plant ___________ 10. Total Employees : Group Company ___________ , Plant _____________ 11. Do you have a Joint Venture for the plant applied: ( If Yes , Mention the partner name ) 12. Plant’s Key products : 13. Plant’s major manufacturing processes : 14. Plant’s Key competitors : 15. Plant’s Major Certifications : Sr No Core Processes % Contribution in your business 1 Foundry 80 2 Machining 10 3 Others

Route Map to reach your plant
Company’s Details 16. Contact Person 1 Information : ( Need to contact thru out the process of ACMA Award ) Name : Designation : Mobile : 17. Contact Person 2 Information : ( Need to Contact if above person is not reachable) Route Map to reach your plant Provide here route map to your company for site diagnosis (Site diagnosis is carried out if your application is shortlisted)

Details of contact person
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 Customer Details Mandatory requirement (not applicable for Excellence in Supplier Development category) Kindly provide details of your top 3 business customers in below table. ACMA Award online application software automatically sends a link to all above addresses to get feedback about your plant. Kindly inform above persons from your side to respond ASAP & ensure that we receive this before you submit the application online.( Your application will not processed without these feedback). S. No Customer Name Location % Business share (for the plant ) Details of contact person Mobile Number & E mail 1 Name 1– Designation – Name 2– Designation 2 3 Note: These feedbacks will be considered by Jury for evaluation & the same will be provided to you as a part of feedback report.

(Not applicable- for 1st time applicants)
Status of actions taken by your company based on previous ACMA Awards feedback report. (Mention top 5 only) (Not applicable- for 1st time applicants) S.N. Area of Improvement Action taken Result / Outcome 1 2 3 4 5

Summary of Achievements
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 Summary of Achievements for the year 1. Did you receive any awards other than Customers? 2. What are your biggest achievements in the last year? 3. What are challenges for you in the future and how are you preparing for it? Example Industry 4.0 , IOT (Internet of things) etc

Company performance at a glance
( Following radar chart shows the scores for each main area as per questionnaire , scores are converted to % ) RADAR Chart OFFICE USE ONLY Performance Results S.N Section Total Marks Actual Marks ( for Office Use only ) % 1 Hygiene factors 60 2 Manufacturing Focus and Business Growth 50 3 Support Functions 40 4 Performance Results 5 Business Results Total 250

OFFICE USE ONLY 30 10 5 Section 1 Hygiene Factors Total marks = 60
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 OFFICE USE ONLY Section 1 Hygiene Factors Total marks = 60 Sr No. Topic Total Marks Marks Obtained % 1A 5S & Plant Upkeep 30 1B Leadership Focus 10 1C Safety 5 1D Poka-yoke / KAIZEN 1E Contribution towards Society & Nation Total 60 marks redistributed

(1.A) 5S & Plant Upkeep 1. Hygiene Factors
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 1. Hygiene Factors (1.A) 5S & Plant Upkeep Total = 30 Mention in following chart status of Must be Facilities. (25 ) Questions are applicable for plant for which you have applied for ACMA Awards. In Status kindly mention % . E.g You have jogging track for 50 % areas , then write 50 % Must be facilities S. No. Description Status 1 Jogging track inside shop floor, along walls 2 Trees in plant campus (86 Trees/ Acre) 3 No earth should be visible in entire company area. There should be concrete, tar roads or green lawns 4 No truck / fork-lift inside shop floor 5 Clean toilet blocks inside shop floor, dry & smell free 6 No nails to be used anywhere in the factory premises 7 All employees to wear uniform, shoes and necessary safety gadgets 8 Noise free DG sets & compressor 9 Clean wash room / change room and rest room facilities 10 Hygienic kitchen, drinking water & dinning hall 11 Good recreational facilities 12 Appropriate fire fighting equipment's should be placed at accessible locations 13 Drive Forward Digitization - Team in place 14 Shop floor- Well Ventilated 15 Shop floor- Illumination (natural lighting) 16 Nothing directly on floor across company 17 Accessibility for differently abled persons (If Applicable) 18 Mock Drill - conducted as per frequency 19 ETP & STP in Well maintained condition 20 Training & Learning Facility 21 Logistics Centre 22 Research Centre 23 Resource Optimization - - Drive Team in Place 24 Is your plant outside surroundings are clean 25 Use of Non-conventional energy mark distribution changed and new questions added

ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 1. Hygiene Factors (1.A) 5S & Plant Upkeep Total = 30 (ii) How you drive 5S Process Explain whether sub areas formed, Sub-Area Owners identified, 5S Audit schedule & mechanism, NC clearance, Award for Best, Cross Audits or any other activities done. ( You may use Photos / Images to support this ) ( 3) mark distribution changed and new questions added

ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 1. Hygiene Factors (1.A) 5S & Plant Upkeep Total = 30 (iii) Shining examples of 5S Improvements Show 4 Photographs, Assessor may interview few operators for checking effectiveness ( 2 ) mark distribution changed and new questions added

1. Hygiene Factors (1.B) Leadership Focus Total = 10 (i) When was your VMV ( Vision , Mission & Values ) Statement was formed ? Have you revisited it afterwards ? When? (2) mark distribution changed and new questions added (ii) How you Communicate VMV to your Stakeholders like Suppliers, Employees etc. (3)

1. Hygiene Factors (1.B ) Leadership Focus Total = 10 (iii) Please give information about all types of communication meetings taking place in your organization indicating frequency, major participants and major issues during these meetings (5 ) ( Assessor may verify with few employees about such meetings) mark distribution changed and new questions added

Total = 5 (1.C) Safety 1. Hygiene Factors
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 1. Hygiene Factors Total = 5 (1.C) Safety Give details of One Accident Investigation analysis and corrective actions (3) If there are no accidents, mention as ZERO Accidents ) mark distribution changed and new questions added (ii) Give details of One Near Miss Accident and corrective actions (2)

(1. D ) Poka-yoke / KAIZEN 1. Hygiene Factors
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 1. Hygiene Factors (1. D ) Poka-yoke / KAIZEN Total = 5 What % of CTQs (Critical to Quality) are being addressed through poka- yoke ? (3) (ii) Show some recent customer complaints, which are addressed through poka-yoke (2) mark distribution changed and new questions added

1. Hygiene Factors (1 E) Contribution towards Society & Nation Building Total = 10 i How you develop ownership of the cleanliness of the neighborhood , improving the aesthetics around the company premises ( outside ) 1 ii Percentage of women employees & how this has increased over the years . Do you have a committee for implementation of policy of POSH (Prevention of Sexual Harassment at Work) Act, 2013? iii Any specific CSR activity you have done in year If Yes, describe iv Mention steps taken by the Company to reduce the usage of plastic in manufacturing and non manufacturing areas. v National Solar & Water Mission - Have you installed Roof Top Solar energy collectors and have earned through net metering. Adoption of Rainwater harvesting? mark distribution changed and new questions added

1. Hygiene Factors 1 L Contribution towards Society & Nation Building Total = 10 vi Please describe how your company encourages family participation ? 1 vii Mention here how company is prepared for disaster support management for affected elements in society ? E.g. support in flood relief , earthquake etc. viii Any Social Awards ix Have you supported any differently abled persons - % age employment provided and accessibility arrangements for differently abled persons x How do you support Make in India drive & skill development. (Import substitution , Entrepreneurship development , Tie ups with skill centers) mark distribution changed and new questions added

Manufacturing Focus and Business Growth Marks = 50
OFFICE USE ONLY Section 2 Manufacturing Focus and Business Growth Marks = 50 S.N. Sub topic Total Marks Actual Marks ( for office use ) % 2.A Process Design and control 10 2.B Waste Elimination 2.C Productivity 2.D Product Quality ,SPC and Poka Yoke 2.E Continuous Improvement TOTAL 50

2. Manufacturing Focus and Business Growth
(2 A.) Process Design and controls Total = 10 (i) How do you design your processes ? Explain what inputs are considered like FMEA ,CTQs ,technology requirements, operator skill etc . ( 5 ) (ii) What are the special processes in your company (welding , painting ,heat treatment etc ? How do you control these and ensure quality ? (like procedures for checking of process parameters, equipment's to control processes like Temperature controls ,humidity controls, dust controls etc (5)

(2.B) Waste Elimination Total = 10 How do you identify different types of wastes in your organisation? (using 7 types of waste principles ?) what methods are deployed to eliminate wastes? Give examples for each type of waste and your actions to reduce What are the forums available for employees to share waste elimination success stories? ( 10 )

(2.C) Productivity Total = 10 (i) How do you measure and monitor productivity ? How do you decide target for productivity ?What are your monthly/yearly productivity targets ? What are the challenges to meet targets ? How do you compare your productivity with the industry practice or best in class ? Explain benchmarking practices(5) (ii) What are the efforts done to improve productivity ? Explain productivity kaizens, low cost automations ,multi machine operations etc (5)

(2.D) Product Quality ,SPC and Poka-Yoke -- Total =10 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 (benchmarking) towards improving quality? provide key product quality results (5 )

(2. E. Continuous improvement Total = 10 (i) How do you drive Continuous Improvement in your company ? (5) S.N. Area No. of Kaizens Done Saving in Rs. Lacs Remarks 1 Productivity 2 Quality 3 Cost 4 Delivery 5 Safety 6 Morale 7 Energy 8 Environment 9 IT Total Share 2 examples of Continuous Improvement ( 5 )

OFFICE USE ONLY Section 3 Support Functions Total Marks = 40 S.N.
Sub topic Total Marks Actual Marks ( for office use ) % 3.A Support Functions Roles and objectives 10 3.B Support function training and development 3.C Support functions value added improvements 3.D Use of IT TOTAL 40

3. Support Functions 3.A . Support functions Roles and Objectives Total =10 What are your support functions ? (5 ) (ii) How do you decide support functions objectives and targets ? Provide details of linkage of company objectives to support functions. How do you monitor Support function objectives and Targets(5)

3. Support Functions 3.B Support functions Training and development Total =10 (i)How do you identify training and development needs of support functions ? What training and development inputs are provided to support functions ? How do you factor future needs in your training and development plan ? (5 ) (ii) How do you motivate support functions to participate in decision making ,innovations , improvement initiatives etc ? How do you form teams involving support functions to implement growth initiatives (5 )

3. Support Functions (3.C) Support function Value added Improvements Total =10 (i) How value adding activities captured / improved & wastages are eliminated in non production area? How do support function help in improving company’s performance ? (5) (ii) Provide few examples of value addition and waste elimination by support functions . Cover at least 3-4 support functions including Quality ,HR etc ( 5 )

3. Support Functions (3.D) Use of IT Total = 10
(i) How do you identify areas for implementation and integration of IT in your entire process chain ? How do you deploy IT initiative? ( 5 ) (ii) How IT integration helped to improve operational performance, give few shining examples of benefits achieved in the areas of quality ,productivity ? Explain how data analysis helps in decision making ? ( 5)

OFFICE USE ONLY Section 4 Performance Results Total Marks = 50 4.E
S.N. Sub topic Total Marks Actual Marks ( for office use ) % 4.A Revenue through New Products 10 4.B Manpower Productivity 4.C Energy Saving 5 4.D Breakdowns 4.E Delivery Performance 4.F Absenteeism 4.G Cost of poor Quality 4.H Customer Returns TOTAL 50

4. Performance Results (4.A) Revenue through New Products Total = 10
(i) Provide your total revenue vs revenue from New Products for last 3 years (5) (ii) What are your plans to increase your revenue from new products ? (5)

4. Performance Results (4.B) Manpower Productivity Total = 10
(i) What is the manpower productivity trend ? (show last 3 year data in Bar graph , illustrate it with your internal Target). Show the data for the Major Business Product Lines. (5) (ii) What are the tools used to analyze & improve manpower productivity ? Explain the methodology. In details (5)

4. Performance Results (4.C) Energy Saving Total = 5
(i) Show energy cost as % Sales, Include all energy resources , illustrate it with your internal Target line (electricity / fuel / gas/air/water) (3) List improvement actions implemented to reduce energy consumption (consider at least two examples each for each type of energy) in the year How employees are motivated to participate in this ? (2)

4. Performance Results (4.D) Breakdowns Total = 5
(i) How much is machine breakdown loss as % of total available time? (Bar graph , illustrate it with your internal Target line ) (3) (ii) Show Actions taken to eliminate break downs . Explain the methodology to reduce break downs.(2) S.N. Breakdown Before Breakdown per month After Breakdown per month Actions Taken 1 2 3 4

4. Performance Results (4.E) Delivery Performance Total = 5
(i) What is the Delivery Performance for all major customers ? (show last 3 year data in Bar graph , illustrate it with your internal Target line). Please consider delivery towards all requirements [models , varieties etc ] while calculating performance (3) (ii) Provide customer rating towards ‘Delivery Parameter’ for all major customers .Incase you have appreciation letters please mention the same (2)

4. Performance Results (4.F) Absenteeism Total = 5
What is absenteeism data ( Average) for last 3 years (3) Mention Target In each year Formula Total absent man-hours for the month ( Authorized + Unauthorized ) Absenteeism = X 100 Total man hours for the month (iii) What unique efforts organization takes to reduce absenteeism? (2)

4. Performance Results (4.G) Cost of poor Quality ( COPQ) Total = 5
Please show cost of poor quality trends for last three years with respect to internal target (3) (ii) Mention all elements of Cost of poor quality captured & monitored.(warranty , customer return ,rework ,rejections ,persons at customers line, logistics cost for return and replacement ,segregation etc Element wise performance before & after action taken for improvement in last 2 years.(2)

4. Performance Results (4.H) Customer Returns Total = 5
(i) Please show the trend of last three years of Customer Returns PPM in bar graph with target. ( 3 ) (ii) How do you eliminate causes related to Customer returns ? (2)

Business Results (General)
OFFICE USE ONLY Section 5 Business Results (General) Total Marks = 50 S.N . Sub topic Total Marks Actual Marks (for office use ) % 5.A Product Results 10 5.B Customer Focused Results 5.C Financial And Market Results 5.D Employee Focused Results 5.E Process Effectiveness Results TOTAL 50

5. BUSINESS RESULTS (5.A) Product Results Total = 10
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 5. BUSINESS RESULTS (5.A) Product Results Total = 10 What is the % of DOL (Direct Online) products? Show trend for last 3 years with target for each year (3 ) (ii) What is the status of customer complaints? Show trend for last 3 years with target for each year (5 )

5. BUSINESS RESULTS (5.A) Product Results Total = 10
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 5. BUSINESS RESULTS (5.A) Product Results Total = 10 (iii) What is the status of Warranty? Show trend for last 3 years with target for each year in PPM (2)

5. BUSINESS RESULTS (5.B) Customer Focused Results Total = 10
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 5. BUSINESS RESULTS (5.B) Customer Focused Results Total = 10 What is the Customer Audit score/ Rating? Show trend for last 3 years with target for each year (3) (ii) What is the Customer satisfaction score? Show trend for last 3 years with target for each year (3)

5. BUSINESS RESULTS (5.B) Customer Focused Results Total = 10
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 5. BUSINESS RESULTS (5.B) Customer Focused Results Total = 10 (iii) What is the status of Customer Awards and Recognitions? Show trend for last 3 years. Consider your top 3 business customers for this data. (4)

5. BUSINESS RESULTS (5.C) Financial And Market Results Total = 10
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 5. BUSINESS RESULTS (5.C) Financial And Market Results Total = 10 What is the sales turnover in INR Cr.? Show trend for last 3 years with target for each year (3) (ii) What is the % value addition to net sales? Show trend for last 3 years with target for each year (3)

5. BUSINESS RESULTS (5.C) Financial And Market Results Total = 10
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 5. BUSINESS RESULTS (5.C) Financial And Market Results Total = 10 (iii) What is the share of business for top 3 products. Show trend for last 3 years with target for each year (4)

5. BUSINESS RESULTS (5.D) Employee Focused Results Total = 10
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 5. BUSINESS RESULTS (5.D) Employee Focused Results Total = 10 What is the Employee satisfaction score? Show trend for last 3 years with target for each year (3) (ii) What are the training man days per employee per year? Show trend for last 3 years with target for each year (3)

5. BUSINESS RESULTS (5.D) Employee Focused Results Total = 10
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 5. BUSINESS RESULTS (5.D) Employee Focused Results Total = 10 (iii) What are the Suggestions per employee per year. Show trend for last 3 years with target for each year (4)

5. BUSINESS RESULTS (5.E) Process Effectiveness Results Total = 10
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 5. BUSINESS RESULTS (5.E) Process Effectiveness Results Total = 10 How much is In house Rejections? Show trend for last 3 years with target for each year (4) (ii) What is the Inventory turn Ratio ITR (Inventory Turn Ratio)? Show trend for last 3 years with target for each year (3) Formula Material cost of sales for the month x 12 in Rs. ITR = (RM + WIP + FG ) in Rs. On 1st of the month

5. BUSINESS RESULTS (5.E) Process Effectiveness Results Total = 10
ACMA Awards : Excellence in Supplier Development PM_44_F41, Rev No 00 5. BUSINESS RESULTS (5.E) Process Effectiveness Results Total = 10 (iii ) What is the value added per employee cost (VAPCO). Show trend for last 3 years with target for each year (3) Formula for VAPCO = (Sales – Variable cost)/ Employee Cost CTC

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