2014-15 acma awards company name : plant location : category : large excellence in manufacturing

2014-15

ACMA Awards

Company Name : Plant Location :

Category : LARGE

Excellence in Manufacturing

Index( For office use only except page no. )

S.N. Section Page No.

Max. Marks Actual Marks

1 Leadership Focus 325

2 Manufacturing Operations & Processes

275

3 Support Functions 100

4 Performance Results 200

5 Business Results 100

Total 1000

For Administrative Queries:

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

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

Mr. Binny TomyEmail- [email protected] Mobile- 9711138869

For Technical Queries:

Mr. V K Sharma Email : [email protected] : 09811392068

Ms. Sapana Baravkar Email : [email protected] : 07350703339

ACMA Centre for Technology (ACT)Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C, Old Mumbai

Pune Highway Wakdewadi, Shivaji Nagar , Pune – 411005, India .www.acma-act.in ; [email protected]

mailto:[email protected]





http://www.acma-act.in/


ACMA Awards 2014-15 : Excellence in Manufacturing

3

Letter for Submission of Award application for 2014-15

Company letterhead details ( Logo , Address )

To ,

The Secretariat ( ACMA Awards ) ,ACMA Centre for TechnologyGodrej Eternia, ”B” Wing ,, 10th Floor, Office No. C, ,Old Mumbai –Pune Highway, Wakdewadi , Shivaji Nagar Pune – 411005, India Tel No. 07387002181 ( Ms. Sakshi ) We are pleased to submit the application for ACMA Award 2014-15 for Excellence in Manufacturing.

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 2014-15

ACMA Awards Category > INR 150 Cr.

( For ACMA Award Process Team )

Large

Criteria for Manufacturing Category :Company Group Annual Sales Turnover > INR150 Cr


4

1. Name of the corporate group (if company is part of a corporate group): -

( Underline the plant for which application is sent )

Plant Address :

2. Name of the Chief executive of the corporate group-

3 Chief Executive (Site) details :

Name : Designation :

Mobile : E-mail :

Land line with extension : Fax No.

4. Plant Head ( Next to Chief Executive (Site)) details :

Name : Designation :

Mobile : E-mail :

Land line with extension : Fax No.

( If Sr. No. 3 & 4 are same , then provide next level person details at Sr. No. 4 )

Company’s Details


5

Company’s Details

5. Company turnover ( in Rs. Crore ) for Year 2014-15 :

6. Plant turnover ( in Rs, Crore ) for Year 2014-15 :

7. Year of Establishment : Company _______ , Plant ___________

8. Total Employees : Company ___________ , Plant _____________

9. Do you have a Joint Venture : ( If Yes , Mention the partner name )

10. Company’s Key products :

11. Plant’s Key products :

12. Plant’s key manufacturing processes :

13. Plant’s Key competitors :

14. Plant’s Major Certifications :


6

As a part of ACMA Award process , feedback from your major customers will be obtained directly and will be provided to Jury as a part of Site diagnosis .The same will be provided to you as a part of Site Diagnosis feedback report

Kindly provide 2 names per Key Customer for the plant for which application is sent

Customer Details

S. No Customer Location

% Business share ( from the plant )

Key person name & Designation

Mobile Number & E mail

1

2

Note- In addition to application & site diagnosis , Customer feedback scores will be also considered for final scores.


7

Use this slide to brief about your company / Plant .

It includes Product names / photos , Plant facility photographs ,

Company / Plant Information


8

Route Map to reach your plant

Contact person name & Designation:

Name :

Designation :

E-Mail :

Mobile :

Landline : ( STD Code ) ( Number ) : Ext. ( if any )

Provide here route map to your company for site diagnosis ( Site diagnosis is carried out if your application is shortlisted )


9

S.N Area Total Marks

Actual Marks ( for Office Use only )

%

1 Leadership Focus 3252 Manufacturing Operations &

Processes 275

3 Support Functions 1004 Performance Results 2005 Business Results 100

Total 1000

( For office use only )

Company performance at a glance ( Following radar chart shows the scores for each main area as per

questionnaire , scores are converted to % )

RADAR Chart

0

25

50

75

100Leadership Focus

Manufacturing Operations &Processes

Support FunctionsPerformance Results

Business Results


10

Section 1

Leadership Focus

Total Marks = 325

S.N. Sub topic Total Marks

Actual Marks ( for office use )

%

1.A Vision, Mission and Strategy 25

1.B New Product Development 25

1. C Operational Excellence 20

1.D Communication 20

1.E Social commitment 20

1.F Training 20

1.G Must Be Facilities 35

1.H 5 S 20

1.I Motivation, creativity and innovation

15

1.J Competitor Study 10

1.K Logistics 20

1.L Small Group Activity 20

1.M Employee Satisfaction 30

1.N Partnering with Customers / suppliers

45

TOTAL 325



11

1. Leadership Focus

(1.A) Vision, Mission and Strategy Total = 15

(i) Please enclose your Statements of vision, mission strategies & dates of when these were Formed and Revised . (5)

VISION : ( Formed on / / , Revised on : / / )

MISSION : ( Formed on / / , Revised on : / / )

STRATEGIES : ( Formed on / / , Revised on : / / )


12

1. Leadership Focus

(ii) Do you have a planning process for deploying vision, mission, strategies (e.g., Policy Deployment, Management by Objective, etc..)? (5)

(iii) Please enclose samples of action plans of people in line and support functions for achieving a common objective. (5)

(1.A) Vision, Mission and Strategy Total = 15


13

1. Leadership Focus

(iv) What is the vision for New product Development ? ( 5 )

(v) What Strategy is deployed to achieve Vision of New Product Development ? Give evidence if company is using tools like quality function deployment, concurrent or simultaneous engineering, etc.. for product development (20 )

(1.B) New Product Development Total =25


14

1. Leadership Focus

(vii) Show shining examples of Operational Excellence ( 10 )

(vi) How company improves operational Excellence ? ( 10 )

photo photo

(1.C) Operational Excellence Total =20


15

1. Leadership Focus

(1.D) Communications Total = 20

(i) How often Leadership communicates to employees ? . (10)

S.N.

Communication by

Daily Monthly Quarterly Half Yearly

Forum

1

2

3

(ii) Show photographs of above communication . (10)

Sr.No. 1 photo Sr.No. 2 photo

Sr.No. 3 photo


16

1. Leadership Focus

(1.E) Social Commitment Total = 20

(i) How do leadership contribute to the society ? What was the budget for last year ? (10)

(ii) Share some shining examples of Social commitment, Photos (10)

Photo Photo


17

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)

25

40

55

0

10

20

30

40

50

60

2012-13 2013-14 2014-15

Trai

ning

hrs

/em

p/ye

ar

(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


18

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. Description Status

1 Jogging track inside shop floor, along walls OK / Not OK

2 Trees in plant campus OK / Not OK

3 No earth should be visible in entire company area. There should be concrete, tar roads or green lawns.

OK / Not OK

4 No truck / fork-lift inside shop floor OK / Not OK

5 Clean toilet blocks inside shop floor, dry & smell free OK / Not OK

6 No nails to be used anywhere in the factory premises. OK / Not OK

7 All employees to wear uniform, shoes and necessary safety gadgets.

OK / Not OK

8 Noise free DG sets & compressor OK / Not OK

9 Clean change room and rest room facilities OK / Not OK

10 Hygienic kitchen, washroom, dinning hall. OK / Not OK

11 Good recreational facilities OK / Not OK

12 Appropriate fire fighting equipments should be placed at accessible locations

OK / Not OK

13 Central display board ( 80 % Digital ) OK / Not OK

(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)


19

1. Leadership Focus

(1.H) 5S Total = 20

50

60

70

60

7475

76 77 77 78 79 80

0

10

20

30

40

50

60

70

80

90

% s

core

s

Target Actual

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

(i) How do you practice 5s culture ( 2 ) (ii) How employees are motivated to follow 5s (3 )

(iii) What is 5s target ? ( 2 ) (iv) Provide 5s results with trends (3)


20

1. Leadership Focus

(1.H) 5S Total = 20

50

60

70

60

7475

76 77 77 78 7980

0

10

20

30

40

50

60

70

80

90

% s

core

s

Target Actual

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

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

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

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

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


21

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.

Level Methods

1

2

3


22

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


23

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


24

1. Leadership Focus

(iii) How many active groups are present in the current year? % employee involvement In QC Activity? (show last three year trend in bar graph) (10 )

15

20

25

50

70

100

0

25

50

75

100

0

5

10

15

20

25

30

2012-13 2013-14 2014-15

active groups% of emp involvement

(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)


25

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)

6878 81

0

25

50

75

100

2012-13 2013-14 2014-15

Empl

oyee

Sati

sfac

tion

Scor

e


26

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)


27

1. Leadership Focus

(1.N) Partnering with Customers / suppliers Total = 45

(I) Give details of your vendor development process. How do you communicate Organisational objectives to vendors How do you interact with vendors provide vendor satisfaction results (15)

(ii) Show one shining example of partnering with Customers / Suppliers .( 10 )


28

1. Leadership Focus

(1.N) Partnering with Customers / 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 )


29

Section 2

Manufacturing operations & processes

Total Marks = 275S.N. Sub topic Total

MarksActual Marks ( for office use )

%

2.A Operations Performance 25

2.B Production Planning Process

15

2.C Product Quality 202.D Waste Elimination 20

2.E Material Handling 20

2.F Total productive maintenance

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.K Statistical process control 20

2.L Kaizen linked to results 20

2.M Tools of quality 20

TOTAL 275



30

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 )


31


(2.A) Operations Performance Total = 25

(iii) Is process FMEA done during process design? ( 5 )

(iv) Does 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 )


32


(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)


33


(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)


34


(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 kaizens, savings accrued etc. ( 10 )

(ii) What are the Benefits of Waste removal in your company (10 )


35


(2. E) Material Handling Total = 20

(i) What are the containers used for material handling ? (10 )

(ii) What % of containers are “ 3 C “ ? Show Shining examples with photographs ( 3C = Count Free, Contact Free, Clean Container) (10 )


36


(2. F) Total Productive Maintenance 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 (10 )

(ii) What are the benefits of TPM ? Quantify . ( 10 )

(ii) How company achieves Zero Defect through TPM ? Mention 2 shining examples .( 5 )


37


(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 )


38


(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)


39


(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 )


40


(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 )


41


(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 monitors Cpk performance for CTQ characteristics . What % of CTQ parameters where Cpk >1.67. (5 )

(ii) Show one latest Run chart / SPC Chart filled by operator ( 5 )


42


(2. L) Kaizens Linked to Results Total = 20

(i) How many Kaizens done in Year 2014-15 as per following ? (10)

(iii) Share two shining examples ? ( 5 )

(ii) What is the per employee Kaizen for last Year ? ( 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


43


(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 ? (10)

S.N. Quality tools Usage purpose % Employees trained

1

2

3

4

5

6

7

(i) How many Management Quality tools are used and for what purpose & what % of employees are trained for each tool ? (10)

S.N. Quality tools Usage purpose % Employees trained

1

2

3

4

5

6

7


44

Section 3

Support Functions

Total Marks = 100



%

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

TOTAL 100



45

3. Support Functions

(3.A) Support Function Strategy Total = 25

(i) What is the policy and strategy for improvements in support functions? ( 10 )

(ii) Please describe the process for implementing this strategy covering all functions.(15)


46


(3.b) Support Department : Goals Vs Actual Total = 25

(i) What is the % achievements of Support function Goals for the year 2014-15 ? ( 15 )

(ii) How Top management ensures that this achievement ratio improve year on year (10)

S.N.

Support Department

Goal Plan Actual % Achievements

Remarks

1

2

3

4

5

6


47


(3.C) Value Adding Improvements Total = 25

(i) What is the shining Value adding improvements done by support departments ( 15 )

S.N. Support Department

Value Adding Improvement

Benefits

1

2

3

4

5

6

(ii) How top management motivates support team ? ( 10 )


48


(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 )


49

Section 4

Performance Results

Total Marks = 200



%

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 Absenteeism 15

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

TOTAL 200



50

4. Performance Results

(4.A) Cost of poor Quality ( COPQ) Total = 20

(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 two action plans for cost of quality reduction

give cost of quality results and trends for last three years (10)

1.2

0.4

0.1

0

0.2

0.4

0.6

0.8

1

1.2

1.4

2012-13 2013-14 2014-15

%

(ii) Show elements of Cost of poor quality and improvements for the year 2014-15 . (10)

S.N. COPQ Element

Before % After % Actions Taken

1

2

3

4

5

6


51


(4.B) Customer Complaints Total = 20

(i) Please describe method of capturing customer complaints? (10)

11

12

11

10

9

8

7

6

5

4

0 00

2

4

6

8

10

12

14Target Actual

(ii) What is the trend of the customer complaints in nos? (Show last one year data in line graph. (10)


52


(4.C) Customer Returns Total = 15

100

70

30

0

20

40

60

80

100

120

2012-13 2013-14 2014-15

Cust

omer

Ret

urn

PPM

(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)


53


(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 )

10001100

300

0

200

400

600

800

1000

1200

2012-13 2013-14 2014-15

PPM

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 )


54


(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)

6000

4000

1200

5000

3000

1000

0

1000

2000

3000

4000

5000

6000

7000

2012-13 2013-14 2014-15

PPM

Target

In-houserejection PPM


55


(4.F) Supplier Rejection Total = 10

(i) how do you measure supplier quality [quality of everything about supplier]

explain your ongoing vendor audit process how do you give feedback to your vendor how do you align vendor with your strategic objectives provide key vendor related results(5)

1500

1200

1500

1600

1456

1235

1124

840

640

540

440

230

0

200

400

600

800

1000

1200

1400

1600

1800

Su

pp

lie

r R

ej i

n P

PM

Target Actual

(ii) Please describe the efforts to reduce the supplier rejection? (5 )


56


(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)

98

5

0

1

2

3

4

5

6

7

8

9

10

2012-13 2013-14 2014-15

Tota

l % a

bsen

teei

sm

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

(i) What is absenteeism data ( Average) for the year 2014-15 ? (5) Authorized = % Unauthorized = %Total = %


57


(4.H) Manpower Productivity Total = 15

(ii) What are the tools used to improve manpower productivity ? (10)

2024

35

0

10

20

30

40

2012-13 2013-14 2014-15

No.

of p

rodu

cts

/m

an/y

ear

(i) What is the productivity trend ? (show last 3 year data in Bar graph , illustrate it with your internal Target line) (5) Show the data for the Major Business Product Line.


58


(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)

1.21.1

0.7

0

0.2

0.4

0.6

0.8

1

1.2

1.4

2012-13 2013-14 2014-15

% E

nerg

y of

sal

es

S.N. Item Before After

Actions Taken

1

2

3

4

(ii) List improvement actions implemented to reduce energy consumption in the year 2014-15 (10)


59


(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)

2.1

0.40.1

0

0.5

1

1.5

2

2.5

2012-13 2013-14 2014-15

% B

reak

dow

ns

S.N. Breakdown Before Breakdown per month

After Breakdown per month

Actions Taken

1

2

3

4


60


(4.K) Delivery Performance Total = 15

(ii) What are the tools / methods used to improve Delivery performance ?(2.5)

98 99 100

0

25

50

75

100

2012-13 2013-14 2014-15

Del

iver

y P

erfr

oman

ce

(i) What is the Delivery Performance ? (show last 3 year data in Bar graph , illustrate it with your internal Target line) (5)


61


(iv) What actions are taken to Avoid Mis-Shipments ? (2.5)

5

10

0

2

4

6

8

10

2012-13 2013-14 2014-15

No.

of

Mis

-Shi

pmen

ts

(iii) 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


62


(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)

0.3 0.3

0.50.6

0.4

0.8

0 0 0 0 0 00

0.2

0.4

0.6

0.8

1

Acc

iden

t fre

quen

cy

Target Actual

Formula No. of accidents

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

Total man hours


63


(4.L) Safety Total = 20

0.3

0.4

0.5

0.6

0.4

0.8

0 0 0 0 0 00

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Acc

iden

t fr

eque

ncy

Target Actual

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 plannedWhat you feel is your Best Practice in Safety What you have learnt from others / shared with others on SafetyDefine 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 106

Total man hours


64


(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)

2024

35

0

10

20

30

40

2012-13 2013-14 2014-15

Inve

ntor

y T

urns

Formula Material cost of sales for the month x 12 in Rs. ITR = ----------------------------------------------------------- (RM + WIP + FG ) in Rs. On 1st of the month

(ii) Show actions taken to improve ITR. (10)

S.N. Products Before Inventory in days

After Inventory in days

Actions Taken

1

2

3

4


65

Section 5

Business Results

Total Marks =100



%

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

TOTAL 100



66

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

50 55 55

0

20

40

60

80

100

2012-13 2013-14 2014-15

Busi

ness

sha

re

%

50 55 55

0

20

40

60

80

100

2012-13 2013-14 2014-15

Busi

ness

sha

re

%

(ii) What efforts are taken to Retain / Improve Business share ( 10 )


67

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)

0

2

4

6

8

10

2012-13 2013-14 2014-15

89

10

56

8

Nos

No. of Key-Customers Awards by key customer

Award photo

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

(ii) What efforts are taken to improve to meet Customer awards Criteria / Expectations (10)


68

5. Business Results

(5.C) Customer Satisfaction Total = 20

85 88 91

0

25

50

75

100

2012-13 2013-14 2014-15

Cust

omer

Sati

sfac

tion

Sc

ore

%

(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 )


69

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 )

1011

13

0

2

4

6

8

10

12

14

2012-13 2013-14 2014-15

Valu

e A

dditi

on to

N

et sa

les

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)


70

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 )

4

5

6

0

1

2

3

4

5

6

7

2012-13 2013-14 2014-15

Valu

e A

dditi

on to

Em

ploy

ee C

ost

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)


Summary of Achievements for the year 2014-15

( Company has to fill up )


For Company:Show your companies excellent photos

2014-15 acma awards company name : plant location : category : large excellence in manufacturing

Documents