acma awards 2014-15 : excellence in export (large) 2014-15 acma awards company name : plant location...

ACMA Awards 2014-15 : Excellence in Export (Large)

2014-15

ACMA Awards

Company Name : Plant Location :

Category : LARGE

Excellence in Export


Index( For office use only except page no. )

S.N. Section Page No.

Max. Marks Actual Marks

1 Work Environment & Employee Involvement.

150

2 Customer Assessment 150

3 Export Operation Performance. 300

4 Export Market Performance. 250

5 Quality Performance. 150

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


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 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 2014-15

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 CrLarge Category- Company Group Annual Sales Turnover > INR 50 Cr


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-

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 )


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 Work Environment & Employee Involvement.

150

2 Customer Assessment 150

3 Export Operation Performance.

300

4 Export Market Performance.

250

5 Quality Performance. 150

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

100

Work Environment &Employee Involvement

Customer Assessment

Export OperationPerformance

Export MarketPerformance

Quality Performance


10

Section 1

Work Environment & Employee Involvement.

Total Marks = 150

S.N. Sub topic Total Marks

Actual Marks ( for office use )

%

1.A Work Place Management 40

1.B Suggestions / Kaizens Per Employee

20

1.C Absenteeism 10

1.D Training 10

1.E Small Group Activities 10

1.F Safety 30

1.G Environment Management

30

TOTAL 150



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. 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

Photo Photo

1. Work Environment and employee engagement

(1.A) Work Place Management Total= 40


12


(ii) illustrate how concept of 5S/house keeping has been deployed in your plant?(5)


5060

7060

74 75 76 77 77 78 79 80

0102030405060708090

% sco

res

Target Actual

(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

(iv) illustrate with photographs examples of good Visual Factory- Before and after. (5)

Before After


Before After



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)



15


(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)

0.30.4

0.50.6

0.4

0.80.9

11.1

1.21.3

1.4

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

No

of s

ugg

impl

emen

ted

/ em

ploy

ee

Target Actual

Formula Total suggestions + Kaizen Implemented in that month Suggestions / Employee =---------------------------------- -------------------------------- X 100 Total direct employees ( Operatives ) for the month


16

(1.C) Absenteeism Total= 10

(i) What is absenteeism data ( Average) for the year 2014-15 ? 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 )

98

5

0

1

2

3

4

5

6

7

8

9

10

2012-13 2013-14 2014-15

Tota

l % a

bsen

teei

sm1. 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

(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 : • • • • •

25

40

55

0

10

20

30

40

50

60

2012-13 2013-14 2014-15

Trai

nin

g h

rs/e

mp

/ye

ar


(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

(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.

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


No

. o

f A

ctiv

e

gro

up

s

%

Em

plo

yee

s I

nvo

lve

me

nt


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) :



20

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

Acci

dent

freq

uenc

y

Target Actual


(1.F) SAFETY Total= 30

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

Formula No. of accidents

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

Total man hoursFormula

Total man-days lost Severity rate =------------------------------- X 106

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

(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)



22

(iii) Please describe the practices of the company to reduce pollution? (10)

(1.G) ENVIRONMENT MANAGEMENT Total= 30


(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

Section 2

Customer Assessment

Total Marks = 150



%

2.A SOB with 3 Major Customers

30

2.B Customer Feedback 40

2.C Feedback Analysis 60

2.D Customer Awards 20

TOTAL 150



24

(i)% SOB with Major 3 Export Customers (show last 3 yr trend) , illustrate it with your internal Target line. (20)

6065

70

2015

10

20 20 20

0

10

20

30

40

50

60

70

80

2012-13 2013-14 2014-15

%

C-1 C-2 C-3

(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


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 )



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= 60



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)



28

(2.D ) Customer Awards Total= 20

(i) Awards / Recognition by Key Customers from Domestic and Export Customers (trend of last 3 years) (20)

0

5

10

2012-13 2013-14 2014-15

89

10

56

8

Nos

Domestic Customer Awards Export Customer Awards

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



29

Section 3

Export Operation Performance

Total Marks = 300



%

3.A Export Sales 80

3.B Export OEM / Tier 1 Sales 50

3.C Foreign Exchange Earned 50

3.D New Product added in Export

50

3.E Royalty Payments 20

3.F General 50

TOTAL 300



30

3. 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)

10

20

30

12

25

38

0

10

20

30

40

05

101520253035

2012-13 2013-14 2014-15

Total Sales

% Growth


31

3. 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)

10

20

30

12

25

38

0

10

20

30

40

05

101520253035

2012-13 2013-14 2014-15

Total Export Sales

% Growth


32

3. Export Operation Performance

10

20

30

12

25

38

0

10

20

30

40

05

101520253035

2012-13 2013-14 2014-15

OEM Export sales

% of total export

(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)


33

3. 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)

10

20

30

12

25

38

0

10

20

30

40

05

101520253035

2012-13 2013-14 2014-15

Total Export Sales

% Growth


34


(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)

110

120

130

100

105

110

115

120

125

130

135

2012-13 2013-14 2014-15

Rs C

rore

Foreign Exc Earned

(3.C ) Foreign Exchange Earned Total= 50

(ii) What are the efforts taken to improve Net foreign exchange ? (20)


35

3. 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)


36


(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


37

3. 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)


38

3. 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)

10

8

3

0

2

4

6

8

10

12

2012-13 2013-14 2014-15

Rs .

Cror

e

Royalty Payments in Rs. Crore

(ii) How have royalty payments reduced ? (10)


39

3. Export Operation Performance (3.F) General Total= 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)


40

3. Export Operation Performance (3.F) General Total= 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)


41

Section 4

Export Market Performance

Total Marks = 250



%

4.A Export growth in Established Market

150

4.B Breakthrough Achievements for Capturing Markets

100

TOTAL 250



42

4. Export Market Performance

(i) Export destinations (Names) – (20)

(ii) Principal OEMs / Tier 1 customers – (20)

(4.A) Export Growth in Established Market Total= 150


43

4. 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 )

0

5

10

15

20

25

30

35

40

2012-13 2013-14 2014-15

Rs in

Cro

res

USA UKGermany JapanChina

(iv) What are the initiatives to improve growth in developed countries ? ( 20 )


44


0

5

10

15

20

25

30

35

40

2012-13 2013-14 2014-15

Rs

Cror

e

Bangladesh Sri Lanka

Middleast Thailand

(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 )


45

4. 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)


46


(iii) Quality and Delivery performance for capturing new markets (20)

(iv) Through Innovation (20)

(4.B) Breakthrough Achievements for capturing new Markets

Total= 100


47

Section 5

Quality Performance

Total Marks = 150



%

5.A In-House Rejection 30

5.B Cost of Poor Quality 25

5.C Rework 25

5.D Poka-Yokes 25

5.E Customer Complaints 25

5.F Customer Returns 20

TOTAL 150



48

(5.A) In-House Rejection Total= 30

5. 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)

5000

3000

1000

4500

2000

800

0

1000

2000

3000

4000

5000

6000

2012-13 2013-14 2014-15

PPM

Target

In-houserejection PPM


49

(5.A) In-House Rejection Total= 30


S.N. Defect Before PPM After PPM Actions Taken

1

2

3

4

Before – After Photo

Before After

(iii) Provide example of actions by which you are able to achieve zero defect for In-House rejection (10)


50


(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)

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) Give two action plans for cost of quality reduction

S.N. COPQ Element

Before % After % Actions Taken

1

2


51

(5.B) Cost of poor Quality Total= 25


(iii) Provide example of actions by which you are able to reduce COPQ ( 5 )

Before – After Photos

Before After

Before After


52

(5.C) Rework Total= 25


(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)

13000

100009000

02000400060008000

100001200014000

2012-13 2013-14 2014-15

PPM


53

(5.C) Rework Total= 25


(iii) Please give details of action taken to reduce rework? (10)

S.N. Rework Before PPM After PPM Actions Taken

1

2

3

4


Before After


54

(5.D) Poka-yoke Total= 25


(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 2014-15 ? (5)

% =


55

(5.D) Poka-yokes Total= 25


(v) Show innovative examples of poka-yoke & Effect on overall Rejection of that Product ( 5)

S.N. Product Before Poka-Yoke Rejection PPM

After Poka-yoke Rejection PPM

Poka-yokes done

1

2

3

4


Before After


56

(5.E) Customer Complaints Total= 25


S.N. Export Complaints

Root Cause Action Taken

1

2

3

4

(i) Customer complaints for Domestic and export customers (show last 3 yr trend, illustrate it with your internal Target line.) (15)

60

40

2020

51

010203040506070

2012-13 2013-14 2014-15

No.

of

Com

plai

nts

Domestic Complaints

Export Complaints

(ii) What actions are initiated to eliminate export Complaints ? (10 )


57

(5.F) Customer Returns Total= 20


S.N. Export Returns Root Cause Action Taken

1

2

3

4

(i) Customer Returns PPM for Domestic and export customers (show last 3 yr trend, illustrate it with your internal Target line.) (10)

400300

100200

10050

0

100

200

300

400

500

2012-13 2013-14 2014-15

PPM

Domestic Return

Export PPM

(ii) What actions are initiated to eliminate export Customer Returns ? (10 )


Summary of Achievements for the year 2014-15

( Company has to fill up )


For Company:Show your companies excellent photos

acma awards 2014-15 : excellence in export (large) 2014-15 acma awards company name : plant location...

Documents

acma awards company

acma awards category

large excellence

secretariat acma awards

acma centre

export slide

group company turnover

export large index