ACMA Awards Excellence in Export Company Name : Plant Location : PM_44_F6 Rev No: 0 Specimen Format* Excellence in Export Company Name : Plant Location : Category : LARGE 2013-14

Index ACMA Centre for Technology (ACT) PM_44_F6 Rev No: 0 Specimen Format* ( For office use only except page no. ) Index S.N. Section Page No. Max. Marks Actual Marks 1 Work Environment & Employee Involvement. 150 2 Customer Assessment 3 Export Operation Performance. 300 4 Export Market Performance. 250 5 Quality Performance. Total 1000 For Technical Queries: Mr. Dinesh Vedpathak Email – dinesh.vedpathak@acma.in Mobile – 09545887799 Mr. K. Chandrasekhar Email – k.chandrasekhar@acma.in Mobile – 09822911139 Mr. V K Sharma Email : vk.sharma@acma.in Mobile : 09811392068 Ms. Sapana Baravkar Email : sapana.baravkar@acma.in Mobile : 07350703339 For Administrative Queries: Mr. Uday Harite Email- usharite@acma.in Mobile – 08149099959 Mr. Jitender Rana Email – Jitender.rana@acma.in Mobile – 09873369699 Ms. Sakshi Karkamkar Email – sakshi.karkamkar@acma.in Mobile - 07387002181 ACMA Centre for Technology (ACT) ( A Division of ACMA ) Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C, Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar , Pune – 411005, India . www.acma-act.in

Letter for Submission of Award application for 2013-14 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 – 411005, India Tel No. 07387002181 ( Ms. Sakshi ) We are pleased to submit the application for ACMA Award 2013-14 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 2013-14 ACMA Awards Category ( For ACMA Award Process Team ) Small Upto INR 50 Cr Large > INR 50 Cr. Not Applicable Criteria for Small and Large Category : Small Category- Company Group Annual Sales Turnover Up to INR 50 Cr Large Category- Company Group Annual Sales Turnover > INR 50 Cr  

Company’s Details 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- Chief Executive (Site) details : Name : Designation : Mobile : E-mail : Land line with extension : Fax No. 4. Plant Head ( Next to Chief Executive (Site)) details : ( If Sr. No. 3 & 4 are same , then provide next level person details at Sr. No. 4 )

Company’s Details Company turnover ( in Rs. Crore ) for Year 2013-14 : Plant turnover ( in Rs, Crore ) for Year 2013-14 : Year of Establishment : Company _______ , Plant ___________ Total Employees : Company ___________ , Plant _____________ Do you have a Joint Venture : ( If Yes , Mention the partner name ) Company’s Key products : 11. Plant’s Key products : Plant’s key manufacturing processes : Plant’s Key competitors : 14. Plant’s Major Certifications :

Customer Details 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 Customers for the plant for which application is send 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.

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

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 ) Contact person name & Designation: Name : Designation : E-Mail : Mobile : Landline : ( STD Code ) ( Number ) : Ext. ( if any )

Actual Marks ( 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 S. N. Area Total Marks Actual Marks ( for Office Use only ) % 1 Work Environment & Employee Involvement. 150 2 Customer Assessment 3 Export Operation Performance. 300 4 Export Market Performance. 250 5 Quality Performance. Total 1000

Work Environment & Employee Involvement. ( For office use only ) 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 10 1.C Absenteeism 1.D Training 1.E Small Group Activities 1.F Safety 1.G Environment Management 30 TOTAL 150

Work Environment and employee involvement (1.A) Work Place Management Total = 40 (i) Specify status in below mentioned checklist for “Must be facilities” for all company employees ? Illustrate with photographs some examples (25)  Must be facilities for all company employees Sr. No. Description Status 1 Jogging track inside shop floor, along walls OK / Not OK 2 Trees in plant campus 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 change room and rest room facilities 10 Hygienic kitchen, washroom, dinning hall. 11 Good recreational facilities 12 Appropriate fire fighting equipments should be placed at accessible locations 13 Central display board ( 80 % Digital ) Photo Photo

Work Environment and employee involvement (1.A) Work Place Management Total = 40 (i) Illustrate how concept of 5S/house keeping has been deployed in your plant? (5 ) (ii) 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 %

Work Environment and employee involvement (1.A) Work Place Management Total = 40 (iii) illustrate with photographs examples of good Visual Factory- Before and after. (5) Before After Before After

Work Environment and employee involvement (1.B) Suggestions / Kaizens Per Employee Total= 10 (i) Is there a suggestion scheme in the company and How company encourages employees to give suggestions? ? Pls Describe: (ii) How company ensures the suggestions are implemented? Pls describe: (iii) Trends of number of suggestions implemented / employee / month? (show last one year trend in line graph, illustrate it with your internal Target line.). Formula Total suggestions + Kaizen Implemented in that month Suggestions / Employee =---------------------------------- -------------------------------- X 100 Total direct employees ( Operatives ) for the month

Work Environment and employee involvement (1.C) Absenteeism Total= 10 (i) What is absenteeism data ( Average) for the year 2013-14 ? What are the trends in regards to total absenteeism? (Three year trend in bar graph, illustrate it with your internal Target line.) ( 5 ) Authorized = % Unauthorized = % Total = % Formula Total absent man-hours for the month ( Authorized + Unauthorized ) Absenteeism =-------------------------------------------------------- -------------------------------- X 100 Total man hours for the month (ii) What efforts organization takes to reduce absenteeism? ( 5 )

Work Environment and employee involvement (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 : Formula Total training man-hours for all employees for year Training hours/employee / year =---------------------------------------- --------------------- Total employees (ii) How training effectiveness is measured and Benefits of Training : Tangible ( in Rs. Lacs ) & Intangible : (Give details for TWO shining examples) : ( 5 )

Work Environment and employee involvement (1.E) Small Group Activities Total= 10 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, illustrate it with your internal Target line.) % Employees Involvement No. of Active groups

Work Environment and employee involvement (1.F) SAFETY Total= 40 Pls describe: with text / Photos How company ensures Safe work practices? (5) (ii)Proactive measures taken by company to reduce accidents (10) (iii)Number of accident free days ( Cumulative ) (5) : Days

Work Environment and employee involvement (1.F) SAFETY Total= 40 (iii) What are the current accident levels? (Show last one year data in line graph) A) Frequency (nos.) Minor + Major both (10) B) Severity (man hrs. lost) (10) Formula No. of accidents Frequency rate =------------------------ X 106 Total man hours Formula Total man-days lost Severity rate =------------------------------- X 106 Total man hours

Work Environment and employee involvement (1.G) Environment Management Total= 30 (i) What is the frequency of scrap disposal? (10) : (Pl explain is it Daily / Weekly ) (ii) Does company have resources conservation strategy? List some recent achievements of company to conserve resource -electricity, water, material? (10)

Work Environment and employee involvement (1.G) ENVIRONMENT MANAGEMENT Total= 30 (iii) Please describe the practices of the company to reduce pollution ? (10)

( For office use only ) 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.B Customer Feedback 40 2.C Feedback Analysis 60 2.D Customer Awards 20 TOTAL 150

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

2. Customer Assessment (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) (ii) Please describe system of getting feedback from the customers? (20) (iii) Is there a warranty involved in supplies? If yes, is there a system to address the same? (10 )

2. Customer Assessment (2.C ) Feedback Analysis Total= 60 (i) How do you analyze this feedback and take actions in weak areas? Explain with a case study. (30)

2. Customer Assessment (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)

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

Export Operation Performance ( For office use only ) Section 3 Export Operation Performance Total Marks = 300 S.N. Sub topic Total Marks Actual Marks ( for office use ) % 3.A Export Sales 80 3.B Export OEM / Tier 1 Sales 50 3.C Foreign Exchange Earned 3.D New Product added in Export 3.E Royalty Payments 20 3.F General TOTAL 300

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

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

3. Export Operation Performance (3.B ) OEM / Tier 1 Export Sales Total= 50 (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) (ii) How has OEM / Tier 1 sales improved ? If not improved , what are the reasons ? (15)

3. Export Operation Performance (3.B ) OEM / Tier 1 Export Sales Total= 50 (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) (iv) How has Aftermarket sales improved ? If not improved , what are the reasons ? (10)

3. Export Operation Performance (3.C ) Foreign Exchange Earned Total= 50 (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) (ii) What are the efforts taken to improve Net foreign exchange ? (20)

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)

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

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)

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

3. Export Operation Performance (3.D) 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)

3. Export Operation Performance (3.D) 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)

Export Market Performance ( For office use only ) 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 150 4.B Breakthrough Achievements for Capturing Markets 100 TOTAL 250

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

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

4. 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 (30) , illustrate it with your internal Target line. ( You can edit / add your export countries in this graph ) (iv) What are the initiatives to improve growth in developing countries ? ( 20 )

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)

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

( For office use only ) Section 5 Quality Performance Total Marks = 150 S.N. Sub topic Total Marks Actual Marks ( for office use ) % 5.A In-House Rejection 30 5.B Cost of Poor Quality 20 5.C Rework 25 5.D Poka-Yokes 5.E Customer Complaints 5.F Customer Returns TOTAL 150

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

Before After 5. Quality Performance (5.A) In-House Rejection Total= 30 (iii) Provide example of actions by which you are able to achieve zero defect for In-House rejection (10) S.N. Defect Before PPM After PPM Actions Taken 1 2 3 4 Before – After Photo Before After

5. Quality Performance (5.B) Cost of poor Quality ( COPQ ) Total= 20 (i) What is the trend for COPQ ? (show last 3 year data in bar graph, illustrate it with your internal Target line. (5) Cost of Poor Quality ( COPQ ) as % of Sales (iii) Show elements of Cost of poor quality and improvements for the year 2013-14 . ( 10 ) S.N. COPQ Element Before % After % Actions Taken 1 2 3 4 5 6

Before After Before After 5. Quality Performance (5.B) Cost of poor Quality Total= 20 (iii) Provide example of actions by which you are able to reduce COPQ ( 5 ) Before – After Photos Before After Before After

5. Quality Performance (5.C) Rework Total= 25 (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) (ii) Explain efforts taken to reduce rework : (10)

Before After 5. Quality Performance (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 Photo Before After

5. Quality Performance (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) % = (iii) What % of Customer complaints are closed by Poka Yoke in 2013-14 ? (5) % = (iv) How do you ensure effectiveness of Poka yoke? (5 )

Before After 5. Quality Performance (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 Photo Before After

5. Quality Performance (5.E) Customer Complaints Total= 30 (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 ? (15 ) S.N. Export Complaints Root Cause Action Taken 1 2 3 4

5. Quality Performance (5.F) Customer Returns Total= 20 (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 ) S.N. Export Returns Root Cause Action Taken 1 2 3 4

Summary of Achievements ( Company has to fill up ) PM_44_F6 Rev No: 0, Specimen Format Summary of Achievements for the year 2013-14 ( Company has to fill up )

Show your companies excellent photos PM_44_F6 Rev No: 0, Specimen Format For Company: Show your companies excellent photos