1. Excellence in Quality & Productivity
ACMA Awards
Year of Inception: 1966
Excellence in Quality & Productivity
Company Name :
Plant Location :
Award Category:
Tick mark in appropriate box as per your ‘Company Group Turnover for ’.
Small < 30 Cr
Medium > INR 30 to 100 Cr
Large > INR 100 to 500 Cr
Very Large > INR 500 Cr
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

2. ACMA Centre for Technology (ACT)
For Administrative Queries:
Mr. Rupesh Somania –
Mobile –
Ms. Sakshi Karkamkar –
Mobile –
Mr. Binny Tomy -
Mobile
Ms. Smita Kulkarni –
Mobile –
For Technical Queries:
Mr. Uday Harite –
Mobile –
Mr. Atul Gupta –
Mobile –
Mr. Vishal Saxena –
Mobile –
Ms. Ekta Agrawal -
Mobile
ACMA Centre for Technology (ACT)
Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C, Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar , Pune – , India, Desk phone – ,

3. 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 Centre for Technology
Office No. C, , 10th Floor, Godrej Eternia,
”B” Wing ,Old Mumbai –Pune Highway, Wakdewadi ,
Shivaji Nagar Pune – , India
We are pleased to submit the application for ACMA Award for Excellence in Quality & Productivity in Small/ Medium / Large / Very Large 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 your plant has won Gold trophy in the year or in Excellence in Q&P category, then your plant will not be eligible to apply in the same category. But they can apply for any other applicable categories.

4. 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

5. 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 :
Chief Executive (Site) details :
Name : Designation :
Mobile :
Website:
4. Plant Head ( Next to Chief Executive (Site)) details :
Name : Designation :
5. HR Head details :
6. Training Head details :
(If Sr. No. 3 & 4 are same , then provide next level person details at Sr. No. 4 )

6. 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 : Company _______ , Plant ___________
10. Total Employees : Company ___________ , Plant _____________
11. Do you have a Joint Venture : ( If Yes , Mention the partner name )
12. Company’s Key products :
13. Plant’s Key products :
14. Plant’s key manufacturing processes :
15. Plant’s Key competitors :
16. Plant’s Major Certifications :

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

8. 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 Information: ( Need to contact thru out the process of ACMA Award )
Name :
Designation :
Mobile :
Contact Person Information: ( Need to Contact if above person is not available)

9. Mandatory requirement
Customer Details
Mandatory requirement
As a part of ACMA Award process, feedback from your major Customers to be obtained by Applicant companies & to be send by your customer directly to as per format. This feedback will be shared to Juries directly & the same will be provided to you as a part of feedback report.
When you register online, you will receive Customer Feedback format. Kindly send to your top 3 Business Customers & ensure that we receive this before you submit the application online. ( Your application will not be processed without this feedback)
Kindly furnish your top 3 Business customer details from whom you will be obtaining feedback.
S. No.
Customer
% Business share (From the plant)
Customer key persons name
Mobile Number &  1
Manufacturing Head
Incoming Quality Head  2  3
Note- In addition to application & your site diagnosis score, Customer feedback will be also considered for final scores.

10. Key Performance Indicators (KPIs)
KPI Sheet for Excellence in Quality & Productivity
S. No.
KPI
UoM
Actual Value
Target Value for
Remarks 1
Sales Turnover
INR CR 2
Employee Satisfaction score % 3
Employee Absenteeism ( Total ) 4
Training Man-hours / man / Year
Nos 5
Number of QC Circles 6
CSR Budget as % of Sales 7
Productivity Trend - No. of Products/ Man/ Year 8
% of operatives operating 2 or more machines or stations 9
Customer Complaints 10
Customer Returns
PPM 11
In house rejection 12
Rework 13
Machine Breakdowns 14
Number of accidents per year 15
Delivery Performance 16
WIP in days
days 17
Inventory Turns 18
Supplier Rejection 19
5 S average score 20
Cost of Poor Quality as % of sales 21
Warranty rejection ( if Applicable ) 22
Energy as % of sales 23
Value addition to net sales 24
Value addition to fixed assets 25
Value addition to employee cost

11. Executive Summary
Synopsis of Application- (write here Specific Achievements (Qualitative & Quantitative) for all 5 areas of application which will support to understand how your company deserves to be a winner)
Area 1-Work Environment & Employee Involvement
Area 2-Customer Assessment
Area 3-Quality Performance
Area 4- Productivity Performance
Area 5-Cost Performance
Key differentiators (Mention here few points which makes you to stand as a winner) :
How you are a better employer compared to others ? (Mention in brief) :

12. (Not applicable- for 1st time applicants)
Status of  actions  taken by your company based   on previous ACMA Awards 2017 feedback report.
(Mention top 5 only) 
(Not applicable- for 1st time applicants)
S.N.
Area of Improvement
Action taken
Result / Outcome

13. Sharing of Best Practices of your company
Best Practices along with photos shown here will be compiled and shared by ACMA to all applicants / members / non-members for learning purpose. (This is OPTIONAL and there are no marks for this)
By tick mark hereby I agree to allow ACMA to use this information for sharing with others (From above topic only)
Please mention your best practices here
Photo
Photo
Photo
Photo

14. 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.
Section
Total Marks
Actual Marks ( for Office Use only ) % 1
Work Environment & Employee Involvement
150 2
Customer Assessment
100 3
Quality Performance
350 4
Productivity Performance
300 5
Cost Performance
Total
1000

15. 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 20
1.C
Absenteeism 10
1.D
Training
1.E
Small Group Activities 15
1.F
Safety
1.G
Environment Management 25
1.H
Contribution of Company towards Nation building
TOTAL
150

16. Work Environment and employee engagement
(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
S. No.
Description
Status 1
Jogging track inside shop floor, along walls
OK / Not OK 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
Photo
Photo

17. Leadership Focus (1.A) Work Place Management Total = 40
(ii) How do you practice 5S culture ( 2 )
(iii) How employees are motivated to follow 5S (2)
(iv ) What is 5S target ? ( 1 )
(v) Provide 5S scores for with target line (5)
Formula
5 S Score = Lowest zone / area score of that month in %

18. Leadership Focus (1.A) Work Place Management Total = 40
(vi) 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) (5)

19. Work Environment and employee engagement
(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? Please Describe (5)
(ii) How company ensures the suggestions are implemented? Please describe: (5)

20. Work Environment and employee engagement
(1.B) Suggestions / Kaizens Per Employee Total= 20
(iii) Trends of number of suggestions implemented / employee / month?
(show last one year trend in line graph , illustrate it with your internal
Target line.). (5)
Formula
Total suggestions + Kaizen Implemented in that month
Suggestions / Employee = X 100
Total direct employees ( Operatives ) for the month
(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)

21. Work Environment and employee engagement
(1.C) Absenteeism Total= 10
(i) Provide results on absenteeism,? 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 forums are available for employees to share grievances ? What efforts organization takes to reduce absenteeism? ( 5 )

22. Work Environment and employee engagement
(1.D) TRAINING Total= 10
(i) Is training and development opportunities available ? ? 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? Mention benefits of Training : Tangible ( in Rs. Lacs ) & Intangible : (Give details for TWO shining examples) : ( 5 )

23. Work Environment and employee engagement
(1.E) Small Group Activities Total= 15
Explain how company encourages small group activities : How do you promote small group activity culture ? How various SGs interact with each other ? Do small group participate in the Quality Conventions-Group/State level/National. Show certificates / trophy photographs. ( 10 )
(ii) How many active groups are present in the current year? % employee involvement In QC Activity? Please provide breakup between Permanent, Temporary, Contract employees as well as Direct and indirect personnel for the above. (Also show last three year trend in bar graph. ( 5 )
No. of Active groups

24. Work Environment and employee engagement
(1.F) SAFETY Total= 20
(i) 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 planned. (5)
(ii) How do you demonstrate preventive measures of accidents? What you have learnt from others / shared with others on Safety. (5)

25. Work Environment and employee engagement
(1.F) SAFETY Total= 20
(iii) What are the current accident levels? (Show last one year data in line graph). Please provide data of fatalities in last three years (10)
A) Frequency (nos.) Minor + Major both
B) Severity (man hrs. lost)
Formula
No. of accidents
Frequency rate = X 106
Total man hours
Formula
Total man-days lost
Severity rate = X 106
Total man hours

26. Work Environment and employee engagement
(1.G) Environment Management Total= 25
(i) What is the frequency of scrap disposal? (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 ? (5)

27. Work Environment and employee engagement
(1.G) ENVIRONMENT MANAGEMENT Total= 25
(iii) Please describe the practices of the company to reduce pollution? Do you measure Carbon Foot Print ? How do you measure it ? What is the score ? (5)
(iv) Please quantify the type and amount of effluents / pollutants
and their reduction over the years. Is an effluent treatment plant
mandated for your industry? If no, please describe the
Arrangements. Please show the trends of Water table measurements
(Monthly Level / Quality) (5)
(v) Mention two achievement of major improvements done to save environment. (5)

28. Work Environment and employee engagement
(1.H) Contribution of Company towards Nation building (10)
Please describe the practices of the company to support the implementation of the issues of national importance with respect to the following – but not limited to this. ( 1 Marks each )
S.No.
Sub-Topic
Actual Marks Obtained
5H.1
Have you encouraged implementation of Sarva Shiksha Abhiyan to key communities for education?
How are you improving the computer literacy of staff and workmen ( Mention in brief )
5H.2
How you develop ownership of the cleanliness of the neighborhood , improving the aesthetics around the company premises ( outside )
5H.3
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?
5H.4
Electric Vehicles readiness (Awareness and if applicable to your company, what steps are taken ). How the Company promotes the use of Electric vehicles or battery operated two or four wheeler?
 5H.5
Any specific CSR activity you have done in year If Yes, describe
Total

29. Work Environment and employee engagement
(1.H) Contribution of Company towards Nation building (10)
Please describe the practices of the company to support the implementation of the issues of national importance with respect to the following – but not limited to this. ( 1 Marks each )
S.No.
Sub-Topic
Actual Marks Obtained
5H.6
Have you supported any differently abled persons - % age employment provided and accessibility arrangements for differently abled persons
5H.7
Mention steps taken by the Company to reduce the usage of plastic in manufacturing and non manufacturing areas.
5H.8
National Solar & Water Mission - Have you installed Roof Top Solar energy collectors and have earned through net metering. Adoption of Rainwater harvesting?
5H.9
How do you support Make in India drive & skill development. (Import substitution , Entrepreneurship development , Tie ups with skill centers)
 5H.10
Do you have a policy for prevention of Child Labour? (As per POCSO Act 2012)
Total

30. Actual Marks ( for office use )
( For office use only )
Section 2
Customer Assessment
Total Marks = 100
S.N.
Sub topic
Total Marks
Actual Marks ( for office use ) %
2.A
Awards by Key Customers 15
2.B
Customer audit of QCD 20
2.C
Customer rating for Quality & Delivery 35
2.D
Feedback from Customer & analysis 30
TOTAL
100

31. 2. Customer Assessment (2.A) Customer Awards Total = 15
How you capture unspoken customer voice? ( 5 )
( ii ) Awards by Key Customers (10)
Note : If your Customer does not have a system of Awards , Mention what kind of supplier recognition is followed by Customer .

32. 2. Customer Assessment (2.B ) Customer audit for QCD Total= 20
(i) Does your key customers rate your performance on quality, cost and delivery regularly? If yes, what is the trend over last three years? , illustrate it with your internal Target line (20)
Note : If your Customer does not have a audit system , Mention what kind of supplier audit system and scoring is followed by Customer .

33. 2. Customer Assessment
(2.C ) Customer rating for Quality & Delivery Total= 35
(i) What are changes you have made in last year in your operating system to improve QCD customer audit score? (20)
( ii) Mention here two shining examples / major improvements done by your company to improve % QCD customer audit score where your customer is happy on your actions. (15)

34. 2. Customer Assessment
(2.D ) Feedback from Customer & analysis Total=30
(i) Please describe system of getting feedback from the customers? (10)
(ii) How do you sensitise employees towards customer issues and how do you motivate them for faster response? how do you analyze this feedback and take actions in weak areas? Explain with two shining examples. (10)
(iii) Please provide information on new Business won / lost during the year (%age, analysis and actions taken). Please highlight the efforts to improve the competitive advantage of the company with respect to competition. (10)

35. Actual Marks ( for office use )
( For office use only )
Section 3
Quality Performance
Total Marks = 350
S.N.
Sub topic
Total Marks
Actual Marks ( for office use ) %
3.A
Customer Complaints 50
3.B
In-House Rejection & Rework 90
3.C
Supplier Rejection 40
3.D
Warranty Rejection
3.E
Cost of Poor Quality 30
3.F
Process Improvement
3.G
Quality Management
TOTAL
350

36. Customer Complaint 3. Quality Performance
(3.A) Customer Complaints Total= 50
(i) Please describe method of capturing customer complaints? Also describe the preventive approach adopted to avoid customer complaints. How these approaches differ with respect to new products Vs existing products (10)
(ii) What is the trend of the customer complaints in numbers? (Show last one year data in line graph , illustrate it with your internal Target line.) (10)
Customer Complaint

37. 3. Quality Performance (3.A) Customer Complaints Total= 50
(iii) Is the Customer complaint data analysis done? (E.g.—Product wise, Customer wise, Process wise, etc). Explain with an example. (10)
(iv) Is analysis of repeated Customer complaints carried out? Explain with an example ? Provide key complaint management results [internal as well as external] (5)

38. 3. Quality Performance (3.A) Customer Complaints Total= 50
(v) Explain the efforts to reduce customer complaints? (10)
(vi) Enclose examples of countermeasure report on Customer complaints. (5)

39. 3. Quality Performance (3.B) In-House Rejection & Rework Total= 90
(i) How rejection is captured at your company, at final inspection (end of line) or at every process step? Describe the preventive approach to rejection & rework & other quality losses & wastes. (10 )
(ii) 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) (20)
(iii) Please describe the actions taken to reduce the in- house rejection?
(10)

40. 3. Quality Performance (3.B) In-House Rejection & Rework Total= 90
(iv) Provide example of actions by which you are able to achieve zero defect at In-house rejection (10)
S.N.
Defect
Before PPM
After PPM
Actions Taken 1 2 3 4
(v) 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.) (20)

41. 3. Quality Performance (3.B) In-House Rejection & Rework Total= 90
Explain efforts taken to reduce rework (10)
(vii) Please give details of action taken to reduce rework? (10)
S.N.
Rework
Before PPM
After PPM
Actions Taken 1 2 3 4

42. 3. Quality Performance (3.C) Supplier Rejection Total = 40
Show the trend of your incoming supplier rejection (PPM) ( in last year in bar graph.) (20)
(ii) Please describe the efforts to reduce the supplier rejection?
Please describe the preventive efforts taken and encouragement to supplier participation in supplier process finalisation and approval.
Please describe the role of automated inspection, Poka yoke and
use of PPAP for process approvals. (10)

43. 3. Quality Performance (3.C) Supplier Rejection Total= 40
(iii) Provide example of actions by which you are able to achieve zero defect at Supplier end (10)
S.N.
Defect from Supplier
Before PPM
After PPM
Actions Taken 1 2 3 4

44. 3. Quality Performance (3.D) Warranty Rejection Total= 50
(i) What are the trends of the warranty ? (show last 3 year data in bar Graph , illustrate it with your internal Target line.) (30)
Note : If warranty is Not applicable for your products , Mention in place of Graph
(ii) Please describe the efforts to reduce the warranty rejection
Also please describe the preventive approach to warranty elimination.
This could include control over design and test / validation and
Product Application approvals for new product introduction. (10).

45. Before After 3. Quality Performance (3.D) Warranty Rejection Total= 50
(iii) Provide example of actions by which you are able to achieve Zero warranty PPM (10)
S.N.
Warranty Defect
Before PPM
After PPM
Actions Taken 1 2 3 4
Before – After Photos
Before
After

46. Insert more rows, total 15 required
3. Quality Performance
(3.E) Cost of poor Quality ( COPQ) Total = 30
Show cost of poor quality trends for last three years (10)
(ii) Mention elements of Cost of poor quality and its trend for last 2 years.(10)
S.N.
COPQ Element
Before %
After %
Remarks 1 2 3 4 5
Insert more rows, total 15 required
(iii) Provide example of actions by which you are able to reduce COPQ ( 10 )

47. 3. Quality Performance (3.F) Process Improvement Total= 40
(i) How company identifies Critical to Quality characteristics (CTQ) ? How do decide on your process control measures. (10)
How are CTQs monitored on daily basis and what are the escalation mechanisms? Who has the authority to stop production if CTQ is out of control? What controls are established for 5M changes?

48. Customer Complaints for
3. Quality Performance
(3.F) Process Improvement Total= 40
(ii) What are your process control metrics ? Does the company insist on Cpk performance for CTQ characteristics? What is the present level of Process capability (Cpk) for CTQ’s identified and controls ? (15)
S.N.
CTQ Para-meter
Customer Complaints for
Not Monitored
Cpk <1.33
Cpk >1.33 <1.67
Cpk >1.67
Present Control 1 2 3 4 5 6
(iii) What steps are taken to improve process capability greater than 1.67? Provide key process matrices results ( 5 )

49. Before After Before After 3. Quality Performance
(3.F) Process Improvement Total= 40
(iv) Show Shining examples of process improvements ( 10 )
Explain with text and Photographs .
Before – After Photo
Before
After
Before
After

50. 3. Quality Performance (3.G) Quality Management Total= 50
(i) How is the quality of safety critical parts ensured on periodic basis? ( 5 )
(ii) Are process / engineering changes also validated and documented? ( 5 )
(iii) How company identifies need for Poka-Yoke ? ( 10 )

51. 3. Quality Performance (3.G) Quality Management Total= 50
(iv) What % of CTQs are controlled by Poka Yoke? (5)
% =
(v) What % of Customer complaints are closed by Poka Yoke in ? (5)
% =
(vi) How do you ensure effectiveness of Poka yoke? (5 )

52. Before After 3. Quality Performance (3.G) Quality Management Total= 50
(vii) Show innovative examples of poka-yokes & Effect on overall Rejection of that Product ( 15 )
S.N.
Product
Before Rejection PPM
After Rejection PPM
Poka-yokes done 1 2 3 4
Before – After Photo
Before
After

53. Productivity Performance
( For office use only )
Section 4
Productivity Performance
Total Marks = 300
S.N.
Sub topic
Total Marks
Actual Marks ( for office use ) %
4.A
Manpower Productivity 75
4.B
Manufacturing Process Improvement
100
4.C
Inventory Management
4.D
Loss of production Hours 50
TOTAL
300

54. 4. Productivity Performance
(4.A) Manpower productivity Total= 75
(i) How do you measure productivity ? How do you decide on Productivity targets ? (5)
(i) What is the productivity trend. Show for your key business line ? (show last 3 year data in Bar graph , illustrate it with your internal Target line (10)
(ii) What are the tools used to improve manpower productivity ? (10)

55. Before After 4. Productivity Performance
(4.A) Manpower Productivity Total= 75
(iii) Show innovative examples of Manpower productivity improvements ( 20 )
S.N.
Operation
Before ( Production / Day )
After ( production / Day )
Actions Taken 1 2 3 4
Before – After Photo
Before
After

56. 4. Productivity Performance
(4.A) Manpower Productivity Total= 75
(i) What % of operators are handling more than one machine? Illustrate it with your internal Target line. (20)
(ii) What opportunities employee have for learning and sharing ? How Company encourages employees for operating multi-machines ? (10)

57. 4. Productivity Performance
(4.B) Manufacturing Process Total= 100
(i) Do you follow Single piece flow or batch flow layout or a mixture of both? Show present material flow for your key business line? (30)
Single piece flow = % , Batch Flow =
Photo
Photo
(ii) Mention in brief, how changes affected in performance of company? (e.g. if improvements in layouts done last year, elaborate benefits of layouts change such as reduction in - material travel distance / manufacturing lead time / WIP etc.) (30)

58. 4. Productivity Performance
(4.B) Manufacturing Process Total= 100
(iii) How process cycle times are reduced ? Share examples (20)
S.N.
Operation
Before Cycle Time
After Cycle Time
Actions Taken 1 2 3 4
(iv) Is planning for safety / quality an integral part of the overall production planning process? Is FMEA carried out during planning stage? (20)

59. 4. Productivity Performance
(4.C) Inventory Management Total= 75
(i) Show the trend of ITR (Inventory Turn Ratio) last three years , illustrate it with your internal Target line. (50)
Formula
Material cost of sales for the month x 12
ITR =
(RM + WIP + FG ) on last day of the month
(ii) Show actions taken to reduce inventory . (25)
S.N.
Products
Before Inventory in days
After Inventory in days
Actions Taken 1 2 3 4

60. 4. Productivity Performance
(4.D) Loss of Production Hours Total= 50
(i) Provide your equipment maintenance plan ? What are the measures tracked for equipment up time ? How much is machine breakdown loss in % of total available time? (Bar graph, illustrate it with your internal Target line ) (20)
(ii)  Show Actions taken to reduce break downs (10)
S.N.
Breakdown
Before Breakdown in a month
After Breakdown in a month
Actions Taken 1 2 3 4

61. 4. Productivity Performance
(4.D) Loss of Production Hours Total= 50
(iii) How much is the Setup loss in % of total available time? (Bar graph, illustrate it with your internal Target line ) (10)
(iv)  Show Actions taken to reduce Setup time (10)
S.N.
Set up
Before
After
Actions Taken 1 2 3 4

62. Actual Marks ( for office use )
( For office use only )
Section 5
Cost Performance
Total Marks = 100
S.N.
Sub topic
Total Marks
Actual Marks ( for office use ) %
5.A
Energy Saving 10
5.B
Value Addition / Net Sales 30
5.C
Value Addition / Fixed Assets
5.D
Value Addition / Employee Cost
TOTAL
100

63. 5. Cost Performance (5.A) Energy Savings Total= 10
(i) Show energy consumption as % Sales, illustrate it with your internal Target line. (5)
(ii) Show examples to reduce energy consumption (5)
S.N.
Item
Before
After
Actions Taken 1 2 3 4

64. 5. Cost Performance (5.B) Value Additions / Net Sales Total= 30
(i) Show the trend of value addition / net sale, last three years in bar graph, illustrate it with your internal Target line. (15)
Formula
Net Sales – Variable Cost
Value Addition to Net Sales =
Net Sales
(ii) What efforts to improve value addition / net sales? (15)

65. 5. Cost Performance (5.C) Value Additions / Fixed Assets Total= 30
(i) Show the trend of last three years in bar graph of value addition / fixed assets, illustrate it with your internal Target line. ( 15 )
Formula
Net Sales - Variable Cost
Value Addition to Fixed Assets = Total Cost of Fixed Assets
(ii) What efforts to improve value addition / fixed assets ? (15)

66. 5. Cost Performance (5.D) Value Additions to Employee cost Total= 30
(i) Show the trend of last three years in bar graph of value addition to Employee Cost , illustrate it with your internal Target line. (10)
Formula
Sales –Variable Cost
Value Addition to Employee Cost =
Total Employee Cost ( CTC )
(ii) What efforts to improve value addition to Employee Cost ? (10)
(iii) Please describe the efforts taken to improve the cost aspect of 4M
1. Material utilisation / consumption & yield
2. Machine output / cycle time improvement
3. Automation of manual work
4. Business process optimisation to improve efficiency
Give shining examples of each (10 Marks)

67. Summary of Achievements ( Company has to fill up )
for the year
( Company has to fill up )
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?