1. 2014-15 ACMA Awards Company Name : Plant Location : Category : Small Excellence in Quality & Productivity

2. Index ( For office use only except page no. ) S.N.SectionPage No. Max. MarksActual Marks 1 Work Environment & Employee Involvement. 75 2 Customer Expectations & Feedback 50 3 Quality Performance.165 4 Productivity Performance.160 5 Cost Performance.50 Total 500 For Administrative Queries: Mr. Jitender Rana Email – Jitender.rana@acma.inJitender.rana@acma.in Mobile – 09873369699 Ms. Sakshi Karkamkar Email – sakshi.karkamkar@acma.insakshi.karkamkar@acma.in Mobile – 07387002181 Mr. Binny Tomy Email- binny.tomy@acma.inbinny.tomy@acma.in Mobile- 9711138869 For Technical Queries: Mr. V K Sharma Email : vk.sharma@acma.in vk.sharma@acma.in Mobile : 09811392068 Ms. Sapana Baravkar Email : sapana.baravkar@acma.insapana.baravkar@acma.in Mobile : 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. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 3 Letter for Submission of Award application for 2014 - 15 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 – 411005, India We are pleased to submit the application for ACMA Award 2014-15 for Excellence in Quality & Productivity in Small 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 Between INR 50 to 150 Cr SmallNot Applicable Criteria for Small and Large Category : Small Category- Company Group Annual Sales Turnover Between INR 20 to 50 Cr Large Category- Company Group Annual Sales Turnover Between INR 50 to150 Cr

4. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 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- 3Chief 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. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 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. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 6 As a part of ACMA Award process, feedback from your major customers will be opted 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 Customer Details S. NoCustomerLocatio n % 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. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 7 Use this slide to brief about your company / Plant. It includes Product names / photos, Plant facility photographs, Company / Plant Information

8. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 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. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 9 S. N. Area Total Marks Actual Marks ( for Office Use only ) % 1 Work Environment & Employee Involvement. 75 2 Customer Expectations & Feedback 50 3Quality Performance.165 4Productivity Performance.160 5Cost Performance.50 Total500 ( 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

10. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 10 Section 1 Work Environment & Employee Involvement. Total Marks = 75 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 1.ASafety20 1.BPlant Upkeep- Inside20 1.CPlant Upkeep- Outside20 1.DEmployee Involvement15 TOTAL75 ( For office use only )

11. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 11 1.Work Environment and employee involvement (i) Does system exists for Safety monitoring / review ? (10) (1.A) Safety Total= 20 (ii) Show last one year trend in line graph for number of accidents. (10)

12. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 12 (1.F) SAFETY Total= 20 1.Work Environment and employee engagement (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. (10) (ii) What you have learnt from others / shared with others on Safety. (5) (ii) Show last one year trend in line graph for number of accidents. (5)

13. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 13 1.Work Environment and employee involvement (iii) Show photographs of production line, raw material stores, finished goods store and employees wash room. (10) (1.B) Upkeep of the plant Inside Total= 20 (ii) What is your system to maintain upkeep of the plant Inside? What is the plan to take all the areas taken for must be facilities. ?(5) Production Line Employees Wash Room Finished Goods Stores Raw Material Stores (i) Is there a plan for must be facilities ? Which are the areas which are taken for plant upkeep ? (5)

14. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 14 1.Work Environment and employee involvement (ii) Show photographs of plant entrance, scrap yard, plant rear (back) side, canteen / dining area. (10) (1.C) Upkeep of the plant Outside Total= 20 (i) What is your system to maintain upkeep of the plant Outside? What is the plan to cover entire area for upkeep ? Have you done any bench marking to maintain the area. (10) Plant Entrance Canteen / Dining Area Plant Rear (Back) Side Scrap Yard

15. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 15 1.Work Environment and employee involvement (1.D) Employee Involvement Total= 15 (i) How company involves employees (mention areas like QCC, Kaizen, Quality Improvement, Cost reduction etc)? What forums are available for employees to share their ideas ?(5) (iii) What is your employee involvement in improvement activities? Provide employee satisfaction results (5) (ii) How do you take inputs from your employees for Process improvements / Quality improvements ? How company motivates employees (rewards / suggestions schemes etc.)? (5)

16. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 16 Section 2 Customer Expectations & Feedback Total Marks = 50 ( For office use only ) S.N.Sub topic Total Marks Actual Marks ( for office use ) % 2.A Understanding of Customer need 20 2.B Customer Complaints- Exports 20 2.C Customer Complaints- Analysis 10 TOTAL50

17. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 17 (i) How do you listen to customer ? How customer issues are communicated and action taken ? (10) (2.A) Understanding of Customer Need Total= 20 2. Customer Expectations & Feedback (ii)Are the customer defined technical specifications clearly understood? How do you sensitise employees towards customer issues and how do you motivate them for faster response?(10)

18. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 18 (i ) Show last one year trend in line graph for number of customer complaints. (20) (i) Mention actions taken to eliminate customer complaints if any. How do you ensure proactive corrective measures in future applications (10) (2.B) Customer Complaints Total= 20 (2.C) Customer Complaints- Analysis Total= 10 2. Customer Expectations & Feedback

19. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 19 Section 3 Quality Performance Total Marks = 165 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 3.ACustomer Complaints25 3.B In-House Rejection & Rework 50 3.CSupplier Rejection20 3.DWarranty Rejection20 3.EProcess Improvement25 3.FPoka-Yokes25 TOTAL165 ( For office use only )

20. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 20 (i) Please describe method of capturing customer complaints? (5) (ii) What is the trend of the customer complaints in nos? (Show last one year data in line graph. (10) (3.A) Customer Complaints Total= 25 3. Quality Performance

21. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 21 (iii) Is the Customer complaint data analysis done? (E.g.—Product wise, Customer wise, Process wise, etc). Explain with an example. (5) (3.A) Customer Complaints Total= 25 3. Quality Performance (iv) Provide key complaint management results [internal as well as external] (5)

22. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 22 (3.B) In-House Rejection & Rework Total= 50 3. 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) (15) (ii) Please describe the actions taken to reduce the in- house rejection. How do you train employees to meet product quality ? Provide key product quality results(10)

23. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 23 (iv) Explain efforts taken to reduce rework. Provide key process matrices results : (10) ((3.B) In-House Rejection & Rework Total= 50 3. Quality Performance (iii) 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) (15)

24. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 24 4. Quality Performance (3.C) Supplier Rejection Total = 20 (i)How do you measure supplier quality [quality of everything about supplier] how do you give feedback to your vendor provide key vendor related results (10) (ii) How do you align vendor with your strategic objectives. Explain your ongoing vendor audit process Please describe the efforts to reduce the supplier rejection? (10 )

25. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 25 (ii) How do you ensure outgoing product quality ? How do you compare your quality with that of your competition ? Please describe the efforts to reduce the warranty rejection (10) (3.D) Warranty Rejection Total= 20 3. Quality Performance (i) What are the trends of the warranty ? (show last 3 year data in bar Graph, illustrate it with your internal Target line) (10) Note : If warranty is Not applicable for your products, Mention in place of Graph

26. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 26 (3.E) Process Improvement Total= 25 3. Quality Performance S.N.S.N. CTQ Param eter C ustomer Complain ts for 2014 - 15 Not Monit ored Cpk < 1.33 Cpk > 1.33< 1.67 Cpk > 1.67 Present Control 1 Hole 10 mm dia 0100 % Inspection 2Bore 25 mm dia 1Sampling done 3 4 5 6 (ii) What are your process control metrics ? What is the present level of Process capability (Cpk) for CTQ’s identified and controls ? (5) (i) How company identifies Critical to Quality characteristics ( CTQ ) ? How do decide on your process control measures(5)

27. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 27 (iii) How do you update or upgrade your process for improvement ? What steps are taken to improve process capability greater than 1.67? Provide key process metrics results( 5 ) Explain with text and Photographs. (3.E) Process Improvement Total= 25 3. Quality Performance BeforeAfter BeforeAfter Before – After Photo

28. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 28 (3.E) Process Improvement Total= 25 3. Quality Performance (v) Are process changes / engg changes validated and documented? (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)

29. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 29 (i) How company identifies need for Poka-Yoke ? ( 7) (ii) What % of CTQs are controlled by Poka Yoke? (5) % = (3.F) Poka-yokes Total= 25 3. Quality Performance (ii) What % of Customer complaints are closed by Poka Yoke in 2014-15 ? (5) % =

30. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 30 (iii) Show innovative examples of poka-yokes & Effect on overall Rejection of that Product ( 8) (3.F) Poka-yokes Total= 25 3. Quality Performance S.N.ProductBefore Rejection PPM After Rejection PPM Poka-yokes done 1 2 3 4 Before – After Photo Before After

31. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 31 Section 4 Productivity Performance Total Marks = 160 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 4.A Manpower Productivity 25 4.B Manufacturing Process Improvement 20 4.C Inventory Management 30 4.D Utilization of Operators 30 4.E Machine Break Down 20 4.F Loss of production Hours 35 TOTAL160 ( For office use only )

32. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 32 (4.A) Manpower productivity Total= 25 4. Productivity Performance (i) How do you measure productivity ? How do you decide on Productivity targets ? (5) (ii) 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)

33. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 33 (4.A) Manpower Productivity Total= 25 4 Productivity Performance (iii) What is the roll of QC/SG in productivity improvement ? How do you motivate employees for improving productivity ? Show innovative examples of Manpower productivity improvements ( 10 ) S.N.OperationBefore ( Production / day ) After ( production / Day ) Actions Taken 1 2 3 4 Before – After Photo Before After

34. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 34 (4.B) Manufacturing Process Total= 20 4. Productivity Performance Before After (i) Show improvements related to manpower productivity done last year, Show benefits of layouts change ( 10 ) Before : Material Travel = Meters ; Manufacturing Lead time = Mins ; WIP = Nos. After : Material Travel = Meters ; Manufacturing Lead time = Mins ; WIP = Nos.

35. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 35 (ii) How process cycle times are reduced ? Share examples (10) (4.B) Manufacturing Process Total= 20 4. Productivity Performance S.N.OperationBefore Cycle Time After Cycle Time Actions Taken 1 2 3 4 Before – After Photo Before After

36. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 36 (i) Show the trend of ITR (Inventory Turn Ratio) last three years, illustrate it with your internal Target line. (20) (4.C) Inventory Management Total= 30 4. Productivity Performance (ii) Show actions taken to reduce inventory. (10) S.N.ProductsBefore Inventory After Inventory Actions Taken 1 2 3 4 Formula Material cost of sales for the month x 12 ITR = ----------------------------------------------------------- (RM + WIP + FG ) on last day of the month

37. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 37 (i) what % of operators are handling more than one machine, illustrate it with your internal Target line? (20) (4.D) Utilization of Operators Total= 30 4. Productivity Performance (ii) How Company encourages employees for operating multi- machines ? (10)

38. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 38 (i) Provide your equipment maintenance plan ? What are the measures tracked for equipment up time ? What is the status of machine break downs? (10) (4.E) Machine Break down Total= 20 4. Productivity Performance (ii) How your maintenance team participate in achievement of strategic goals ? Share innovative examples for machine break down reduction? provide key maintenance related results (10)

39. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 39 (i) How much is machine breakdown loss in % of total available time? (Bar graph, illustrate it with your internal Target line ) (11) (ii) Show Actions taken to reduce break downs (8) (4.F) Loss of Production Hours Total= 35 4. Productivity Performance S.N.BreakdownBefore Breakdown After Breakdown Actions Taken 1 2 3 4

40. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 40 (4.F) Loss of Production Hours Total= 35 4. Productivity Performance (iii) How much is the Setup loss in % of total available time? (Bar graph, illustrate it with your internal Target line ) (8) (iv) Show Actions taken to reduce Setup time (8) S.N.Set upBeforeAfterActions Taken 1 2 3 4

41. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 41 Section 5 Cost Performance Total Marks = 50 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 5.AEnergy Saving10 5.BValue Addition / Net Sales20 5.C Value Addition / Employee Cost 20 TOTAL50 ( For office use only )

42. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 42 (5.A) Energy Savings Total= 10 5. Cost Performance (i) Show energy consumption as % Sales, illustrate it with your internal Target line. (5) S.N.ItemBeforeAfterActions Taken 1 2 3 4 (ii) Show examples to reduce energy consumption ( 5 )

43. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 43 (i) How do you track various cost ? Show the trend of last three years in bar graph, illustrate it with your internal Target line. ( 10 ) (5.B) Value Additions / Net Sales Total= 20 5. Cost Performance Formula Net Sales – Variable Cost Value Addition to Net Sales = ---------------------------------------------------- Net Sales (ii) How do you sensitise employees for costs and motivate them to participate in cost reduction drives ? What is the benchmark & efforts to improve value addition / Net sales? (10)

44. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) 44 (i) Show the trend of last three years in bar graph, illustrate it with your internal Target line. ( 10 ) (5.C) Value Additions to Employee cost Total= 20 5. Cost Performance (ii) What is the benchmark & efforts to improve value addition to Employee Cost ? (10) Formula Sales –Variable Cost Value Addition to Employee Cost = ------------------------------------------------------- Total Employee Cost ( CTC )

45. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) Summary of Achievements for the year 2014-15 ( Company has to fill up )

46. ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Small) For Company: Show your companies excellent photos