ACMA Awards 2017 18 Excellence in Automation PM44F

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 Year of Inception: 1966 Excellence in Automation Company Name : Plant Location : Award Category Tick mark in appropriate box as per your ‘Company Group Turnover for 2017 -18’. Medium Large Very Large > INR 30 to 100 Cr > INR 100 to 500 Cr > 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 2017 -18 1

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 For Technical Queries: For Administrative Queries: Mr. Uday Harite Email – uday. harite@acma. in Mobile – 8149099959 Mr. Rupesh Somania Email – rupesh. somania@acma. in Mobile – 9992603010 Mr. Atul Gupta Email – atul. Gupta@acma. in Mobile – 9971888751 Ms. Sakshi Karkamkar Email – sakshi. karkamkar@acma. in Mobile – 7387002181 Mr. Binny Tomy Mr. Vishal Saxena Email – Vishal. saxena@acma. in Email- binny. tomy@acma. in Mobile- 9711138869 Mobile – 9650988154 Ms. Ekta Agrawal Email- ekta. agrawal@acma. in Mobile - 9657657258 Ms. Smita Kulkarni Email – smita. kulkarni@acma. in Mobile – 9922922500 ACMA Centre for Technology (ACT) Godrej Eternia-C, ‘B’ Wing, '10 th Floor, Office No. - C, Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar , Pune – 411005, India, Desk phone – 020 66061219 act@acma. in www. acma. in , www. digitalact. in 2

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 Letter for Submission of Award application Company letterhead details ( Logo , Address ) To , The Secretariat ( ACMA Awards ) , ACMA Centre for Technology Godrej Eternia, ”B” Wing , 10 th Floor, Office No. C, Old Mumbai –Pune Highway, Wakdewadi , Shivaji Nagar Pune – 411005, India We are pleased to submit the application for ACMA Award 2017 -18 for Excellence in Automation in 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 2014 -15 2 2015 -16 3 2016 -17 Note – 1) If you have applied & won multiple awards in one year, please mention accordingly. 3

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 Automotive Component Manufacturers Association of India 6 th Floor, The Capital Court Olof Palme Marg, Munirka New Delhi - 110 067, 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 4

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 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 : 3 Chief Executive (Site) details : Name : Mobile : Website: Designation : E-mail : 4. Plant Head ( Next to Chief Executive (Site)) details : Name : Mobile : Designation : E-mail : 5. HR Head details : Name : Mobile : Designation : E-mail : 6. Training Head details : Name : Mobile : Designation : E-mail : (If Sr. No. 3 & 4 are same , then provide next level person details at Sr. No. 4 ) 5

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 Company’s Details 7. Company Group Annual Sales Turnover (in INR Cr. ) for Year 2017 -18: 8. Plant (for which application is submitted) turnover ( in INR Cr. ) for Year 2017 -18 : 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 : 6

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 Company / Plant Information Use this slide to brief about your company / Plant. It includes Product names / photos, Plant facility photographs. 7

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 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 : E-Mail : Mobile : Contact Person Information: ( Need to Contact if above person is not available) Name : Designation : E-Mail : Mobile : 8

9 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 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 ekta. agrawal@acma. in 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) 1 2 3 Customer key persons name Mobile Number & Email Manufacturing Head Incoming Quality Head Note- In addition to application & your site diagnosis , Supplier feedback scores will be also considered for final scores. 9

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 Key Performance Indicators (KPIs) KPI Sheet for Excellence in Automation Target Value Remar 2015 - 2016 - 2017 - for ks 16 17 18 201718 Actual Value S. No. KPI Uo. M 1 % of Machines automated % 2 Number of pick and place devices Nos 3 Number of Robos ( Cobos ) Nos 4 % of inspection points automated % 5 % of Manpower saved due to automation % 6 % of saved manpower re-deployed % 7 WIP in days 8 Number of patents applied for automation Nos 9 No. of patents Awarded for automation Nos 10 Customer Complaints Nos 11 Customer Returns PPM 12 In house rejection PPM % 14 Sales Turnover INR CR 15 Export Sales Turnover INR CR 16 ROI of automation ( Number of years ) Years Nos 18 Number of accidents per year Nos 19 Employee Absenteeism ( Total ) % 20 Employee Satisfaction Score % 21 Customer Satisfaction Score % 22 Delivery Performance % PPM Nos 13 Machine Breakdowns 17 Productivity Trend - No. of Products/ Man/ Year 23 Supplier Rejection 24 Number of Experts developed for automation 25 Awards won for Automation case studies 10

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 Executive Summary A. 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 -Business Strategy Area 2 -Automation Process Area 3 -Automation Results Area 4 –Stakeholders Delight Area 5 - Nation delight B. Key differentiator (Mention here few points which makes you to stand as a winner ) C. How you are a better employer compared to others ? ( Mention in brief ) 11

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 Status of actions taken by your company based on previous ACMA Awards feedback report. (Mention top 5 only) (Not applicable- for 1 st time applicants)’ S. N. Area of Action taken Improvement 12 Result / Outcome

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 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 13

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 ( 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 1 Business Strategy 150 2 Automation Process 250 3 Automation results 300 4 Stakeholders delight 200 5 Nation delight 100 Total 1000 14 Actual % Marks ( for Office Use only )

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 ( For office use only ) Section 1 Business Strategy Total Marks = 150 S. N. Sub topic Total Marks 1. A Automation Vision 30 1. B Automation Road map 30 1. C Automation teams 30 1. D ROI of Automation 30 1. E Automation Capability development TOTAL 15 30 150 Actual % Marks ( for office use )

1 6 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 1. Business Strategy (1. A) Automation Vision (i) Total = 30 Please enclose your Automation Objectives ( 10 ) (ii) How automation objectives are inline with your company vision ? (10 ) (iii) How you arrive at automation Objectives ? (5 ) (iv) Is your automation drive is customer driven? (3) (v) Is automation drive is JV Driven ? Mention NA if your do not have JV driven activity . (2) 16

1 7 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 1. Business Strategy (1. B) Automation Roadmap (i) Total = 30 Do have road map for automation ? If Yes , kindly attach as photo. If there is no Road map , then share your other document for finalizing automation ? ( 10 ) (ii) How automation road map is derived ? Mention its process (10 ) (iii) How often you revise Automation road map ? Provide few recent examples of such revisions (10 ) 17

1 8 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 1. Business Strategy (1. C) Automation Teams (i) Total = 30 Do you have separate teams for Automation ? If yes , Mention in short , roles of each person. ( 10) (ii) Is this teams work full time / Part time on Automation (5) (iii) What kind of qualification your teams have ? ( e. g. Automation Degree , Certifications etc. ) (10 ) (iv) What is the motivation Management provides for these team members ? ( 5 ) 18

1 9 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 1. Business Strategy (1. D) ROI of Automation (i) Total = 30 How do you calculate ROI of Automation. ( 10) (ii) How much years do you consider OK for ROI (5 ) (iii) When ROI is beyond your policy , do you still automate ? If Yes , then what parameters are considered for this type of automation ( e. g. Safety , Quality or you may add -- Provide few examples (5 ) (iv) Share 2 glaring examples where you have done automation beyond ROI within your targets ( 10 ) 19

2 0 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 1. Business Strategy (1. E) Automation capability Development (i) Total = 30 How do you develop capability for Automation ( e. g by training people / sending them for OJT outside / ? ) ( 10) (ii) How do you certify capability of these people ? (5 ) (iii) Did you set up Automation Lab inside your company or any other location ? If yes , what facilities are installed ? , If NO , then do you have any ties ups with some service providers ? (5 ) (ii) How much content of automation is from inhouse talent and how much is outsourced ? ( 10 ) 20

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 ( For office use only ) Section 2 Automation Process Total Marks = 250 S. N. Sub topic Total Marks 2. A Need for automation 50 2. B Steps of automation 50 2. C Concept designs 50 2. D Proving of Concept designs 2. E Success / Failures of concepts 50 TOTAL 21 50 250 Actual % Marks ( for office use )

2 2 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 2. Automation Process (2. A) Need for automation (i) Total = 50 How do you decide need for automation ? Mention your present process to arrive for automation with few examples ( 20) (ii) Do you use benchmarking process with other companies / competitors for automation ? If yes , then share some areas used for benchmarking , If NO , then how do you decide that this automation is the best ? Share your views (15 ) (iii) What are the important advantages you look for due to automation ? (5 ) (iv) Do you have a structured document for finalizing automation ? IF yes , Share its image (Data is optional) ( 10 ) 22

2 3 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 2. Automation Process (2. B) Steps for Automation (i) S. N. Total = 50 What are the steps you follow for automation ? Share steps and training topics/ techniques for each step considered for training teams ( 25) Steps for automation Support training topics / techniques 1 2 3 ADD 20 ROWS (ii) How do you ensure completion of each step ? Do you use any process to validate each step , if yes , Mention 5 glaring examples. (25 ) 23

2 4 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 2. Automation Process (2. C) Concept Designs Total = 50 (i) How do you generate ideas for automation ? ( 10) (ii) How do you validate these ideas ? ( e. g By Computer simulation / prototype ) (10 ) (iii) Which software do you have for computer simulation and how much is the variance for Computer simulation with actual is accepted ? ( 10 ) (iv) How many iterations are normally made to finalize the concept and why ? Give few examples ( 5 ) (v) Are you doing risks analysis of automation ? Explain with few examples of analysis ( e. g. Risk of line stoppage , Risk of breakdowns ) ( 15 ) 24

2 5 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 2. Automation Process (2. D) Concept Proving (i) Total = 50 How much is the lead time from concept generation to concept proving ? ( 10 ) (ii) What efforts you have taken to reduce lead time and how much you were able to achieve ? Mention with 2 examples (20 ) (iii) How many levels do you use to prove the concept before handing over to production ? Mention in details various observation and actions taken. ( e. g. Automation team / Production Supervisor / Operator ) ( 20 ) 25

2 6 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 2. Automation Process (2. E) Success / failures of Concepts (i) Total = 50 What % of concepts are successful compared to actual (10) (ii) Do you have any major failures in this stage and if yes , why this happened ? ( Wrong designs / Wrong simulation / any other ). Are you updating FMEA after automation ( 10 ) (iii) How do you ensure that these failures are not repeating in future ? Mention 2 examples ( 20 ) (iv) Do you maintain a failure directory for this ? Share one sample (10 ) 26

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 ( For office use only ) Section 3 Automation Results Total Marks = 300 S. N. Sub topic Total Marks 3. A Automation areas 80 3. B Safety results 40 3. C Quality results 50 3. D Productivity Results 50 3. E Business growth 80 TOTAL 27 300 Actual % Marks ( for office use )

2 8 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 3. Automation Results (3. A) Automation Areas (i) Total = 80 Mention % of automation as per following table you have implemented and its benefit ( 60 ) S. N. Automation Area Total Opportuni ties Opportunitie s completed % automated Benefits 1 Loading 20 10 50 % Manpower saving 2 Unloading 20 20 100 % 3 Auto transfer 4 Auto input checking 5 Auto output checking 6 Clamping 7 Unclamping 8 Cleaning 9 Data recording 10 Tool life monitoring You may add more areas Total 28

2 9 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 3. Automation Results (3. A) Automation Areas Total = 80 (ii) Share 2 examples for each automation area with before after photos ( 20 ) 29

3 0 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 3. Automation Results (3. B) Safety results (i) Total = 40 What issues were there before automation related to safety and how you have improved ? Mention in brief and share 2 to 3 photos ( 20 ) (ii) Number of accidents before and after automation ? And how safety is ensured for automation ? Mention with 2 examples ( 20 ) Before Automation / year = After automation / Year = 30

3 1 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 3. Automation Results (3. C) Quality results (i) Total = 50 What issues were there before automation related to Quality and how you have improved ? Mention in brief and share 2 to 3 photos ( 20 ) (ii) Share rework & rejection data for before and after automation ? ( 30 ) Rework Before Automation / year = PPM Rework After automation / Year = PPM Rejection Before Automation / year = PPM Rejection After automation / Year = PPM 31

3 2 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 3. Automation Results (3. D) Productivity results (i) Total = 50 What issues were there before automation related to Productivity and how you have improved ? Mention in brief and share 2 to 3 photos ( 20 ) (ii) Share Productivity / per man data ? ( 20 ) No. of Components Before Automation / day = Nos No. of Components After automation / day = Nos (iii) Share 2 best examples of cycle time reduction (10 ) 32

3 3 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 3. Automation Results (3. E) Business Growth (i) Total = 50 Mention in brief , how automation has helped for Business Growth ( 20 ) (ii) % of additional Sales turnover due to automation ? (20) (iii ) Total sales turnover before and after automation ( 10 ) 33

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 ( For office use only ) Section 4 Stakeholders Delight Total Marks = 200 S. N. Sub topic Total Marks 4. A Manpower Utilization 50 4. B Employee satisfaction 50 4. C Customer satisfaction 50 4. D Plant upkeep 50 TOTAL 34 200 Actual % Marks ( for office use )

3 5 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 4. Stakeholders delight (4. A ) Manpower utilization (i) Total = 50 As a result of automation what % of manpower is saved ( 20 ) (ii) How much % of saved manpower is re-deployed ? (10 ) (iii) How this change is accepted by employees and are there any obstacles you faced and how you handle this ? Mention in Brief ? (10 ) (iv) Do you plan is advance for saving of manpower redeployment prior to automation or after automation ? ( 10 ) 35

3 6 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 4. Stakeholders delight (4. B ) Employee Satisfaction Total = 50 (i) Do you measure employee satisfaction for Automation ? If yes , mention satisfaction levels , If No , then how you ensure that automation is helping employees ? ( 10 ) (i) Share 5 feedbacks from employees regarding automation (10 ) (iii) What % of ideas employees have given for automation and what % you have implemented ? ( 10 ) (iv) Share top 2 employee ideas for automation (10 ) (v) What recognition you have for employees contributing to automation (10 ) 36

3 7 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 4. Stakeholders delight (4. C ) Customer Satisfaction Total = 50 (i) Do you measure Customer satisfaction for Automation ? If yes , mention satisfaction levels , If No , then how you ensure that automation is helping Customers ? ( 10 ) (i) Share 5 feedbacks from Customers regarding automation (10 ) (iii) What is trend of customer complaints before and after automation ? ( 20 ) (iv) Share top 2 Customer complaints / issue resolved due for automation (10 ) 37

3 8 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 4. Stakeholders delight (4. D ) Plant Upkeep Total = 50 (i) How automation heled you to improve plant upkeep ? Mention in brief with text and photos ( e. g. Layout improved ? ( 20 ) (i) Is there any effect on Inventory , If Yes , then mention its effect (10 ) (iii) What impact is noticed on material handling / storage ? (10) (iv) Is there any space saving due to automation ? (10 ) 38

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 ( For office use only ) Section 5 Nation Delight Total Marks = 100 S. N. Sub topic Total Marks 5. A Impact of Automation 10 5. B Net savings 40 5. C Horizontal Deployment 30 5. D Sharing with others 20 TOTAL 39 100 Actual % Marks ( for office use )

4 0 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 5. Nation delight (5. A ) Impact of Automation (i) Total = 10 In your views , what is the major impact of automation for you ( 5 ) (ii) Have you applied for patents for automation ? Mention in brief (5 ) 40

4 1 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 5. Nation delight (5. B ) Net savings (i) Total = 40 As a result of automation , what are the net savings and in which areas ( 30 ) S. N. Saving area Per year Saving in INR Lakhs 1 Manpower 20 2 Energy 20 3 Quality 4 Pl add Total (ii) What efforts are there to increase these savings for next project , Mention in Brief (10 ) 41

4 2 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 5. Nation delight (5. C ) Horizontal Deployment (i) Total = 30 As a result of automation , what are the net savings and in which areas ( 20 ) S. N. Manufacturing Line / area 1 Line 1 2 Line 2 Target date for automation 3 4 (ii) How horizontal deployment is carried ? E. g. Designing automation outside shop floor ? (10 ) 42

4 3 ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 5. Nation delight (5. D ) Sharing with others (i) Total = 20 How you are sharing your automation to your supply chain ? Mention in brief ( 5 ) (ii) Share 2 improvement from your supplier end ? (5 ) (iii) How do you motivate your supply chain for automation ? (5 ) (iv) Do you support financially to your suppliers for automation ? (5) 43

ACMA Awards 2017 -18 : Excellence in Automation PM_44_F 41, Rev No. 00 Summary of Achievements for the year 2017 -18 ( Company has to fill up ) 1. What are unique things about your company for considering “ACMA consistent performing Company” 2. What are challenges for you in the future and how are you preparing for it? 44