ACMA Awards 2018 19 Excellence in Manufacturing PM44F

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 ACMA Awards Year of Inception: 1966 Excellence in Manufacturing Company Name : Plant Location : Award Category: Tick mark in appropriate box as per your ‘Company Group Turnover for 2018 -19’. Small < 50 Cr Medium > INR 50 to 150 Cr Large > INR 150 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 2018 -19

ACMA Awards 2018 -19 : Excellence in Manufacturing 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.

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 For Technical Queries: For Administrative Queries: Mr. Arun Bage Email – arun. bage@acma. in Mobile – 9552532184 Ms. Sakshi Karkamkar Email – sakshi. karkamkar@acma. in Mobile – 7387002181 Mr. Atul Gupta Email – atul. gupta@acma. in Mobile – 9971888751 Ms. Smita Kulkarni Email – smita. kulkarni@acma. in Mobile – 9922922500 Mr. Vishal Saxena Email – vishal. saxena@acma. in Mobile – 9650988154 Mr. Sanket Jadhav Email- sanket. jadhav@acma. in Mobile- 7768046868 Ms. Tanu Ahuja Email – tanu. ahuja@acma. in Mobile – 09899237770 Ms. Surekha Deshmukh Email- S. DESHMUKH@unido. org Mobile- 9552599463 ACMA – Skilling and Mentoring 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

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 Letter for Submission of Award application Company letterhead details ( Logo , Address ) To , The Secretariat (ACMA Awards) , ACMA – Skilling and Mentoring 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 2018 -19 for Excellence in Manufacturing 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) 1 2015 -16 2 2016 -17 3 2017 -18 ACMA Awards Category. Applied Award / Certificate Won Note – 1) If you have applied & won multiple awards in one year, please mention accordingly. 2) If a plant has won Gold trophy in the year 2016 -17 or 2017 -18 in any of the above categories, then that particular plant will not be eligible to apply in the same category. But they can apply for any other categories.

ACMA Awards 2018 -19 : Excellence in Manufacturing 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

ACMA Awards 2018 -19 : Excellence in Manufacturing 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 ) 2. Plant Address : 3. Invoicing Details (Applicable only for shortlisted companies for site diagnosis): a) GST Numberb) Invoicing Address (write complete address with pin code)4. Chief Executive Officer details : Name : Mobile : Website: Designation : E-mail : 5. Plant Head details : Name : Mobile : Designation : E-mail : 6. HR Head details : Name : Mobile : Designation : E-mail :

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 Company’s Details 7. Company Group Annual Sales Turnover (in INR Cr. ) for Year 2018 -19: 8. Plant ( for which application is submitted) turnover ( in INR Cr. ) for Year 2018 -19 : 9. Year of Establishment : Group Company _______ , Plant ______ 10. Total Employees : Group Company ______ , Plant _______ 11. Do you have a Joint Venture for the plant applied: ( If Yes , Mention the partner name ) 12. Plant’s Key products : 13. Plant’s major manufacturing processes : Sr No Core Processes % Contribution in your business 1 Foundry 80 2 Machining 10 3 Others 10 14. Plant’s Key competitors : 15. Plant’s Major Certifications :

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 Company’s Details 16. Contact Person 1 Information : ( Need to contact thru out the process of ACMA Award ) Name : Designation : E-Mail : Mobile : 17. Contact Person 2 Information : ( Need to Contact if above person is not reachable) Name : Designation : E-Mail : Mobile : 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)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 Customer Details Mandatory requirement (not applicable for Excellence in Supplier Development category) 1. Kindly provide details of your top 3 business customers in below table. S. No Customer Name % Business share (for the plant ) Location 1 2 3 Details of contact person Name 1– Designation – Name 2– Designation Mobile Number & E mail 2. ACMA Award online application software automatically sends a link to all above email addresses to get feedback about your plant. 3. Kindly inform above persons from your side to respond ASAP & ensure that we receive this before you submit the application online. ( Your application will not processed without these feedback). Note: a) These feedbacks will be considered by Jury for evaluation & the same will be provided to you as a part of feedback report.

ACMA Awards 2018 -19 : Excellence in Manufacturing 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. 1 2 3 4 5 Area of Action Improvement taken Result / Outcome

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 Summary of Achievements for the year 2018 -19 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? Example Industry 4. 0 , IOT (Internet of things) etc

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 Abbreviation

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 Formulas

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 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 1 Hygiene Factor 200 2 HSE systems & Approach 150 3 HSE Deployment & Compliance 350 4 HSE Related Results 100 5 Business Results 200 Total 1000 Actual Marks % ( for Office Use only )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 OFFICE USE ONLY Section 1 Hygiene Factors Total marks =200 Sr Topic No. 1 A 1 B 1 C 1 D 1 E 1 F 1 G 1 H 1 I 1 J 1 K 1 L 5 S & Plant Upkeep Leadership Focus Quality Management Stakeholder Happiness Safety Employee Engagement Environment Protection Poka-yoke / KAIZEN Legal/Statutory Compliances Code of Conduct Wastages Reductions / Non Value Adding reduction Automation and Digitization in various activities Contribution towards Society & Nation Total Marks Total Obtain Marks ed 30 20 30 30 20 15 5 10 5 5 10 20 200 %

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. A) 5 S & Plant Upkeep (i) Total = 30 Mention in following chart status of Must be Facilities. (10 ) Questions are applicable for plant for which you have applied for ACMA Awards. In Status kindly mention %. E. g You have jogging track for 50 % areas , then write 50 % Must be facilities S. No. Description 1 Jogging track inside shop floor, along walls Trees in plant campus (86 Trees/ Acre) No earth should be visible in entire company area. There should be concrete, tar roads or green lawns No truck / fork-lift inside shop floor Clean toilet blocks inside shop floor, dry & smell free No nails to be used anywhere in the factory premises All employees to wear uniform, shoes and necessary safety gadgets Noise free DG sets & compressor Clean wash room / change room and rest room facilities Hygienic kitchen, drinking water & dinning hall Good recreational facilities 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Appropriate fire fighting equipment's should be placed at accessible locations Drive Forward Digitization - Team in place Shop floor- Well Ventilated Shop floor- Illumination (natural lighting) Nothing directly on floor across company Accessibility for differently abled persons (If Applicable) Mock Drill - conducted as per frequency ETP & STP in Well maintained condition Training & Learning Facility Logistics Centre Research Centre Resource Optimization - - Drive Team in Place Is your plant outside surroundings are clean Use of Non-conventional energy Status

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. A) 5 S & Plant Upkeep (ii) How you drive 5 S Process Total = 30 (10) Explain whether sub areas formed, Sub-Area Owners identified, 5 S Audit schedule & mechanism, NC clearance, Award for Best, Cross Audits or any other activities done. ( You may use Photos / Images to support this ) (iii) How you drive Workplace Ownership concept (4) Explain responsibilities of operating people to keep workplace surrounding Clean & Safe

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. A) 5 S & Plant Upkeep Total = 30 (iv) Shining examples of 5 S Improvements (3) Show 4 Photographs, Assessor may interview few operators for checking effectiveness (v) Share few sample audit findings & actions taken (3)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. B) Leadership Focus Total = 20 (i) When was your VMV ( Vision , Mission & Values ) Statement was formed ? Have you revisited it afterwards ? When? (2) (ii) How you Communicate VMV to your Stakeholders like Suppliers, Employees etc. (3)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. B) Leadership Focus Total = 20 (iii) What Process is followed forming Annual Business Plan i. e. Organizational Targets ? (6) Specify Process time schedule, inputs considered, competitors performance and Benchmarks, who all participate in the Process, whether the Targets are based on last year performance or market oriented, giving some examples of market oriented targets. Also specify, how the Stretched factor is considered during this process. Show KPI (Key Performance Indicators) of any one employee and explain how it is linked to Organizational target

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. B) Leadership Focus Total = 20 (iv) How frequently the Organizational Targets are reviewed ? and show action plans for any two Targets, which were below the expected level - few months prior to year end (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. B ) Leadership Focus Total = 20 (v) Please give information about all types of communication meetings taking place in your organization indicating frequency, major participants and major issues during these meetings (4) ( Assessor may verify with few employees about such meetings)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. C) Quality Management Total = 30 (i) Explain What actions have been taken in your organization to sensitize employees about Quality Culture (Defects should not go outside company – to - Defects should not get produced) (5) Specify Quality tool training, control gates, empowerment, problem solving training , next station is your customer etc. You may also show photographs of posters for awareness creation

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. C) Quality Management Total = 30 (ii) How you identify CTQs and show some examples of Process capability improvement for two identified CTQs (10)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. C) Quality Management Total = 30 (iii) Show examples of use of Quality Tools like Six Sigma Project, Poka-yoke, Do. E, Why-Why Analysis, 8 D etc. (15)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. D) Stakeholders Happiness Total = 30 (i) Show top 3 concern areas each from your Stakeholders like Customer / Suppliers / Employees and actions taken / planned for these concerns (10 ) Specify major dissatisfaction points received as feedback from these stakeholders

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors Total = 30 (1. D) Stakeholders Happiness (ii) Show score of Supplier Satisfaction for 3 years (10) 100 80 78 96 84 60 40 2016 -17 2017 -18 Supplier Satisfaction Score 2018 -19 Target (iii) What are the actions initiated during last year? (10 ) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. E) Safety Total = 20 (i) Give details of One Accident Investigation analysis and corrective actions (4) If there are no accidents mention as ZERO Accidents ) (ii) Give details of One Near Miss Accident and corrective actions (4)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. E) Safety Total = 20 (iii) At what frequency your Plant Head / CEO take round for Safety purpose only ? Give details of Unsafe Behaviour and Unsafe Condition observed during such round and how you take corrective actions (4) (iv) Indicate 3 identified Accident Prone areas in your factory and actions planned / taken (4)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. E) Safety Total = 20 (v) Do you conduct Mock Drills, Share one Report (2) ( vi) Are you aware about any Fatal Accident happened in any factory (either in your group companies / competitor / customer / supplier etc. ) and what preventive actions have you planned / implemented in your organization (2)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. F) Employee Engagement Total = 15 (I) Whether any of your Teams, participate in External Contests held by various agencies ? Give details indicating where they have participated / Topic of Presentation and level of Team members (Operatives / Supervisory / Managerial etc). Mention about the Awards won by your Team ( 10). (ii) Whether you have Cross Functional Teams working in your organization ? Give details. Whether these Teams, gets an opportunity to make presentation to CEO / Plant Head ? CEO / Plant Head Give one example, where such a cross functional Team has contributed handsomely (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. G) Environment Protection Total = 5 (i) List some of the recent achievements of your organization, regarding Resource Conservation like Energy / Water / Air / Oil (5). (1. H ) Poka-yoke / KAIZEN Total = 10 (i) What % of CTQs (Critical to Quality) are being addressed through poka- yoke ? (3) (ii) Show some recent customer complaints, which are addressed through poka-yoke (2)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (iii) Show some shining examples of Poka-yoke / KAIZEN (3 ) (iv) Show your mechanism for sustenance of poka-yoke / KAIZEN (2).

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1. I) Legal / Statutory Compliance Total = 5 (i) How do you ensure compliance of Statutory issues (5), Give few shining examples

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1 J ) Wastage Reduction / Non Value adding activity reduction Total = 5 (i) Show some shining examples of Wastage Reduction / Non Value Adding Activity Reduction (3) (ii) Give shining examples where you have made improvements based on Benchmarking Best Practices Sharing from Industry or Knowledge sharing within Group organizations (2)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1 K) Automation / Digitization of various activities Total = 10 (i) Give shining examples of Automation / Digitization in different areas (6) (ii) What is your strategy for Industry 4. 0 (4) Specify actions taken / Planned

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors (1 L) Contribution towards Society & Nation Building i ii Total = 20 How you develop ownership of the cleanliness of the neighborhood , improving the aesthetics around the company premises ( outside ) 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? 2 2 Any specific CSR activity you have done in year 2018 -19. If Yes, describe iii 2 Mention steps taken by the Company to reduce the usage of plastic in manufacturing and non manufacturing areas. iv v 2 National Solar & Water Mission - Have you installed Roof Top Solar energy collectors and have earned through net metering. Adoption of Rainwater harvesting? 2

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 1. Hygiene Factors 1 L Contribution towards Society & Nation Building vi Total = 20 Please describe how your company encourages family participation ? Mention here how company is prepared for disaster support management for affected elements in society ? E. g. support in flood relief , earthquake etc. vii 2 2 Any Social Awards viii 2 Have you supported any differently abled persons - % age employment provided and accessibility arrangements for differently abled persons ix 2 How do you support Make in India drive & skill development. (Import substitution , Entrepreneurship development , Tie ups with skill centers) x 2

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 OFFICE USE ONLY Section 2 Manufacturing Focus and Business Growth Marks = 280 S. N. Sub topic Total Actual Marks % Marks ( for office use ) 50 2. A Business Growth 2. B Manufacturing operations and Production Planning Process Design and control 2. C 2. D Waste Elimination 30 30 35 Material planning and Logistics planning Productivity 10 2. G Cellular manufacturing 10 2. H CAD/CAM & computer integrated manufacturing 2. I Product Quality , SPC and Poka Yoke 2. J Tools of Quality 10 2. K Kaizen and continuous Improvement (Suggestion schemes , Theme based competitions etc) 20 2. E 2. F 15 60 10 TOTAL 280

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2 A) Business Growth Total = 50 (i) What inputs do you take to decide that you need a Business growth plan ? (explain past present and future market/product data inputs and projections , customer demand projections , competitive scenario etc ) (5) (i) How do you formulate your growth strategy and prepare a Long Term Business plan and who all participate in such strategic exercise ? Explain considerations like Mergers and Acquisitions , New plant installation, Capacity enhancement , New products development etc. Give few key areas of your LTP and expected realisation (10)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2 A) Business Growth Total = 50 (iii) How you do you make a risk analysis of your Growth plan ? How do you prepare a risk mitigation plan ? (5) (iv) How do you communicate your Business Growth Strategy to employees ? How do you cascade such strategic objectives within your organisation ? (10)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2 A) Business Growth Total = 50 (v) How do you allocate resources towards your Growth Plan ? Explain resource allocation like financial provisions, Manpower allocations etc. Do you have teams towards Long Term Objectives ? How do you decide targets ? How do you review progress against Targets ? (20)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. B) Manufacturing Operations and Production planning process Total = 30 (i) What is your manufacturing strategy ? And what are the processes used to manufacture your products ? Explain how you decide “Make or Buy “ ( what you will make and what will be purchased from suppliers) ? Explain all inputs like customer requirements, available technology , Your strengths etc . (10) (ii) How do you decide the targets for your annual business plan ? How these targets are cascaded at all levels in your organization ? How do you factor future requirements in your manufacturing plan ? ( 5 )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2 B. ) Manufacturing Operations and production planning process Total = 30 (iii) How do you plan to meet your customer/market demand ? How do you plan for fluctuations in demand for varying volumes and varying product requirements ? How do you identify bottleneck operations and mitigate the impact ? Explain preparation of Annual plan and monthly plan and day to day production requirements ( 10 ) (iv) How do you ensure continuous improvement in your operations ? how do you motivate your employees to participate in Improvement initiatives? (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2 C. ) Process Design and controls Total = 30 (i) How do you design your processes ? Explain what inputs are considered like FMEA , CTQs , technology requirements, operator skill etc. ( 10 ) (ii) How do you consider Cpk of a process for a CTQ parameter (your plan when Cpk is low and your plan when Cpk is above 1. 67) ? How many of your processes are having Cpk above 1. 67 ? Provide graph showing trend for number processes with Cpk >1. 67 for last three years. What are your controls to ensure defect free process operations ? explain Std Work Procedures , operator training, mistake proofing etc (10)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2 C. ) Process Design and Controls Total = 30 (iii) How do you validate your processes to ensure meeting product specifications ? In case of a design change how do incorporate new requirement and also validate the same ? (5) (iv) What are the special processes in your company (welding , painting , heat treatment etc ? How do you control these and ensure quality ? (like procedures for checking of process parameters, equipments to control processes like Temperature controls , humidity controls, dust controls etc (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. D) Waste Elimination Total = 35 (i) How do you identify different types of wastes in your organisation? (using 7 types of waste principles ? ) What methods are deployed to eliminate wastes? Give examples for each type of waste and your actions to reduce. What are the forums available for employees to share waste elimination success stories? ( 15 ) (ii) How do you optimize all your resources ? How Waste removal in your company results in improving resource utilisation? Provide key results such as ’Improving Changeover time’ , No of Kaizens towards waste removal, savings accrued etc. (5 )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. D) Waste Elimination Total = 35 (iii)What is your target for OEE ? What all factors are considered to improve OEE ? (5) (iv)How do you prepare your equipment maintenance plan? Provide details of considerations such as high cycle time, critical to quality, TPM methodology etc (5) (v) What are the measures tracked for Equipment Up Time like MTTR and MTBF etc and how are they linked to strategic objectives ? Provide key maintenance related results. (5 )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. E) Material planning and logistics planning Total =10 (I) How do you plan your material requirements to meet production plan ? How do you ensure FIFO ? (3) (I) How do you monitor input material cost in your product and explain your material cost reduction efforts ? (considering customer demands for higher quality at lower cost )(3) (I) How do plan and improve your logistics cost ? (2 ) (iv) What innovations / best practices are adopted to improve packing / packaging and dispatch ? Do you consider environment friendly approach in packaging ? Explain principles like reuse, recycle , etc (2 )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. F) Productivity Total = 15 (i) How do you measure and monitor productivity ? How do you decide target for productivity ? What are your monthly/yearly productivity targets ? What are the challenges to meet targets ? How do you compare your productivity with the industry practice or best in class ? Explain benchmarking practices(8) (ii) What are the efforts taken to improve productivity ? Explain productivity kaizens, low cost automations , multi machine operations etc (5) (iii) How do you motivate employees to participate in productivity improvement initiatives ? (2)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. G) Cellular Manufacturing Total = 10 (i) How do you identify need to use cellular manufacturing process ? How do you design cell? (5 ) (ii) What is the % of processes in your manufacturing where cellular Manufacturing is used? Give two examples of cell manufacturing with before and after layouts with benefits achieved (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. H) CAD / CAM & Computer Integrated Manufacturing Total = 10 (i) What are the areas where digitisation such as CAD / CAM / Bar Coding / ERP can be implemented in your company ? (5) (ii) What are the latest software's used for Manufacturing Shop in your company ? How does these software's help in improving Quality, Productivity. Cost etc ? (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. I) Product Quality , SPC and Poka-Yoke -- Total =60 (i) How do you ensure conformance to product specifications? how do you communicate product requirements in your organisation? how do you ensure skill with your employees to meet product requirements (10) (ii) What is your quality policy? how do you ensure outgoing product quality? how do you take customer / competitive inputs (benchmarking) towards improving quality? provide key product quality results (10) (iii) Does the company follow the APQP process? If not, please specify the alternate methodology followed for (new) component development? (5) (iv) What is the system for conformity check (system level and part level) after start of production as done like the initial PPAP submission? (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. I) Product Quality , SPC and Poka-Yoke Total =60 (v) How many of your CTQ related processes have Cpk more than 1. 67 ? How do you use SPC charts to control ’in process quality’ ? What is the training imparted to operators about SPC and How to use it on a day to day basis ? (5) (vi) How do you analyze various quality related data [like warranty rejection , customer returns , in house rejection , rework etc ] to decide improvement initiatives ? What methodology is adopted to implement improvements [Poka-Yoke , Quality circle , SGA , Kaizen etc (10) (vii)How many Poka- yoke are operational in your company ? Categories them in safety, quality , process etc. What is the trigger for implementing a poka-yoke ? (10) (viii) How do you measure quality cost ? how do you plan to reduce costs ? How do you reduce or eliminate inspection stages in your manufacturing process ? (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. J) Quality Tools (i) Total = 10 How many basic Quality tools are used and for what purpose & what % of employees are trained for each tool ? Explain few problems solved by operators by using quality tools. (5) S. N. Quality tools Usage purpose % Employees trained 1 2 3 4 5 6 7 (ii) How do you measure effectiveness of training for quality ? (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 2. Manufacturing Focus and Business Growth (2. K) Kaizens and continuous improvement ( suggestion schemes, theme based competitions etc ) Total = 20 (i) Give details of Kaizens done in Year 2018 -19 as per following categories ? (5) S. N. Area 1 Productivity 2 Quality 3 Cost 4 Delivery 5 Safety 6 Morale 7 Energy 8 Environment 9 IT No. of Kaizens Saving in Rs. Done Lacs Remarks Total (ii) Do you have any suggestion scheme ? Please explain details. Do you decide any theme based suggestion drive ? what are the triggers for the same ? (5)

2. Manufacturing Focus and Business Growth (2. K) Kaizens and continuous improvement ( suggestion schemes, theme based competitions etc Total-20 • Iii) What is your target for Kaizen per employee for this year ? Show results for last three years for kaizen per employee? Do you include all employees of your organisation ( 5 ) 96 100 90 80 70 60 50 50 40 30 20 10 35 30 25 10 0 2016 -17 2017 -18 Suggestionsw/employee/year • 2018 -19 % employee participation iv) Share few examples of Kaizens/Suggestions done in last six months and the benefits for the company ? (5 )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 OFFICE USE ONLY Section 3 Support Functions Total Marks = 120 S. N. Sub topic 3. A 3. B 3. C 3. D Total Marks Support Functions Roles and objectives Support function training and development Support functions value added improvements Use of IT TOTAL 40 20 20 40 120 Actual Marks % ( for office use )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 3. Support Functions 3. A. Support functions Roles and Objectives Total =40 (i) What are your support functions ? (10) (ii) How do you capture inputs from Support functions to decide Business Growth strategy ? Consider inputs on Man power skill sets, Types of machines , Layout planning , Supplier related issues etc (10) (iii) How do you decide support functions objectives and targets ? Provide details of linkage of company objectives to support functions. How do you monitor Support function objectives and Targets(10) (iv) Provide details of performance against targets for at least 3 support functions for past six months (10)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 3. Support Functions 3. B Support functions Training and development Total =20 (i)How do you identify training and development needs of support functions ? What training and development inputs are provided to support functions ? How do you factor future needs in your training and development plan ? (10) (ii) How do you motivate support functions to participate in decision making , innovations , improvement initiatives etc ? How do you form teams involving support functions to implement growth initiatives (10)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 3. Support Functions (3. C) Support function Value added Improvements Total =20 (i) How value adding activities captured / improved & wastages are eliminated in non production area? How do support function help in improving company’s performance ? (10) (ii) Provide few examples of value addition and waste elimination by support functions. Cover at least 3 -4 support functions including Quality , HR etc ( 10 )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 3. Support Functions (3. D) Use of IT Total = 40 (i) How do you identify areas for implementation and integration of IT in your entire process chain ? How do you deploy IT initiative? Elaborate the IT road map ( 20 ) (ii) How IT integration helped to improve operational performance, Give few shining examples of benefits achieved in the areas of quality , productivity ? Explain how data analysis helps in decision making ? ( 20 )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 OFFICE USE ONLY Section 4 Performance Results Total Marks = 200 S. N. Sub topic Total Marks 4. A Revenue through New Products 4. B Number of projects on time 4. C Manpower Productivity 10 4. D Energy Saving 20 4. E Breakdowns 10 4. F Delivery Performance 15 4. G Inventory Turns 20 4. H Absenteeism 10 10 15 4. I Cost of poor Quality 20 4. J All types of Rejections 35 4. K Customer Complaints 25 4. L Customer Returns TOTAL 10 200 Actual % Marks ( for office use )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. A) Revenue through New Products Total = 10 (i) Provide your total revenue vs revenue from New Products for last 3 years indicating trend ? (5) 100 90 80 70 60 50 40 30 20 10 0 90 60 50 30 20 10 2016 -17 Total Revenue in Rs. Cr 2017 -18 2018 -19 Total Revenue from New Products in Rs. Cr. (ii) What are your plans to increase your revenue from new products ? (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. B) Number of Projects on time Total 10 (i) Please give details of all projects under execution vs projects completed on time (use a tabular format). To maintain secrecy you may provide only numbers per category like new products under development and products introduced on time , new machines planned for installation vs machines installed and running , Re-layouts planned vs re-layouts completed on time , new markets being considered vs new markets started etc (10)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. C) Manpower Productivity Total = 15 (i) What is the productivity trend ? (show last 3 year data in Bar graph , illustrate it with your internal Target line). Show the data for the Major Business Product Lines. (5) 100 90 80 70 60 50 40 30 20 10 0 90 80 70 60 50 45 2016 -17 Target 2017 -18 2018 -19 No. of Products per man per year (ii) What are the tools used to analyze & improve manpower productivity ? Explain the methodology. In details (10)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. D) Energy Saving Total = 20 (i) Show energy cost as % Sales, Include all energy resources , illustrate it with your internal Target line (electricity / fuel / gas/air/water) (5) 8 7 6 5 5 4 4 4 3. 5 3 3 2. 5 2 1 0 2016 -17 2017 -18 Target (ii) S. N. 2018 -19 Energy cost as % of Sales List improvement actions implemented to reduce energy consumption (consider at least two examples each for each type of energy) in the year 2018 -19. How employees are motivated to participate in this ? (10) Item Before After Actions Taken 1 2 3 4 (iii) How do you evaluate alternate energy sources like solar , wind power etc ? Have you implemented any alternate energy project ? (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. E) Breakdowns Total = 10 (i) How much is machine breakdown loss as % of total available time? (Bar graph , illustrate it with your internal Target line ) (5) 8 7 6 5 5 4 4 4 3. 5 3 3 2. 5 2 1 0 2016 -17 2017 -18 Target 2018 -19 Breakdown % (ii) Show Actions taken to eliminate break downs. Explain the methodology to reduce break downs. (5) S. N. 1 2 3 4 Breakdown Before After Actions Taken Breakdown per month

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. F) Delivery Performance Total = 15 (i) What is the Delivery Performance for all major customers ? (show last 3 year data in Bar graph , illustrate it with your internal Target line). Please consider delivery towards all requirements [models , varieties etc ] while calculating performance (5) 100 98 96 94 92 90 88 86 84 100 100 98 90 86 2016 -17 2017 -18 Target 2018 -19 Delivery % (ii)Also provide data on production plan vs actual for last 12 months (% compliance wrt customer demand for all major customers ) (5) (iii) Provide customer rating towards ‘Delivery Parameter’ for all customers. Incase you have appreciation letters please mention the same (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. G) Inventory Turns Total = 20 (i) Show the trend of ITR (Inventory Turn Ratio) last three years , illustrate it with your internal Target line. (10) 60 55 50 35 40 30 25 40 30 35 20 10 0 2016 -17 Target 2017 -18 2018 -19 Inventory Turn Ratio Formula Material cost of sales for the month x 12 in Rs. ITR = ------------------------------ (RM + WIP + FG ) in Rs. On 1 st of the month (ii) How do you control your inventory wrt RM, WIP & FG despite fluctuations in demand. Provide Examples of actions to control /reduce inventory. (5) S. N. Category 1 RM 2 WIP 3 FG Before After Actions Taken Inventory in days (iii) How do you categories your inventory ? ( A B C analysis, lead time based , bulk items , imported material etc ) (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. H) Absenteeism Total = 10 (i) What is absenteeism data ( Average) for the year 2018 -19 ? Provide trends for last 3 years (5) 9 8 8 5 6 4 3 3 3 2016 -17 2017 -18 2018 -19 2 0 Target % Absenteeism Formula Total absent man-hours for the month ( Authorized + Unauthorized ) Absenteeism =---------------------------- X 100 Total man hours for the month (iii) What unique efforts organization takes to reduce absenteeism? (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. I) Cost of poor Quality ( COPQ) (i) Total = 20 Please show cost of poor quality trends for last three years with respect to internal target (10) 8 5 6 4 4 4 3. 5 3 2. 5 2 0 2016 -17 2017 -18 Target 2018 -19 COPQ % (ii) Mention all elements of Cost of poor quality captured & monitored. (warranty , customer return , rework , rejections , persons at customers line, logistics cost for return and replacement , segregation etc Element wise performance before & after action taken for improvement in last 2 years. (10) S. N. COPQ Element 1 2 3 4 5 6 7 8 9 10 11 Before % After % Remarks

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. J) All types of Rejections Total =35 (i) Provide details of all rejections like warranty , Pre dispatch inspection, process rejection, in coming rejection related to supplier parts etc (give data for last three years showing trends with your internal Target line in each of the category) (10 ) 1200 1000 1100 800 600 400 200 0 2016 -17 2017 -18 Rejection PPM 2018 -19 Column 1 (ii) Please describe the actions taken to eliminate rejection with data before and after in high occurrence or high value. (10 ) (iii) Besides process controls and prevention efforts how do you consider re-skilling , upgrading of employees and other soft skill related issues for reducing rejections ? (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results 4. J All types of Rejections Total = 35 (iv) How do you eliminate rework ? (show last 3 year data related to rework in bar graph , illustrate it with your internal Target line) (5) 6000 5000 4000 3000 2000 1000 0 2016 -17 Target 2017 -18 2018 -19 In-house rejection PPM

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Quality Performance (4. J) All types of rejections Total = 35 (v)How do you work with your supplier to reduce in coming rejections ? Provide before and after data (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. K) Customer Complaints Total = 25 (i)How do you capture customer complaints? How do you plan to control and eliminate customer complaints? How do you track customer complaint and related actions ? (20) (ii) What is the trend of the customer complaints in nos? (Show last one year data in line graph for 2018 -19 & actions to eliminate the same (5) Customer Complaints Target 15 12 10 9 10 8 7 8 0 0 0 2 0 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 Feb-18 Mar-18 7 May-17 5 6 Apr-17 20 18 16 14 12 10 8 6 4 2 0

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 4. Performance Results (4. L) Customer Returns Total = 10 (i) Please show the trend of last three years of Customer Returns PPM in bar graph. ( 5 ) Customer Returns in PPM 120 100 80 70 60 40 30 2015 -16 2016 -17 2017 -18 (ii) How do you eliminate causes related to Customer returns ? (5)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 OFFICE USE Only Section 5 Business Results (General) Total Marks = 200 S. N. Sub topic Total Marks 5. A Product Results Customer Focused Results Financial And Market 5. C Results Employee Focused 5. D Results Process Effectiveness 5. E Results 5. B TOTAL 40 40 40 200 Actual % Marks (for office use )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 5. BUSINESS RESULTS (5. A) Product Results (i) Total = 40 What is the % of DOL (Direct Online) products? Show trend for last 3 years with target for each year (10) 100 78 80 96 84 60 40 2016 -17 2017 -18 Target 2018 -19 % DOL Products (ii) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. ) (iii) What is the status of customer complaints? Show trend for last 3 years with target for each year (10) 25 20 20 15 15 10 5 5 0 2016 -17 2017 -18 Customer Complaints 2018 -19 Target (iv) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text)

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 5. BUSINESS RESULTS (5. A) Product Results Total = 40 (v) What is the status of Warranty? Show trend for last 3 years with target for each year in PPM (8) 4000 3000 2000 1000 96 0 2016 -17 2017 -18 Warranty 2018 -19 Target (vi) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text.

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 5. BUSINESS RESULTS (5. B) Customer Focused Results (i) Total = 40 What is the Customer Audit score/ Rating? Show trend for last 3 years with target for each year (10) 100 80 78 84 96 60 40 2016 -17 2017 -18 Customer Audit Scores / Rating 2018 -19 Target (ii) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. (iii) What is the Customer satisfaction score? Show trend for last 3 years with target for each year (10) 100 80 67 76 91 60 40 2016 -17 2017 -18 Customer Complaints 2018 -19 Target (iv) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text.

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 5. BUSINESS RESULTS (5. B) Customer Focused Results Total = 40 (v) What is the status of Customer Awards and Recognitions? Show trend for last 3 years. Consider your top 3 business customers for this data. (8) 25 20 15 10 5 20 18 15 8 9 2017 -18 2018 -19 5 0 2016 -17 Possible Awards Actual Award received (vi) What are the actions initiated during last year? (4) (Mention here reasons for receiving / not receiving all customer awards. Share 2 shining examples with photos and text.

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 5. BUSINESS RESULTS (5. C) Financial And Market Results (i) Total = 40 What is the sales turnover in INR Cr. ? Show trend for last 3 years with target for each year (10) 1500 13001250 800 840 1000 500 530 0 2016 -17 2017 -18 Target 2018 -19 Sales Turnover (Cr. ) (ii) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. ) (iii) What is the % value addition to net sales? Show trend for last 3 years with target for each year (10) 25 20 15 15 17 12 14 17 18 10 5 0 2016 -17 Target 2017 -18 2018 -19 % Value addition to net sales (iv) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 5. BUSINESS RESULTS (5. C) Financial And Market Results Total = 40 (v) What is the share of business for top 3 products. Show trend for last 3 years with target for each year. (8) 100 80 60 40 20 50 50 50 45 20 50 55 60 30 0 2016 -17 Product 1 2017 -18 Product 2 2018 -19 Product 3 (vi) What are the actions initiated during last year? (4) (Mention here reasons for improving / reducing business share. Provide 2 shining examples with photos and text. )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 5. BUSINESS RESULTS (5. D) Employee Focused Results (i) Total = 40 What is the Employee satisfaction score? Show trend for last 3 years with target for each year (10) 100 80 75 70 100 90 85 80 60 40 2016 -17 Target 2017 -18 2018 -19 Employee satisfaction score (ii) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. ) (iii) What are the training man days per employee per year? Show trend for last 3 years with target for each year (10) 90 72 70 50 56 48 60 50 35 30 10 2016 -17 Target 2017 -18 2018 -19 Training man days / employee / year (iv) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 5. BUSINESS RESULTS (5. D) Employee Focused Results Total = 40 (v) What are the Suggestions per employee per year. Show trend for last 3 years with target for each year. (8) 100 80 60 40 20 48 25 35 20 45 30 0 2016 -17 Target 2017 -18 2018 -19 Suggestion / employee / year (vi) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 5. BUSINESS RESULTS (5. E) Process Effectiveness Results (i) Total = 40 How much is In house Rejections? Show trend for last 3 years with target for each year (10) 6000 5000 4000 3000 2000 1000 0 2016 -17 Target 2017 -18 2018 -19 In-house rejection PPM (ii) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. ) (iii) What is the Inventory turn Ratio ITR (Inventory Turn Ratio)? Show trend for last 3 years with target for each year 55 (10)60 50 35 40 30 25 40 30 35 20 10 0 2016 -17 Target 2017 -18 2018 -19 Inventory Turn Ratio (iv) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. )

ACMA Awards 2018 -19 : Excellence in Manufacturing PM_44_F 41, Rev No 00 5. BUSINESS RESULTS (5. E) Process Effectiveness Results Total = 40 (v ) What is the value added per employee cost (VAPCO). Show trend for last 3 years with target for each year. (8) 20 15 10 5 6 8 4 10 6 8 0 2016 -17 2017 -18 Target 2018 -19 VAPCO Formula for VAPCO = (Sales – Variable cost)/ Employee Cost CTC (vi) What are the actions initiated during last year? (4) (Mention here reasons for exceeding/not achieving targets and share 2 shining examples with photos and text. )