Transcript Slide 1

PM_44_F8 Rev. No. : 00 , Specimen Format*
ACMA Awards
Excellence in Quality &
Productivity
Company Name :
Plant Location :
Category : Large
2013-14
PM_44_F8 Rev. No. : 00 , Specimen Format*
( For office use only except page no. )
Index
S.N.
1
Section
Page
No.
Max. Marks
150
2
Work Environment & Employee
Involvement.
Customer Assessment
3
Quality Performance.
350
4
Productivity Performance.
300
5
Cost Performance.
100
100
Total
For Administrative Queries:
Mr. Uday Harite
Email- [email protected]
Mobile – 08149099959
Mr. Jitender Rana
Email – [email protected]
Mobile – 09873369699
Ms. Sakshi Karkamkar
Email – [email protected]
Mobile - 07387002181
Actual
Marks
1000
For Technical Queries:
Mr. Dinesh Vedpathak
Email – [email protected]
Mobile – 09545887799
Mr. K. Chandrasekhar
Email – [email protected]
Mobile – 09822911139
Mr. V K Sharma
Email : [email protected]
Mobile : 09811392068
Ms. Sapana Baravkar
Email : [email protected]
Mobile : 07350703339
ACMA Centre for Technology (ACT)
( A Division of ACMA )
Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C,
Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar ,
Pune – 411005, India .
www.acma-act.in
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
Letter for Submission of Award application for 2013-14
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 2013-14 for
Excellence in Quality & Productivity in Large category .
All data submitted is duly verified and true to the best of our knowledge .
With regards
( Name & Designation of the Plant CEO )
Group
Company
Name
Turnover in INR
Cr. For 2013-14
ACMA Awards Category
Small Upto
INR 50 Cr
Large
Between INR
50 to 150 Cr.
Not
Applicable
Large
( For ACMA
Award
Process
Team )
Criteria for Small and Large Category :
Small Category- Company Group Annual Sales Turnover Up to INR 50 Cr
Large Category- Company Group Annual Sales Turnover Between INR 50 to 150 Cr
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
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 :
2.
Name of the Chief executive of the corporate group-
3
Chief 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 )
4
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
Company’s Details
5.
Company turnover ( in Rs. Crore ) for Year 2013-14 :
6.
Plant turnover ( in Rs, Crore ) for Year 2013-14 :
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 :
5
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
Customer Details
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
S. No
Customer
Locatio %
Key person name Mobile
n
& Designation
mail
Business
share
( from the
plant )
Number & E
1
2
Note- In addition to application , site diagnosis , Customer
feedback scores will be also considered for final scores.
6
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
Company / Plant Information
Use this slide to brief about your company / Plant .
It includes Product names / photos , Plant facility photographs ,
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
Route Map to reach your plant
Provide here route map to your company for site diagnosis ( Site
diagnosis is carried out if your application is shortlisted )
Contact person name & Designation:
Name :
Designation :
E-Mail :
Mobile :
Landline : ( STD Code ) ( Number ) :
Ext. ( if any )
8
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
( 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. Area
N.
1
Total Marks
150
2
Work Environment &
Employee Involvement.
Customer Assessment
3
Quality Performance.
350
4
Productivity Performance.
300
5
Cost Performance.
100
Total
Actual Marks
( for Office Use
only )
%
100
1000
9
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
( For office use only )
Section 1
Work Environment & Employee Involvement
Total Marks = 150
S.N. Sub topic
Total
Marks
1.A
Work Place Management
40
1.B
20
1.C
Suggestions / Kaizens Per
Employee
Absenteeism
1.D
Training
10
1.E
Small Group Activities
10
1.F
Safety
30
1.G
Environment
Management
30
TOTAL
Actual Marks %
( for office
use )
10
150
10
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.A) Work Place Management
Total= 40
(i) Specify status in below mentioned checklist for “Must be facilities”
for all company employees ? Illustrate with photographs some
examples (25)
Must be facilities for all company employees
Description
Sr. No.
Status
1
Jogging track inside shop floor, along walls
OK / Not OK
2
Trees in plant campus
OK / Not OK
3
OK / Not OK
4
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
5
Clean toilet blocks inside shop floor, dry & smell free
OK / Not OK
6
No nails to be used anywhere in the factory premises.
OK / Not OK
7
All employees to wear uniform, shoes and necessary
safety gadgets.
Noise free DG sets & compressor
OK / Not OK
8
OK / Not OK
OK / Not OK
9
Clean change room and rest room facilities
OK / Not OK
10
Hygienic kitchen, washroom, dinning hall.
OK / Not OK
11
Good recreational facilities
OK / Not OK
12
Appropriate fire fighting equipments should be placed at
accessible locations
13 Central display board ( 80 % Digital )
Photo
OK / Not OK
OK / Not OK
Photo
11
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.A) Work Place Management
Total= 40
(ii) illustrate how concept of 5S/house keeping has been deployed in
your plant?(5)
(iii) What methods are adopted to assess 5S levels/scores? (show last
one year trend in line graph , illustrate it with your internal Target line.).
(5)
Target
Actual
90
80
70
% scores
60
50
74
70
60
75
76
77
77
78
79
80
60
50
40
30
20
10
0
Formula
5 S Score = Lowest zone / area score of that month in %
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.A) Work Place Management
Total= 40
(iv) illustrate with photographs examples of good Visual Factory- Before
and after. (5)
Before
After
Before
After
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.B) Suggestions / Kaizens Per Employee
Total= 20
(i) Is there a suggestion scheme in the company and How company
encourages employees to give suggestions? ? Pls Describe: (5)
(ii) How company ensures the suggestions are implemented? Pls
describe: (5)
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.B) Suggestions / Kaizens Per Employee
Total= 20
(iii) Trends of number of suggestions implemented / employee / month?
(show last one year trend in line graph , illustrate it with your internal
Target line.). (5)
Formula
Total suggestions + Kaizen Implemented in that month
Suggestions / Employee =---------------------------------- -------------------------------- X 100
Total direct employees ( Operatives ) for the month
(iv) ) Is there a forum (as well as escalation process) for employees to
raise issues / concerns etc.--- shop floor / HR / personal etc. If yes,
please elaborate. . (5)
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.C) Absenteeism
Total= 10
(i) What is absenteeism data ( Average) for the year 2013-14 ? What
are the trends in regards to total absenteeism? (Three year trend in bar
graph , illustrate it with your internal Target line.) ( 5 )
Authorized =
%
Unauthorized =
%
Total
=
%
10
9
9
8
8
Total % absenteeism
7
6
5
5
4
3
2
1
0
2011-12
2012-13
2013-14
Formula
Total absent man-hours for the month ( Authorized + Unauthorized
)
Absenteeism =-------------------------------------------------------- -------------------------------- X 100
Total man hours for the month
(ii) What efforts organization takes to reduce absenteeism? ( 5 )
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.D) TRAINING
Total= 10
(i) In which areas do you provide training to your employees ? List
some benefits achieved by trainings in recent past. What is the trend of
the training hours / employee over the years? (show last three year
trend in bar graph , illustrate it with your internal Target line.) ( 5 )
Training Areas :
•
•
•
•
•
60
55
Training hrs/emp/year
50
40
40
30
25
20
10
0
2011-12
2012-13
2013-14
Formula
Total training man-hours for all employees for year
Training hours/employee / year =---------------------------------------- --------------------Total employees
(ii) How training effectiveness is measured and Benefits of
Training : Tangible ( in Rs. Lacs ) & Intangible : (Give details for
TWO shining examples) : ( 5 )
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.E) Small Group Activities
Total= 10
(i) Explain how company encourages small group activities :
(ii) Do small group participate in the Quality Conventions-Group/State
level/National. Show certificates / trophy photographs :
(iii) How many active groups are present in the current year? % employee
involvement In QC Activity? (show last three year trend in bar graph.
25
No. of Active groups
100
active groups
% of emp involvement
100
25
75
20
20
70
15
15
50
50
10
25
5
0
0
2011-12
2012-13
% Employees Involvement
30
2013-14
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.F) SAFETY
Total= 30
Pls describe: with text / Photos
(i) How company ensures Safe work practices? (5)
(ii) Proactive measures taken by company to reduce accidents (5)
(iii) Number of accident free days ( Cumulative ) (5) :
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.F) SAFETY
Total= 30
(iv) What are the current accident levels? (Show last one year data in
line graph) (15)
A) Frequency (nos.) Minor + Major both
B) Severity (man hrs. lost)
Formula
No. of accidents
Frequency rate =------------------------ X 106
Total man hours
Formula
Severity rate
Total man-days lost
=------------------------------- X 106
Total man hours
20
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.G) Environment Management
Total= 30
(i) What is the frequency of scarp disposal? (5) : (Pl explain is it Daily /
Weekly … )
(ii) Does company have resources conservation strategy? List some
recent achievements of company to conserve resource -electricity,
water, material , etc ? (10)
21
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.G) ENVIRONMENT MANAGEMENT
Total= 30
(iii) Please describe the practices of the company to reduce pollution?
(10)
(iv) Does the company have a do’s and don’ts policy for employees
especially with regard to safety / quality / manufacturing practices /
environment care etc? (5)
22
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
( For office use only )
Section 2
Customer Assessment
Total Marks = 100
S.N. Sub topic
Total
Marks
2.A
Awards by Key Customers
10
2.B
Customer audit of
Quality system
Customer rating for
Quality & Delivery
Feedback from Customer
& analysis
TOTAL
20
2.C
2.D
Actual Marks %
( for office
use )
30
40
100
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
2. Customer diagnosis
(2.A ) Awards by Key Customers
Total= 10
(i) Awards by Key Customers (trend of last 3 years) (10)
No. of Key-Customers
10
8
6
Nos
8
Award photo
6
5
4
10
9
8
Awards by key customer
2
0
2011-12
2012-13
2013-14
Note : If your Customer does not have a system of Awards , Mention
what kind of supplier recognition is followed by Customer .
Total= 20
(2.B ) Customer audit of Quality system
(i) Does your key customers audit your quality system regularly? Has
the audit results improved over the years? What is the trend over last
three years? % , illustrate it with your internal Target line. (20)
100
85
Actual
Target
QCD audit % score
75
55
50
45
25
0
2011-12
2012-13
2013-14
Note : If your Customer does not have a audit system , Mention what
kind of supplier audit system and scoring is followed by Customer .
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
2. Customer diagnosis
(2.C ) Customer rating for Quality & Delivery
Total= 30
(i) Does your key customers rate your performance on quality and
delivery regularly? If yes, what is the trend over last three years? ,
illustrate it with your internal Target line. (30)
100
85
86
2011-12
2012-13
90
75
50
25
0
2013-14
Mention here major improvements done by your company to improve above
performance :
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
2. Customer diagnosis
(2.D ) Feedback from Customer & analysis
Total= 40
(i) Please describe system of getting feedback from the customers? (10)
(ii) If yes, how do you analyze this feedback and take actions in weak
areas? Explain with two shining examples. (30)
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
( For office use only )
Section 3
Quality Performance
Total Marks = 350
S.N. Sub topic
Total
Marks
3.A
Customer Complaints
50
3.B
90
3.C
In-House Rejection &
Rework
Supplier Rejection
3.D
Warranty Rejection
50
3.E
Cost of Poor Quality
30
3.F
Process Improvement
40
3.G
Quality Management
50
TOTAL
Actual Marks %
( for office
use )
40
350
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.A) Customer Complaints
Total= 50
(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 , illustrate it with your internal Target line.) (20)
Target
Actual
14
12
12
11
10
11
10
9
8
8
7
6
6
5
4
4
2
0
0
0
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.A) Customer Complaints
Total= 50
(iii) Is the Customer complaint data analysis done? (E.g.—Product wise,
Customer wise, Process wise, etc). Explain with an example. (5)
(iv) Is analysis of repeated Customer complaints carried out? Explain
with an example ? (5)
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PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.A) Customer Complaints
Total= 50
(v) Explain the efforts to reduce customer complaints?
(10)
(vi) Enclose examples of countermeasure report on Customer
complaints. (5)
30
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.B) In-House Rejection & Rework
Total= 90
(i) Does the company follow the APQP process? If not, please specify
the alternate methodology followed for component development? (10 )
PPM
(ii) What are the trends of the Total in-house rejection in PPM ? (show
last 3 year data in bar graph , illustrate it with your internal Target line.)
(20)
7000
6000
5000
4000
3000
2000
1000
0
6000
5000
Target
In-house
4000
rejection PPM
3000
12001000
2011-12
2012-13
2013-14
(iii) Please describe the actions taken to reduce the in- house rejection
(10)
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.B) In-House Rejection & Rework
Total= 90
(iv) Provide example of actions by which you are able to achieve
zero defect at In-house rejection (10)
S.N.
Defect
Before PPM
After PPM
Actions Taken
1
2
3
4
Before – After Photos
Before
After
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.B) In-House Rejection & Rework
Total= 90
(v) What is the current level of the rework in PPM ? (show trend for last
3 year in bar graph , illustrate it with your internal Target line.) (20)
13000
10000
9000
PPM
14000
12000
10000
8000
6000
4000
2000
0
2011-12
2012-13
2013-14
(vi) Explain efforts taken to reduce rework : (10)
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.B) In-House Rejection & Rework
Total= 90
(vii) Please give details of action taken to reduce rework? (10)
S.N.
Rework
Before PPM
After PPM
Actions Taken
1
2
3
4
Before – After Photo
Before
After
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.C) Supplier Rejection
Total= 40
(i) What are the trends of the supplier rejection in PPM ? (show last 1
year data in bar Graph , illustrate it with your internal Target line.) (20)
Target
Actual
1800
1600
1600
1500
1500
1400
Supplier Rej in PPM
1200
1200
1000
800
600
400
1456
1235
1124
840
640
540
440
230
200
0
(ii) Please describe the efforts to reduce the supplier rejection? (10)
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.C) Supplier Rejection
Total= 40
(iii) Provide example of actions by which you are able to achieve
zero defect at Supplier end (10)
S.N.
Defect from
Supplier
Before PPM
After PPM
Actions Taken
1
2
3
4
Before – After Photos
Before
After
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.D) Warranty Rejection
Total= 50
(i) What are the trends of the warranty ? (show last 3 year data in bar
Graph , illustrate it with your internal Target line.) (30)
1200
1000
1000
1100
PPM
800
600
400
300
200
0
2011-12
2012-13
2013-14
Note : If warranty is Not applicable for your products , Mention in
place of Graph
(ii) Please describe the efforts to reduce the warranty rejection (10)
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.D) Warranty Rejection
Total= 50
(iii) Provide example of actions by which you are able to achieve
Zero warranty defect (10)
S.N.
Warranty
Defect
Before PPM
After PPM
Actions Taken
1
2
3
4
Before – After Photos
Before
After
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.E) Cost of Poor Quality ( COPQ)
Total= 30
(i) What is the trend for this data/current status? (show last 3 year data
in bar graph , illustrate it with your internal Target line. (10)
Cost of Poor Quality ( COPQ ) as a % of Sales
1.4
1.2
1.2
1
%
0.8
0.6
0.4
0.4
0.2
0.1
0
2011-12
2012-13
2013-14
(ii) Show elements of Cost of poor quality and improvements for the
year 2013-14 . ( 10 )
S.N.
COPQ
Element
Before %
After %
Actions Taken
1
2
3
4
5
6
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.E) Cost of Poor Quality ( COPQ )
(iii) Provide example of
COPQ ( 10 )
Total= 30
actions by which you are able to reduce
Before – After Photos
Before
After
Before
After
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.F) Process Improvement
Total= 40
(i) How company identifies Critical to Quality characteristics (CTQ) ?
(10)
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.F) Process Improvement
Total= 40
(ii) Does the company insist on CpK performance for CTQ
characteristics? What is the present level of Process capability (Cpk)
for CTQ’s identified and controls ? (15)
S
.
N
.
CTQ
Param
eter
Customer
Complain
ts for
2013-14
Not
Monit
ored
CPk <
1.33
CPk>1
.33<1.
67
CPk>1.
67
Present Control
1
2
3
4
5
6
(iii) What steps are taken to improve process capability greater than
1.67? ( 5 )
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.F) Process Improvement
Total= 40
(iv) Show Shining examples of process improvements ( 10 )
Explain with text and Photographs .
Before – After Photo
Before
After
Before
After
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.G) Quality Management
Total= 50
(i) How is the quality of safety critical parts ensured on periodic basis? (5 )
(ii) Are process / engineering changes also validated and documented? (5 )
(iii) How company identifies need for Poka-Yoke ? ( 10 )
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.G) Quality Management
Total= 50
(iv) What % of CTQs are controlled by Poka Yoke? (5)
% =
(v) What % of Customer complaints are closed by Poka Yoke in
2013-14 ? (5)
% =
(vi) How do you ensure effectiveness of Poka yoke? (5 )
45
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.G) Quality Management
Total= 50
(vii) Show innovative examples of poka-yokes & Effect on overall
Rejection of that Product ( 15 )
S.N.
Product
Before
Rejection
PPM
After
Rejection
PPM
Poka-yokes done
1
2
3
4
Before – After Photo
Before
After
46
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
( For office use only )
Section 4
Productivity Performance
Total Marks = 300
S.N. Sub topic
Total
Marks
4.A
Manpower Productivity
100
4.B
Manufacturing Process
Improvement
Inventory Management
75
4.C
4.D Loss of production Hours
TOTAL
Actual Marks %
( for office
use )
75
50
300
47
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
4. Productivity Performance
(4.A) Manpower productivity
Total= 100
(i) What is the productivity trend. Show for your key business line ?
(show last 3 year data in Bar graph , illustrate it with your internal Target
line.) (20)
No. of products
/man/year
40
35
30
20
20
24
10
0
2011-12
2012-13
2013-14
(ii) What are the tools used to improve manpower productivity ? (10)
48
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
4 Productivity Performance
(4.A) Manpower Productivity
Total= 100
(iii) Show innovative examples of Manpower productivity
improvements ( 20 )
S.N.
Operation
Before
( Production
/ day )
After
( production
/ Day )
Actions Taken
1
2
3
4
Before – After Photo
Before
After
49
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
4. Productivity Performance
(4.A) Manpower Productivity
Total= 100
(i) What % of operators are handling more than one machine? Illustrate
it with your internal Target line. (30)
% of operators operating
more than one machine
120
100
100
76
80
60
56
40
20
0
2011-12
2012-13
2013-14
(ii) How Company encourages employees for operating multimachines ? (20)
50
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
4. Productivity Performance
(4.B) Manufacturing Process
Total= 75
(i) Do you follow Single piece flow or batch flow layout or a mixture
of both? Show present material flow for your key business line ? (15)
Single piece flow =
%
, Batch Flow =
(ii) Show improvements in layouts done last year , Show benefits
of layouts change ( 25 )
Before
Before : Material Travel =
Manufacturing Lead time =
Meters ;
Mins ;
WIP =
Nos.
After
After : Material Travel =
Meters ;
Manufacturing Lead time =
Mins ; WIP =
Nos.
51
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
4. Productivity Performance
(4.B) Manufacturing Process
Total= 75
(iii) How process cycle times are reduced ? Share examples
S.N.
Operation
Before
Cycle Time
After
Cycle Time
(20)
Actions Taken
1
2
3
4
Before – After Photo
Before
After
52
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
4. Productivity Performance
(4.B) Manufacturing Process
Total= 75
(iv) Is planning for safety / quality an integral part of the overall
production planning process? Is FMEA carried out during planning
stage? (15)
53
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
4. Productivity Performance
(4.C) Inventory Management
Total= 75
(i) Show the trend of ITR (Inventory Turn Ratio) last three years ,
illustrate it with your internal Target line. (50)
Inventory Turns
40
35
30
20
20
24
10
0
2011-12
2012-13
2013-14
Formula
ITR =
Material cost of sales for the month x 12
----------------------------------------------------------(RM + WIP + FG ) on last day of the month
(ii) Show actions taken to reduce inventory . (25)
S.N.
Products
Before
Inventory in
days
After
Inventory in
days
Actions Taken
1
2
3
4
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
4. Productivity Performance
(4.D) Loss of Production Hours
Total= 50
(i) How much is machine breakdown loss in % of total available time?
(Bar graph, illustrate it with your internal Target line ) (20)
2.5
% Breakdowns
2.1
2
1.5
1
0.4
0.5
0.1
0
2011-12
2012-13
2013-14
(ii) Show Actions taken to reduce break downs (10)
S.N.
Breakdown
Before
Breakdown
in a month
After
Breakdown
in a month
Actions Taken
1
2
3
4
55
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
4. Productivity Performance
(4.D) Loss of Production Hours
Total= 50
(iii) How much is the Setup loss in % of total available time?
(Bar graph, illustrate it with your internal Target line ) (10)
% Set up Time
0.12
0.1
0.1
0.08
0.07
0.06
0.04
0.03
0.02
0
2011-12
2012-13
2013-14
(iv) Show Actions taken to reduce Setup time (10)
S.N.
Set up
Before
After
Actions Taken
1
2
3
4
56
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
( For office use only )
Section 5
Cost Performance
Total Marks = 100
S.N. Sub topic
Total
Marks
5.A
Energy Saving
10
5.B
Value Addition / Net Sales
30
5.C
Value Addition / Fixed
Assets
Value Addition /
Employee Cost
TOTAL
30
5.D
Actual Marks %
( for office
use )
30
100
57
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
5. Cost Performance
(5.A) Energy Savings
Total= 10
(i) Show energy consumption as % Sales, illustrate it with your
internal Target line. (5)
1.4
% Energy of sales
1.2
1.2
1.1
1
0.7
0.8
0.6
0.4
0.2
0
2011-12
2012-13
2013-14
(ii) Show examples to reduce energy consumption (5)
S.N.
Item
Before
After
Actions Taken
1
2
3
4
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
5. Cost Performance
(5.B) Value Additions / Net Sales
Total= 30
(i) Show the trend of last three years in bar graph, illustrate it with
your internal Target line. (15)
Value Addition to
Net sales
14
12
10
13
11
10
8
6
4
2
0
2011-12
2012-13
2013-14
Formula
Net Sales – Variable Cost
Value Addition to Net Sales
=
---------------------------------------------------Net Sales
(ii) What is the benchmark & efforts to improve value addition / Net
sales? (15)
59
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ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
5. Cost Performance
(5.C) Value Additions / Fixed Assets
Total= 30
(i) Show the trend of last three years in bar graph, illustrate it with
your internal Target line. ( 15 )
Value Addition to fixed
assets
10
8
9
8
7
6
4
2
0
2011-12
2012-13
2013-14
Formula
Value Addition to Fixed Assets =
Net Sales - Variable Cost
--------------------------------------------------------Total Cost of Fixed Assets
(ii) What is the benchmark & efforts to improve value addition / Fixed
assets ? (15)
60
PM_44_F4 Rev. No. : 00, Specimen Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
5. Cost Performance
(5.D) Value Additions to Employee cost
Total= 30
(i) Show the trend of last three years in bar graph, illustrate it with
your internal Target line. ( 15 )
Value Addition to Employee
Cost
7
6
6
5
4
5
4
3
2
1
0
2011-12
2012-13
2013-14
Formula
Sales –Variable Cost
Value Addition to Employee Cost = ------------------------------------------------------Total Employee Cost ( CTC )
(ii) What is the benchmark & efforts to improve value addition to
Employee Cost ? (15)
61
PM_44_F4
Rev.
No. : 00, Specimen
PM_44_F8 Rev.
No. : 00
, Specimen
Format* Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
Summary of Achievements
for the year 2013-14
( Company has to fill up )
PM_44_F4
Rev.
No. : 00, Specimen
PM_44_F8 Rev.
No. : 00
, Specimen
Format* Format*
ACMA Awards 2013-14 : Excellence in Quality & Productivity (Large)
For Company:
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