Transcript Slide 1

ACMA Awards
Excellence in Quality &
Productivity
Company Name :
Plant Location :
Category : Large
2014-15
( 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
Actual
Marks
100
Total
1000
For Administrative Queries:
For Technical Queries:
Mr. Jitender Rana
Email – [email protected]
Mobile – 09873369699
Mr. V K Sharma
Email : [email protected]
Mobile : 09811392068
Ms. Sakshi Karkamkar
Ms. Sapana Baravkar
Email – [email protected] Email : [email protected]
Mobile – 07387002181
Mobile : 07350703339
Mr. Binny Tomy
Email- [email protected]
Mobile- 9711138869
ACMA Centre for Technology (ACT)
Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C,
Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar ,
Pune – 411005, India .
www.acma-act.in
ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
Letter for Submission of Award application for 2014 - 15
Company letterhead details ( Logo , Address )
To ,
The Secretariat ( ACMA Awards ) ,
ACMA Centre for Technology
Office No. C, , 10th Floor, Godrej Eternia,
”B” Wing ,Old Mumbai –Pune Highway, Wakdewadi ,
Shivaji Nagar Pune – 411005, India
We are pleased to submit the application for ACMA Award 2014-15 for
Excellence in Quality & Productivity in 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 2014-15
ACMA Awards Category
Small
Between
INR 20 to
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 Between INR 20 to 50 Cr
Large Category- Company Group Annual Sales Turnover Between INR 50 to 150 Cr
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ACMA Awards 2014 - 15 : 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 )
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
Company’s Details
5.
Company turnover ( in Rs. Crore ) for Year 2014 - 15:
6.
Plant turnover ( in Rs, Crore ) for Year 2014-15 :
7.
Year of Establishment : Company _______ , Plant ___________
8.
Total Employees : Company ___________ , Plant _____________
9.
Do you have a Joint Venture : ( If Yes , Mention the partner name )
10. Company’s Key products :
11.
Plant’s Key products :
12. Plant’s key manufacturing processes :
13. Plant’s Key competitors :
14. Plant’s Major Certifications :
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ACMA Awards 2014 - 15 : 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 Customer for the plant for which
application is sent
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.
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ACMA Awards 2014 - 15 : 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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ACMA Awards 2014 - 15 : 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 )
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ACMA Awards 2014 - 15 : 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
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ACMA Awards 2014 - 15 : 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
45
1.B
20
1.C
Suggestions / Kaizens Per
Employee
Absenteeism
1.D
Training
10
1.E
Small Group Activities
10
1.F
Safety
25
1.G
Environment
Management
30
TOTAL
Actual Marks %
( for office
use )
10
150
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.A) Work Place Management
Total= 45
(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
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
1. Leadership Focus
(1.A) Work Place Management
Total = 45
(ii) How do you practice 5s culture ( 5 )
(iii) How employees are motivated to follow 5s (5)
(iv ) What is 5s target ? ( 5 )
(V) Provide 5s results with trends (5)
Target
Actual
90
76
80
77
77
78
79
80
75
70
% scores
60
50
74
70
60
60
50
40
30
20
10
0
Formula
5 S Score = Lowest zone / area score of that month in %
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
1. Leadership Focus
(1.A) Work Place Management
Total = 45
(Vi) How you drive 5S in your Organization (making Zones,
accountability, checklist, inclusion of all areas, trophy, audits, corrective
actions, non conformity points closure, cross audits, negative marking
for critical points, time allotted for m/c cleaning) (4)
( vii ) What you feel is your Best Practice in 5S (2)
( viii ) How the 5S Results are moving in last 3 years. How the Targets
are set (are the targets modified, consistency in targets, improvements
etc). Gap between Highest Zonal Score & Bottom lowest Score (2)
( ix ) What corrective actions are planned based on 5S results (2)
Formula
5 S Score = Lowest zone / area score of that month in %
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ACMA Awards 2014 - 15 : 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 2014 - 15 : 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)
Target
Actual
1.6
No of sugg implemented / employee
1.4
1.4
1.3
1.2
1.2
1.1
1
1
0.9
0.8
0.8
0.6
0.6
0.5
0.4
0.4
0.4
0.3
0.2
0
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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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.C) Absenteeism
Total= 10
Total % absenteeism
(i) Provide results on absenteeism,? What are the trends in regards to
total absenteeism? (Three year trend in bar graph , illustrate it with your
internal Target line.) ( 5 )
Authorized =
%
Unauthorized =
%
Total
=
%
10
9
8
7
6
5
4
3
2
1
0
9
8
5
2012-13
2013-14
2014-15
Formula
Total absent man-hours for the month ( Authorized + Unauthorized )
Absenteeism =-------------------------------------------------------- -------------------------------- X 100
Total man hours for the month
(ii) What forums are available for employees to share grievances ?
What efforts organization takes to reduce absenteeism? ( 5 )
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.D) TRAINING
Total= 10
(i) Is training and development opportunities available ? ? List some
benefits achieved by trainings in recent past. What is the trend of the
training hours / employee over the years? (show last three year trend
in bar graph , illustrate it with your internal Target line.) ( 5 )
Training hrs/emp/year
Training Areas :
•
•
•
60
•
•
50
55
40
40
30
25
20
10
0
2012-13
2013-14
2014-15
Formula
Total training man-hours for all employees for year
Training hours/employee / year =---------------------------------------- --------------------Total employees
(ii) How training effectiveness is measured? Mention benefits of
Training : Tangible ( in Rs. Lacs ) & Intangible : (Give details for
TWO shining examples) : ( 5 )
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ACMA Awards 2014 - 15 : 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 : How do you
promote small group activity culture ? How various SGs interact with each
other ? ( 2 )
(ii) Do small group participate in the Quality Conventions-Group/State
level/National. Show certificates / trophy photographs : ( 3 )
(iii) How many active groups are present in the current year? % employee
involvement In QC Activity? (show last three year trend in bar graph. ( 5 )
30
No. of Active groups
active groups
% of emp involvement
100
25
25
75
20
15
70
20
15
50
50
10
25
5
0
% Employees Involvement
100
0
2012-13
2013-14
2014-15
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.F) SAFETY
Total= 25
(i) How do you do incident investigation? Do you track near miss
Incidences? Do you have system of Office staff's round in shop floor for
observing Unsafe Acts / Conditions, How this system works?. Indicate
the Top 3 Incident prone areas in your Factory and Preventive actions
planned. (5)
(ii) What you have learnt from others / shared with others on Safety. (5)
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
1. Work Environment and employee engagement
(1.F) SAFETY
Total= 25
(iv) What are the current accident levels? (Show last one year data in
line graph) (15)
A) Frequency (nos.) Minor + Major both
Target
Accident frequency
1
0.8
Actual
0.8
0.6
0.6
0.5
0.4
0.4
0.3
0.3
0.2
0
0
0
0
0
0
0
B) Severity (man hrs. lost)
Target
Actual
0.9
Accident frequency
0.8
0.8
0.7
0.6
0.6
0.5
0.5
0.4
0.3
0.4
0.4
0.3
0.2
0.1
0
0
0
0
0
0
0
Formula
No. of accidents
Frequency rate =------------------------ X 106
Total man hours
Formula
Severity rate
Total man-days lost
=------------------------------- X 106
Total man hours
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ACMA Awards 2014 - 15 : 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)
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ACMA Awards 2014 - 15 : 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?
Do you measure Carbon Foot Print ? How do you measure it ? What is
the score ? (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)
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ACMA Awards 2014 - 15 : 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
15
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 )
35
30
100
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
2. Customer Assessment
(2.A) Customer Awards
(i)
( ii )
How do you listen to customer ( 5 )
Awards by Key Customers
No. of Key-Customers
10
8
8
4
5
(10)
Awards by key customer
10
9
6
Nos
Total = 15
8
6
Award photo
2
0
2012-13
2013-14
2014-15
Note : If your Customer does not have a system of Awards , Mention what kind of
supplier recognition is followed by Customer .
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
2. Customer diagnosis
Total= 20
(2.B ) Customer audit of Quality system
(i) how do you ensure proactive corrective measures in future
applications 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
QCD audit % score
75
Actual
Target
55
50
45
25
0
2012-13
2013-14
2014-15
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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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
2. Customer diagnosis
(2.C ) Customer rating for Quality & Delivery
Total= 35
(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. (20)
100
90
85
86
2012-13
2013-14
75
50
25
0
2014-15
( II ) How do you ensure proactive corrective measures in future
applications ? Mention here major improvements done by your
company to improve above performance : ( 15 )
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
2. Customer diagnosis
(2.D ) Feedback from Customer & analysis
Total=30
(i) How customer issues are communicated and actions are taken ?
Please describe system of getting feedback from the customers? (10)
(ii) How do you sensitise employees towards customer issues and how
do you motivate them for faster response? how do you analyze this
feedback and take actions in weak areas? Explain with two shining
examples. (20)
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ACMA Awards 2014 - 15 : 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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ACMA Awards 2014 - 15 : 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 2014 - 15 : 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 ? Provide key complaint management results [internal
as well as external] (5)
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ACMA Awards 2014 - 15 : 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)
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ACMA Awards 2014 - 15 : 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
2012-13
2013-14
2014-15
(iii) Please describe the actions taken to reduce the in- house rejection
How do you train employees to meet product quality ? Provide key
product quality results (10)
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ACMA Awards 2014 - 15 : 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 2014 - 15 : 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
2012-13
2013-14
2014-15
(vi) Explain efforts taken to reduce rework. Provide key process
matrices results : (10)
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ACMA Awards 2014 - 15 : 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 2014 - 15 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.C) Supplier Rejection
(i)
Total = 40
how do you measure supplier quality [quality of everything about
supplier]
explain your ongoing vendor audit process
how do you give feedback to your vendor
how do you align vendor with your strategic objectives
provide key vendor related results(20)
Target
1800
1600
Actual
1600
1500
1500
1456
Supplier Rej in PPM
1400
1200
1200
1235
1124
1000
840
800
640
600
540
440
400
230
200
0
(ii) Please describe the efforts to reduce the supplier rejection? (10 )
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ACMA Awards 2014 - 15 : 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 2014 - 15 : 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
2012-13
2013-14
2014-15
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 2014 - 15 : 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 2014 - 15 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.E) Cost of poor Quality ( COPQ)
(i)
Total = 30
what are different elements of Cost of quality
what measures are monitors towards cost of quality
how do you reduce cost of quality
how do you communicate cost of quality to your employees
and prepare action plans ?
give cost of quality results and trends for last three years (10)
1.4
1.2
1.2
1
%
0.8
0.6
0.4
0.4
0.2
0.1
0
2012-13
2013-14
2014-15
(ii) Show elements of Cost of poor quality and improvements for the
year 2014-15 . (10) Give two action plans for cost of quality
reduction
S.N.
COPQ
Element
Before %
After %
Actions Taken
1
2
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ACMA Awards 2014 - 15 : 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 2014 - 15 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.F) Process Improvement
Total= 40
(i) How company identifies Critical to Quality characteristics (CTQ) ?
How do decide on your process control measures. (10)
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ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
3. Quality Performance
(3.F) Process Improvement
Total= 40
(ii) What are your process control metrics ? Does the company insist
on Cpk performance for CTQ characteristics? What is the present
level of Process capability (Cpk) for CTQ’s identified and controls ?
(15)
S
.
N
.
CTQ
Param
eter
Customer
Complain
ts for
2014-15
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? Provide key process matrices results ( 5 )
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ACMA Awards 2014 - 15 : 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 2014 - 15 : 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 2014 - 15 : 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
2014-15 ? (5)
% =
(vi) How do you ensure effectiveness of Poka yoke? (5 )
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ACMA Awards 2014 - 15 : 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
47
ACMA Awards 2014 - 15 : 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
48
ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
4. Productivity Performance
(4.A) Manpower productivity
Total= 100
(i) How do you measure productivity ? How do you decide on
Productivity targets ? (5)
(i) What is the productivity trend. Show for your key business line ?
(show last 3 year data in Bar graph , illustrate it with your internal Target
line.) (15)
No. of products
/man/year
40
35
30
20
20
24
10
0
2012-13
2013-14
2014-15
(ii) What are the tools used to improve manpower productivity ? (10)
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ACMA Awards 2014 - 15 : 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
50
ACMA Awards 2014 - 15 : 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
2012-13
2013-14
2014-15
(ii) What opportunities employee have for learning and sharing ? How
Company encourages employees for operating multi-machines ?
(20)
51
ACMA Awards 2014 - 15 : 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.
52
ACMA Awards 2014 - 15 : 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
53
ACMA Awards 2014 - 15 : 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)
54
ACMA Awards 2014 - 15 : 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
2012-13
2013-14
2014-15
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
55
ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
4. Productivity Performance
(4.D) Loss of Production Hours
Total= 50
(i) Provide your equipment maintenance plan ? What are the measures
tracked for equipment up time ? How much is machine breakdown
loss in % of total available time? (Bar graph, illustrate it with your
internal Target line ) (20)
2.5
% Breakdowns
2.1
2
1.5
1
0.4
0.5
0.1
0
2012-13
2013-14
2014-15
(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
56
ACMA Awards 2014 - 15 : 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
2012-13
2013-14
2014-15
(iv) Show Actions taken to reduce Setup time (10)
S.N.
Set up
Before
After
Actions Taken
1
2
3
4
57
ACMA Awards 2014 - 15 : 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
58
ACMA Awards 2014 - 15 : 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
2012-13
2013-14
2014-15
(ii) Show examples to reduce energy consumption (5)
S.N.
Item
Before
After
Actions Taken
1
2
3
4
59
ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
5. Cost Performance
(5.B) Value Additions / Net Sales
Total= 30
(i) How do you track various cost ? 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
2012-13
2013-14
2014-15
Formula
Net Sales – Variable Cost
Value Addition to Net Sales
=
---------------------------------------------------Net Sales
(ii) How do you sensitise employees for costs and motivate them to
participate in cost reduction drives ? What is the benchmark & efforts to
improve value addition / Net sales? (15)
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ACMA Awards 2014 - 15 : 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
2012-13
2013-14
2014-15
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)
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ACMA Awards 2014 - 15 : 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
2012-13
2013-14
2014-15
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)
62
ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
Summary of Achievements
for the year 2014-15
( Company has to fill up )
ACMA Awards 2014 - 15 : Excellence in Quality & Productivity (Large)
For Company:
Show your companies excellent photos