ACMA Awards Year of Inception: 1966

1. ACMA Awards Year of Inception: 1966 Excellence in Manufacturing 1000 Marks Company Name : Plant Location : Award Category: Tick mark in appropriate box as per your ‘Company Group Turnover for 2018-19’. Small < 50 Cr ( NA ) Medium > INR 50 to 150 Cr ( NA ) 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

2. Company / Plant Information Use this slide to brief about your company / Plant. It includes Product names / photos , Plant facility photographs.

3. For Administrative Queries: • Ms. Sakshi Karkamkar • Email –sakshi.karkamkar@acma.in • Mobile – 7387002181 • Ms. Smita Kulkarni • Email – smita.kulkarni@acma.in • Mobile –9922922500 • Mr. Sanket Jadhav • Email- sanket.jadhav@acma.in • Mobile- 7768046868 • Ms. Surekha Deshmukh • Email- S.DESHMUKH@unido.org • Mobile- 9552599463 For Technical Queries: Mr. Arun Bage Email – arun.bage@acma.in Mobile – 9552532184 Mr. Atul Gupta Email – atul.gupta@acma.in Mobile – 9971888751 Mr. Vishal Saxena Email – vishal.saxena@acma.in Mobile – 9650988154 Ms. Tanu Ahuja Email – tanu.ahuja@acma.in Mobile – 09899237770 ACMA – Skilling and Mentoring Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C, Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar , Pune – 411005, India, Desk phone – 020 66061219 act@acma.inwww.acma.in , www.digitalact.in

4. Letter for Submission of Award application Company letterhead details ( Logo , Address ) To , The Secretariat (ACMA Awards) , ACMA – Skilling and Mentoring Godrej Eternia, ”B” Wing ,, 10th 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 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 ) 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.

5. Automotive Component Manufacturers Association of India 6th  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

6. Company’s Details • 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 Number- • b) Invoicing Address (write complete address with pin code)- • 4. Chief Executive Officer details : • Name : Designation : • Mobile : E-mail : • Website: • 5. Plant Head details : • Name : Designation : • Mobile : E-mail : • 6. HR Head details : • Name : Designation : • Mobile : E-mail :

7. 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 : 14. Plant’s Key competitors : 15. Plant’s Major Certifications :

8. 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)

9. Customer Details Mandatory requirement (not applicable for Excellence in Supplier Development category) • Kindly provide details of your top 3 business customers in below table. • ACMA Award online application software automatically sends a link to all above email addresses to get feedback about your plant. • 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: • These feedbacks will be considered by Jury for evaluation & the same will be provided to you as a part of feedback report.

10. Status of  actions  taken by your company based  on previous ACMA Awards feedback report. (Mention top 5 only)  (Not applicable- for 1st time applicants)

11. 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

12. 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

13. OFFICE USE ONLY Section 1 Hygiene Factors Total marks =200

14. 1. Hygiene Factors (1.A) 5S & Plant Upkeep 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 %

15. 1. HygieneFactors (1.A) 5S & Plant Upkeep Total = 30 (ii) How you drive 5S Process (10) Explain whether sub areas formed, Sub-Area Owners identified, 5S 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

16. 1. Hygiene Factors (1.A) 5S & Plant Upkeep Total = 30 (iv) Shining examples of 5S Improvements (3) Show 4 Photographs, Assessor may interview few operators for checking effectiveness (v) Share few sample audit findings & actions taken (3)

17. 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)

18. 1. Hygiene Factors (1.B) Leadership Focus Total = 20 (iii) What Process is followed for 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

19. 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)

20. 1. Hygiene Factors (1.B ) Leadership Focus Total = 20 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)

21. 1. Hygiene Factors (1.C) Quality Management Total = 30 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

22. 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)

23. 1. Hygiene Factors (1.C) Quality Management Total = 30 (iii) Show examples of use of Quality Tools like Six Sigma Project, Poka-yoke, DoE, Why-Why Analysis, 8D etc. (15)

24. 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

25. 1. Hygiene Factors (1.D) Stakeholders Happiness Total = 30 (ii) Show score of Supplier Satisfaction for 3 years (10) • (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.)

26. 1. Hygiene Factors (1.E) Safety Total = 20 Give details of One Accident Investigation analysis and corrective actions (4) (ii) Give details of One Near Miss Accident and corrective actions (4)

27. 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)

28. 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)

29. 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)

30. 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 What % of CTQs (Critical to Quality) are being addressed through poka- yoke ? (3) Show some recent customer complaints, which are addressed through poka-yoke (2)

31. 1. Hygiene Factors (1. H ) Poka-yoke / KAIZEN Total = 10 (iii) Show some shining examples of Poka-yoke / KAIZEN (3 ) (iv) Show your mechanism for sustenance of poka-yoke / KAIZEN (2).

32. 1. Hygiene Factors Total = 5 (1. I) Legal / Statutory Compliance (i) How do you ensure compliance of Statutory issues (5), Give few shining examples

33. 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)

34. 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

35. 1. Hygiene Factors (1 L) Contribution towards Society & Nation Building Total = 20

36. 1. Hygiene Factors 1 L Contribution towards Society & Nation Building Total = 20

37. OFFICE USE ONLY Section 2 Manufacturing Focus and Business Growth Marks = 280

38. 2. Manufacturing Focus and Business Growth (2A) Business Growth Total = 50 • 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) (ii)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)

39. 2. Manufacturing Focus and Business Growth (2A) 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)

40. 2. Manufacturing Focus and Business Growth (2A) 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)

41. 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 )

42. 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)

43. 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 ) • 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)

44. 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)

45. 2. Manufacturing Focus and Business Growth (2.D) Waste Elimination Total = 35 • 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 )

46. 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 )

47. 2. Manufacturing Focus and Business Growth (2.E) Material planning and logistics planning Total =10 • How do you plan your material requirements to meet production plan ? How do you ensure FIFO ? (3) • 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) • 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 )

48. 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)

49. 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)

50. 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)