supershopfloorawards.themachinist.insupershopfloorawards.themachinist.in/...form-ssf-2020 … ·...

of 16

Nomination Form

Name of the Company

Plant location

Name of the Plant Head /

Manufacturing Head

Total No. employees at plant including

contractualTotal facility area

(sq m)

Annual production capacity

Name of person sending nomination

Phone number/s

Email Id

A. Tick the relevant segment. Overall Company / Group turnover must be taken into consideration, not the individual plant’s turnover.

o Large enterprises (Rs1,000 crore turnover and above)

o SMEs (Less than Rs1,000 crore turnover)

Please read the Nominations FAQs carefully before filling up the Nomination Form and sending it to us.If required, please use separate sheets of paper to provide information related to the nomination.

of 16

B. Select the appropriate Category with a tick mark

o Covid-19 Innovation (Recently Launched)

o Safety

o Quality

o Productivity

o Green Manufacturing

o Innovation (Product / Process)

o Machining Excellence

o Digital Manufacturing

o Human Resources (HR)

o Corporate Social Responsibility (CSR)

o Supply Chain

o Maintenance

Nomination Declaration: On behalf of my manufacturing plant and shopfloor, I submit this nomination for ‘The Machinist Super Shopfloor Awards 2020’ for the category mentioned in this form. I hereby declare that the information provided in this Nomination Form is latest and correct. I have read, and I comply with the participation guidelines, and agree to accept the verdict of the jury and the organisers of ‘The Machinist Super Shopfloor Awards 2020’.

Name

Designation

Date

Signature

Company stamp


of 16

Instructions

Stick to one category per entry: Every category must have separate entry. You cannot combine two or more categories in one entry. The nomination form has pages related to different categories. Fill in the page/s related only to the category that you are choosing. Of course, you may send as many entries as possible.

Stick to your shopfloor: The information must pertain only to the shopfloor that is being nominated.

Send soft copies for the moment: The Nomination form can be sent in soft copy considering the current scenario. Images related to the nomination should be sent on separate document with appropriate captions.

Don’t go beyond 15 pages in all: Number of A4 size sheets of paper for the nomination details you are sending (including the form, other details and supporting documents) per each entry must not exceed 12 pages. Number of A4 size sheets of paper for images must not exceed 3 pages. Total number of pages including nomination details and images must not exceed 15 pages.

Wherever necessary, please expand the table to provide the necessary information in support of your nomination.

Nomination Deadline: Completely filled nomination forms need to reach us before 6pm on 10th August 2020

Completely filled nominations must be mailed to: [email protected]

For any further clarity on the nomination or the nomination process please contact Fiona Fernandes | +91 9930723498 | [email protected]


of 16

The Machinist Super Shopfloor Award Covid-19 Innovation*

Provide following details along with relevant supporting documents wherever applicable.

Name of the Covid-19 Innovation

Use / Objective of the Innovation

Time taken for development of the Innovation

USP of the Innovation

Target users of the Innovation

Material/s used for the Innovation

Equipment / Technology used for the Innovation

Any additional information you feel is necessary

*This category is newly introduced to recognize innovations implemented in the current scenario.


of 16

The Machinist Super Shopfloor Award in Safety for 2020

Provide following details along with relevant supporting documents wherever applicable.

General informationFY 2019-20 FY 2018-19

Total employees (Full time)Total employees (contractual)Safety training in hours / employee / year

AccidentsFY 2019-20 FY 2018-19

Accident-free man-hoursMajor accidents reportedMinor accidents reportedDowntime due to accidents

Safety FY 2019-20 FY 2018-19

Safety related certifications

Essential documents related to worker safety at the shopfloorFrequency of safety auditsUse and encouragement of personal protection equipmentAvailability of basic medical assistance, easy access to emergency medical assistance & periodical medical examinationsMonitoring & maintenance of equipmentSafety campaigns / contestsActivities aimed to reduce the levels of health hazard factorsProper and scientific disposal of waste and hazardous materialsOther relevant information, if any


of 16

The Machinist Super Shopfloor Award in Productivity for 2020

The winning shopfloor must clearly show measurable improvement in terms of productivity and substantiate the same by providing relevant and credible data for the current as well as the last year for comparative assessment.

Factor (provide data in terms of percentage or relevant units as applicable. See examples in the first two columns)

FY 2019-20 FY 2018-19

Actual capacity utilisation against installed capacity

Actual productivity

Operating profits

Production lines used

New products added

Material cost

Energy cost

Number of machines used

Labour (number of workers)

Implementation of any technology or equipment or solution

Downtime in man-hours or man-days (with brief reason for the same)

Other highlights, if any


of 16

The Machinist Super Shopfloor Award in Digital Manufacturing for 2020

The winning shopfloor must have effectively adopted technology in the context of concepts like Industry 4.0 (or Industrial IoT) and Smart factory (or Digital factory). This could mean implementation of various tools like (but not limited to) automation, robotics, IT & software solutions, advanced machines & equipment, testing facilities, mobile applications, cloud computing and so on. It could also mean a combination of two or more of these tools.

Explain the technology adopted:

Why was this technology required?

What was investment required:

Key challenges faced in implementation:

Solutions to address the above:

Time required for implementation:

What kind of training was required for the staff to use the new technology?

Is the project replicable at other shopfloors?

Benefits achievedProductivity benefits

Cost benefits

Impact on flexibility

Improvement in processes

Impact on quality

Impact on innovation

Savings in time

Savings related to space

Impact on delivery schedule

Environmental benefits


of 16

Others

The Machinist Super Shopfloor Award in Innovation for 2020

The winning nomination must demonstrate the implementation of a product or process, which is either totally new or is a significantly enhanced version of a previous edition.

General informationParameter FY 2019-20 FY 2018-19R&D expenditure (percentage of turnover)Number of patents filed, if anyOther highlights, if any

The entry must answer the following questions related to the actual innovation:

NameDescriptionPatent, if anyCompliance with regulatory normsTime required for developmentTime required for implementationRole of supply chain partnersRole of customersInvestmentsAny other information

Benefits derived through this innovation

OperationalCostTimeEnergyCapacityEnvironmentalHuman ResourcesSupply ChainAny other benefits

Does your plant have an official programme or system in place to encourage employees to share their ideas for innovation and improvement? Yes / No

Please tell us about the same.When started


of 16

Total No. of employees who have participatedNo. of employees participating in current yearBenefits derived as a result of the above, if any

The Machinist Super Shopfloor Award in Green Manufacturing for 2020

The winning entry would be a live example of Green makes great Business sense. Each entry will be primarily judged against the following key parameters. The box provided below is only a reference point. Feel free to add more sheets if you feel it is not enough to provide the relevant information.

Parameter Activities / AchievementsImplementation of GreenManufacturing policy at the plantEmployee involvement

Use of Renewable Energy

Overall energy efficiency achievedOverall water efficiency in terms of use versus availabilityRain water harvesting

How Green is your supply chain?Efficient utilisation of raw materialGreen House Gas Mitigation

Utilisation of green raw material

Utilisation of technology to reduce carbon footprintGreen products

Disposal of waste

Recycling of waste

Tree plantation activities

Relevant Green certifications

Carbon credits earned, if any

Other highlights, if any,


of 16

The Machinist Super Shopfloor Award in Quality for 2020

Quality is one of the key defining factors for a manufacturing organisation. And it goes beyond the product; it is a matter of mindset. So, if you think your shopfloor is the best when it comes to quality, please share the information against the following key parameters.

Parameter Actual achievements / activitiesCustomer satisfaction: Provide information in terms of results of customer surveys / feedback collected on a regular basis.Reduction of warranty costMultistage in-process quality systemVarious quality improvement initiatives taken by floor supervisorsFormal system implemented to promote and encourage employee engagement in improving quality apart from KaizenProcess and Gap analysis identified in various DRMs & management reviews. This indicates that the quality assurance is being driven through process approach.Use of state-of-the-art machinery and equipmentReduction in PPM at customer, if applicableLine Quality - In- process quality check done at least at 3 distinct gates on assembly to ensure zero defectProcess and product audit to ensure change management in product and process including dynamic checking done to avoid recurrence of field failures or PDI defectsKaizen – Provide two key examples that have resulted in improvement of qualityInstitutionalisation of continual improvement as a system and cultureContinuous monitoring and review of Key performance indicators at Strategic, tactical and operational levelContinuous monitoring and review of Key performance indicators at Strategic, tactical and operational levelSupplier / vendor PPM of incoming componentsDocumentation of learnings and standardisation of documentsSystem Health Check-ups through cross functional internal audits across all operationsQuality related certifications


of 16

Other relevant information

The Machinist Super Shopfloor Award in Machining Excellence for 2020

It will not be an exaggeration to claim that we are the first ones to institute an award for Machining Excellence. Of course, we are sure that others will soon follow suit and try to replicate this category in near future. The reason we have introduced this category is because it is directly related to the core activity of discrete manufacturing – machining. (That’s where our magazine derives its name from!)

Parameter Actual achievements / activitiesProduction cycle time – This measure the time taken to actually manufacture a given product from the time an order is released to production, to finished goods.Time for changeovers – The time required to switch a manufacturing line or plant from making one product over to making a different product.Actual yield – Percentage of products produced accurately and to specifications the first time without scrap or rework.Customer Rejects / Returns – How many times / units customers reject products or request returns of products based on receipt of a bad or out of specification product.Throughput – Quantifies how much product is being produced on a machine, line, unit, or plant over a specified period of time.Capacity utilization – Total manufacturing output capacity being utilised at a given point in time in terms of machining. Please state the number of machines installed with brief specifications, if required.Overall Equipment Effectiveness (OEE) – A multiplier of Availability x Performance x Quality used to show the overall effectiveness of a piece of production equipment, or an entire production line.WIP inventory – Measuring the efficient use of inventory materials. It is calculated by dividing the cost of goods sold by the average inventory used to produce those goods.Planned vs. Actual maintenance work – Indicator of how often scheduled maintenance takes place, versus more disruptive/un-planned maintenance.Downtime ratio to operating time – Direct indicator of asset availability for production.Total manufacturing cost per unit excluding materials – Controllable manufacturing costs that go into the production of a given manufactured unit, item or volume.Return on assets - Financial performance calculated by dividing the net income from a manufacturing plant or business unit by the value of fixed assets and working capital deployed.


of 16

Energy cost per unit – Cost of energy (electricity, steam, oil, gas, etc.) required for manufacturing a specific unit or volume of production.Operator training – Time spent in training operatorsReduction in non-machining activities directly related to the machine-like loading and unloading components, new fixtures, tool changing and so on.Any other detail

The Machinist Super Shopfloor Award in Human Resources for 2020

This winning entry must demonstrate how the plant has facilitated the engagement, empowerment and evolution of its employees in its journey of success. Of course, retention of existing employees and attracting new and relevant talent is part of this journey. The judges will give marks on the basis of the following data:

Brief on Recruitment programme:

Brief training & development programme:

Ensuring employee safety and overall well-being:

Involvement of employees in improvement and innovation programmes:

Policy and system to address employee grievances:

Policy and system to prevent and address sexual harassment at workplace:

Employee performance assessment system:

Initiatives for dialogue and collaboration between employees and management:

Cultural and sports activities:

Other highlights, if any:


of 16

The Machinist Super Shopfloor Award in Corporate Social Responsibility (CSR) for 2020

What is your shopfloor doing in terms of giving back to the society and the community? How deeply are you involved in making a difference to your surroundings in terms of the impact areas?

Parameter FY 2019-20 FY 2018-19Expenditure on CSR activities in terms of percentage of turnover

Please share details on the CSR activities undertaken by the plant in the following areas.

Healthcare:

Environment:

Education:

Supporting the Girl Child:

Empowering the local women:

Sports & cultural activities:

Vocational training to local youth:

Contribution during natural disaster / social unrest:

Others, if any:


of 16

The Machinist Super Shopfloor Award in Supply Chain Management for 2020

The winning nomination entry must satisfactorily answer the following questions and provide relevant supporting documents:

Briefly describe the supply chain management (SCM) system implemented at the plant:

When was the above system implemented and why?

Please share information on the following parameters in the context of SCM system used at the plant?Parameter FY 2019-20 FY 2018-19Impact on delivery schedules

Impact on inventory

Impact customer service

Impact on environment

Impact on performance of the procurement function

Impact efficiency of overall operations

Briefly share information if you have made use of technology / automation to improve the SCM function within the facility.

How do you measure and report supplier performance?

Tell us about your supplier certification programme

Tell us about your supplier recognition programme


of 16

Other highlights, if any?

The Machinist Super Shopfloor Award in Maintenance for 2020

Note: In the quest for world-class manufacturing, many industries are appreciating the need for efficient maintenance systems that have been effectively integrated with corporate strategy. It is vital that maintenance management becomes integrated with corporate strategy to ensure equipment availability, quality products, on-time deliveries, and competitive pricing. Managerial attitudes have changed toward maintenance because of the emergence of new management philosophies. In addition, social trends such as lack of capital, fluctuations in currencies, competition, quality, and environmental consciousness, have also encouraged a new focus on maintenance. It is in this context that we are introducing the category of maintenance with this year.

Please share the following details in the context of your shopfloor’s maintenance practicesPlease share information on the following parameters in the context of maintenance system used at the shopfloor.Parameter FY 2019-20 FY 2018-19Machine downtime (operational)Downtime cost incurredMeantime between machine failuresExpenditures on partsTechnician response timeImpact efficiency of overall operations

What is the process of data collection on the shopfloor and what is its frequency in the context of maintenance?

What kind of training and upgradation programmes have you undertaken for the staff members in the last 15 months?

Have you invested in any technology solution to improve the maintenance of your shopfloor? Please share details about the same and about its overall impact?

How would you break-down your shopfloor’s overall maintenance time (100%) in the following? The total should add up to 100. Input NA, if not applicable. Use the other fields to describe schedules on mentioned below:Emergency: _________________Predictive / Preventive: _________________Routine repair: _________________Shutdown: _________________Others: _________________ (Please provide a relevant heading here: _________________)Others: _________________ (Please provide a relevant heading here: _________________)Others: _________________ (Please provide a relevant heading here: _________________)


of 16

Others: _________________ (Please provide a relevant heading here: _________________)

Please feel free to share any relevant information in the context of this nomination below:(Do not exceed beyond 300 words)


supershopfloorawards.themachinist.insupershopfloorawards.themachinist.in/...form-ssf-2020 … ·...

Documents