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India Manufacturing Excellence Awards 2016 www.frost.com/imea

COMPANY NAME

MAILING ADDRESS

NATURE OF INDUSTRY

Application for Corporate nomination: YES NO Please refer the IMEA brochure for further details

DECLARATION:

I state that this application represents the organization’s irreversible decision to participate in the complete

awards process of IMEA 2016. We also understand that in case we are short-listed for the subsequent stages in

the process we shall have to pay the relevant site visit fees and abide by the terms and conditions as mentioned

overleaf and arrange the site visit for the assessment team.

SIGNATURE OF AUTHORIZING OFFICIAL WITH SEAL: DATE:

Sl. No.

Site Location Sales Turnover

(in Rs. Cr) No. of Employees Include in IMEA

(Y/N) Permanent Temporary

1.

2.

3.

4.

Name of liaison person for correspondence:

Designation: Email ID:

Phone: Hand Phone:

Name of senior most official in the company:


Phone: Hand Phone:

Name of authorizing official:


Phone: Hand Phone:

COMPANY DETAILS

LIST OF SITES/FACILITIES THAT FORM PART OF YOUR COMPANY

CONTACT DETAILS (Liaison person for correspondence)

TERMS & CONDITIONS

India Manufacturing Excellence Awards 2016 www.frost.com/imea

Application fee of INR 84,550/- per facility should be sent along with the duly completed application

documents. If the facility is not short-listed, INR 57,250/- will be refunded.

The to and fro air travel, local conveyance and lodging/boarding will have to be provided and arranged

for by the site being assessed.

The demand draft or cheque should be drawn in favor of "Frost & Sullivan India Private Limited" payable

at Chennai.

At the event, Awards will be given to top management (C-level executives) of the respective companies.

* The above mentioned fee is inclusive of 14% Service Tax and 0.5% Swachh Bharat Cess. Government taxes are

subject to change. In case of change in Service tax rate, incremental percentage change will be passed on from

the applicable date.

Please Mail Completed Application and Self-Assessment Docket to:

CATEGORY SALES TURNOVER (INR) APPLICATION

FEE* SITE ASSESSMENT FEE*

EMERGING BUSINESS 20 Cr – 100 Cr

INR 84,550

INR 194,200

MEDIUM BUSINESS 100 Cr – 500 Cr INR 321,800

LARGE BUSINESS 500 Cr – 2000 Cr INR 460,100

MEGA LARGE BUSINESS > 2000 Cr INR 595,400

Mr. Ravindra Singh,

Frost & Sullivan India Private Limited,

D2/2, Convergence contact Centre, 4th Floor, Block – EP, Sec- V Salt lake city Kolkata - 700091 Ph: +91 (33) 66273056

FEE DETAILS

For any queries/clarifications, please contact

Mr. Abubaker B,

Frost & Sullivan India Private Limited,

101, Prestige Loka, No. 7/1, Brunton Road,

Bangalore - 560025

Ph: +91 (80) 67028079, +91 98866 19720

Email: [email protected]

COMPANY NAME

FACILITY LOCATION

Please mail the completed Self-Assessment Docket along with a site-specific corporate presentation of the company to the following address – Mr. Abubaker B, Frost & Sullivan India Pvt Limited,

101, Prestige Loka, No. 7/1, Brunton Road,

Bangalore - 560025, India

Ph: +91 (80) 6702 8079

Cell: +91 9886619720

Email: [email protected]

Self Assessment Docket – 2016

Page 2 of 11

Tick Mark the relevant Boxes

1

Are Customer ratings available?

Not Available Being Planned CSI for 1 year

available CSI used to improve

processes

CSI for at least 3 years available and is used to improve

processes

2

Possession of Quality certifications & ratings

Not Available Being Planned In First Year of Certification

Certification used to improve processes

Been through at least one review (only if used to

improve processes)

3

Rate of New Product Introduction &

Acceptance Never

Planning to introduce new

products

New Product launched in last 5

years

New Product launched every

year

NPI on a regular basis

4

Place for everything and everything in its place

No Order to storage nor any plan to improve

Plan to implement 5S

5S implemented in one / a few major operation areas

5S implemented in all major operation

areas

5S implemented throughout plant

5 Material Flow

Totally Disjoint with large buffers

in all areas

Disjoint with large buffers. Efforts to link processes on

Disjoint, large buffers in a few

areas

Large buffers only before the bottleneck

No Buffers-Well Balanced Line

6

Visibility of team's performance on PQCDSM

parameters Not at all Visible Planning to do so Visible in one area

Visible in a few areas

Visible throughout the Plant

7 Yield Monitoring Non Existent Being Planned

In one area of the plant

In substantial areas of the plant

Well established throughout the

Plant

8 Material handling

Systems

Manual handling in most of the areas

Primitive & Manual…but Plans for modernization

are on

Use of material handling

equipment can be seen in few areas

Significant deployment of

forklifts, conveyors, etc

Complete deployment of

forklifts, conveyors, AGVs, etc

Part – A

Self-Gradation


Page 3 of 11


9

What is the overall inventory turnover,

including FG, WIP & RM 0-3 4-6 7-12 13-24 25+

10 Non-moving Inventory > 20% 15 - 20% 10 - 14% 5 - 19% < 5%

11

Skill Matrix & Competency Mapping

Non Existent Being Planned In one area of the

plant In substantial areas

of the plant


Plant

12

What percentage of workers are active members of formal

workteams, quality teams or problem solving teams

<5 6-10 11 to 30 31 to 90 91-100

13

Does maintenance have and follow a predefined Preventive maintenance

schedule

Non Existent Being Planned On a few machines On substantial

number of machines


Plant

14

Operator Routine Maintenance

Non Existent Being Planned On a few machines On substantial

number of machines


Plant

15 Supplier Certification No procedure Being Planned

A class suppliers certified

A & B class certified All suppliers

certified

16

Supplier performance is measured and reported

back to them

No effort ever made to

communicate Being Planned

Policy put in place, but partially

implemented

Well established and implemented for A class items

Well established for all categories


Page 4 of 11


17

Evaluation of logistics efficiency

No defined Matrices

Plans to define matrices exists

Performance on defined matrices is monitored for past

one year

Performance on defined matrices is monitored for over

3 years

Improving trends in the matrices

18

What portion of manufacturing

employees have had basic SPC training? (%)

0-6 7-55 56-80 81-93 94-100

19

Use of Information Technology in the plant

None Being Implemented ERP system for one

year ERP system in use

for 3 years

ERP system in use for more than 3

years

20 Level of Automation

Manual operations and a strategy in

place for automation

Automation is limited to

Monitoring of the variations. Controls

are manual

Mostly operations are automated for

controls

Mostly operations are automated and system data is used

for reducing variation

Automation resulting in reduction of variations,

manpower, losses and improvement

of operations

21

Measurement of NPD efficiency

No defined Matrices

Plans to define matrices exists

Performance on defined matrices is monitored for past

one year

Performance on defined matrices is monitored for over

3 years

Improving trends in the matrices

22

Benchmarking Technology and

Processes No such studies

Planning to conduct studies

Studies have been conducted once

and improvement plans are prepared

Studies are being conducted for past

3 years and improvements have

been initiated

Benchmarking is a regular exercise

with focus on continuous

improvement


Page 5 of 11

No. Parameter 2013-14 2014-15 2015-16

Site Data

1 Total Number of Company Employees (Current Year Data)

2 Total Number of Casual / Contract Employees

(Current Year Data)

3 Area of Facility (Sq Mtr) Built up area:

4 Production Capacity Current Capacity with unit of measurement:

Future expansion if any in next 3 years:

Growth Indicators

5 Market Share of Major Product Family (%)

6 Annual Sales (in Crore Rs.)

7 Sales Margin (%)

8 EBITDA Margin (%)

9 Current Ratio/ Working Capital Ratio

10 Quick Ratio

11 Inventory Turnover Ratio

12 Payroll Expenses (as percentage of turnover)

13 Sales of New Product to Total Sales (%)

14 Contribution %

15 Expenditure on R&D (% of turnover)

16 ROCE

17 Total Asset Turnover

Cost Heads (From P&L as percentage of sales)

18 Cost of Labour to Sales (%)

Part – B (Refer to Explanation of Matrices in Annexure)

Please Furnish Data as Requested Below


Page 6 of 11

No. Parameter 2013-14 2014-15 2015-16

19 Cost of Raw Material to Sales (%)

20 Cost of Consumables to Sales (%)

21 Cost of Power and Fuel to Sales (%)

22 Manufacturing Over Heads to Sales (%)

23 Sales Over Heads to Sales (%)

24 Marketing Over Heads to Sales (%)

Manufacturing Health Matrices

25 Customer Delivery reliability (%)

26 Customer Return Rates (PPM)

27 Warranty/Product liability cost as a % of Sales Turnover

28 First Pass Yield (%)

29 Internal Reject Rates (%)

30 Supplier Return Rates (PPM)

31 Supplier Delivery Reliability (%)

32 Predictive / Preventive maintenance as a percentage of total maintenance time

33 Capacity Utilization (%)

34 Employee suggestions implemented per employee per year

35 Training Man-days per employee per year

36 Employee Attrition Rate (%)

37 Accident frequency rates (%)


Page 7 of 11

ANNEXURE

Explanation to terms used in Part - B

1) Latest data of total number of employees on-roll

2) Total Number of Casual / Contract Employees

Average number of casual / Contract workers on any given day

3) Area of facility (in Sq Mtr)

= Built up area / Total covered area of the facility which is directly or

indirectly used for production.

4) Production Capacity: a. Current Capacity: Total current production capacity of the unit with unit of

measurement b. Future Expansion: Additional capacity that will be added. (Applicable only if

there is a future plan to expand in next 3 years.) 5) Market Share: 3 year market share of major product family in per-centage. 6) Annual Sales = Total sales in Crore Rupees in a financial year

7) Sales Margin

8) EBITDA Margin

9) Current Ratio/ Working Capital Ratio

10) Quick Ration:

11) Inventory Turnover Ratio (ITR)


Page 8 of 11

12) Payroll expenses

13) Sales of new products to total sales (in %)

Note: ‘New product sales’ can be defined as the sales derived from any product that is materially different in application or from products previously manufactured and sold by the firm, and that carry a separate identity (such as product number).

14) Contribution (in %)

15) Expenditure on R&D (% of turnover)

16) Return on capital employed (ROCE)

17) Total Asset Turnover

18) Cost of Labour to Sales (%)

19) Cost of RM to Sales (%)


Page 9 of 11

20) Cost of Consumables to Sales (%)

21) Cost of Power and Fuel to Sales (%)

22) Manufacturing Over Heads to Sales (%)

23) Sales Over Heads to Sales (%)

24) Marketing Over Heads to Sales (%)

25) Customer delivery reliability (in %)

26) Customer return rate (in PPM)

Or

If product variety is high, then the following may be used

27) Warranty/Product liability cost as a % of sales turnover

( )


Page 10 of 11

28) First Pass Yield (in %)

29) Internal reject rate (in %)

Or

If the product variety is high, then the following may be used

30) Supplier return rate (in PPM)

Or

If product variety is high, then the following may be used

31) Supplier delivery reliability (in %)

32) Predictive/preventative maintenance as a % of total maintenance time

( )

33) Capacity Utilization (in %):


Page 11 of 11

34) Employee suggestions implemented

35) Training Man-days per employee per year

36) Employee Attrition rate (in %)

37) Accident frequency rate (in %)

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