6Thficci QUALITY SYSTEMS EXCELLENCE AWARDS FORINDUSTRY- 2017

6thFICCI QUALITY SYSTEMS EXCELLENCE AWARDS FORINDUSTRY- 2017

APPLICATION FORM

Large Sized Organization

Terms and Conditions of the Awards:

• Scope of the Awards cover the following sectors:

Construction & Infrastructure

Manufacturing (including energy)

Mining

Power (including Generation,Transmission and Distribution)

• The description and attachments should be clearly linked with the relevant question

• In certain questions, guideline(s) in the form of note is given to help the applicant in providing specific information required. Also, in few questions a detailed explanation of technical term and the exact data required is given.

• The application for the award is foraunit in Manufacturing, Mining & Power sector. But, multiple units of single organization are eligible to apply for Awards. Whereas, in Construction & Infrastructure sector the application for the award is for the organization and not for the individual project of the organization. However, in case of Ports and Airports, application of individual unit would be considered.

• In case of any clarification, applicant should get their doubts clarified before applying. FICCI or QCI shall not be responsible for any lack of information in application once organization has applied for awards.

• Any misrepresentation of facts will disqualify the organization from awards and any fees submitted would be non-refundable.

• The evaluation is a three-stage process as mentioned below:

Application evaluation

On site assessmentafter application evaluation

Jury selection by the presentation of qualifying unit/mine/organization after on-site assessment

• The category of the applicant unit for Awards & Feeswill be determined by the category of the organization owning the unit as per the criteria defined below.

• Application fee (Non-refundable and inclusive of GST @ 18%) for the award for each of the four sectors i.e. Construction & Infrastructure, Manufacturing. Mining & Power covers under the scope of awards is as follows :

Rs47,200/- for large sized organization (Organization having either turnoveror investment excluding working capital more than Rs 500 crore).Please share your unit/organization’s GST Number and state code while doing payment as it is mandatory in GST regime.

• Unit/Organization that qualify for on-site assessmentwillhave to bear the expenses of auditor(s)’ travelling and accommodation in addition to the fees mentioned above. Also, they have to pay an additional fee of Rs 11,800/- per man day to FICCI as the auditor fees for the on-site assessment of its unit/organization. Generally, two auditors will be deployed for one day audit of the unit/Organization.

P.S: In case of change in tax rates, the rates will be applicable at the time of Invoicing will be considered

• In case any question is not applicable for your Organization/Unitthen please justify the reason(s) for the same

• Wherever an organization is participating through unit level,only the individual unit level data should be shared for evaluation in the application for Question No. 1.6 and beyond in the form

• Last date for receiving duly filled Application Form in FICCI Office is10thNovember 2017by close of business hour.

• In case of any query, please contact:

Mr Samir Mathur

011 - 2348 7269 (Direct)

• Application fees should be sent through Cheque/DD in favour of “Federation of Indian Chambers of Commerce & Industry (FICCI)” payable at New Delhi to the below mentioned contact along with the application form

• The duly filled application form could be sent through post to:

Mr Samir Mathur

Manufacturing Division

FICCI, Federation House

Tansen Marg

New Delhi – 110001

Quality System Excellence Building Blocks

Application forthe Sixth Edition of FICCI Quality Systems ExcellenceAwards for Industry

Excellence Pillars / 1.1 / Name of the Applicant Unit/Mine/Organization
Brief aboutOrganisations / Organisation General Information
1.2 / Address
Pin Code:
1.3 / Details of the Highest-Ranking Official of the organization and of Alternate Contact Person
Highest Ranking official of the Organization Details: / Alternate Contact Person Details:
Name: / Name:
Designation: / Designation:
Office (Tel): / Office (Tel):
Mobile: / Mobile:
Email: / Email:
1.4 / Turnover or Sales of the Organization (last three years’ turnover in rupees)
Note: In case of individual unit/mine applying for the awards, please share the Turnover/Sales both unit/mineand for the Organization as of whole
1.5 / Investment of the Organization excluding working capital (last three years’ investment in rupees)
Note: In case of individual unit/mine applying for the awards, please share the Investment excluding working capital both unit and for the Organization as of whole
1.6 / Main products produced/services offered by the applicant unit/mine/
organization
1
2
3
1.7 / Main Customers of the applicant unit/mine/organization
1
2
3
1.8 / Work force management (Number of Employees in the applicant unit/mine/organization)
Note: Regular employees in the unit/mine/organization:
Note: Other than regular (Contractor/ Consultant etc) in the unit/mine/organization:
1.9(a) / E2E Organisation Process flow, which is involved for conversion of input to output. (For example, machining, welding, casting, forging, grinding, packaging, distillation, mining operation like drilling, blasting, excavation, hauling, beneficiation/processing, blending & suppling to customers etc.)
Note: Attach process chart describing your E2E conversion process
1.9(b) / Foremost/Latest technologies, equipment, facilities and innovative solutions used by applicant unit/mine/construction site. For Eg. Industry 4.0, IoT Solutions, Automation, digitalization etc.
Brief Description Note: Mention latest technologies use cases, List the major equipment’s.
Key Drivers / 2 / QUALITY MANAGEMENT SYSTEM
Quality
System / 2.1(a) / Provide a short history of quality system development of your unit/mine/organization. Mention credentials/ certifications obtained from external agencies relevant for your industry.
(For example, ISO 9001 & 14001, ISO 17025, TS 16949, c-GMP, WHO-GMP, AS 9100, TQM, Six Sigma, OHSAS 18000 etc.)
Note: 1 – Attach Quality Manual as applicable (Do not attach Procedure Manual)
Note: 2 – Limit the above description within one page
2.1 (b) / Explain the organisation structure for deploying quality throughout the organisation and the roles & responsibility of the QA/QC function?
Note: Attach the organisation structure and provide a description of the roles and responsibilities of personnel towards producing quality products/services
Strategy Development & Deployment Mechanism / 2.2(a) / What is the level of commitment of the leadership team to the Quality vision? Involvement of Leadership team - Managing Director/Business Head of organization in quality management? Also, explain how do leaders understand and develop the underlying capabilities of the organization?
Note: Underlying capabilities – Capabilities, Strength, Weakness, Opportunities and Risk
2.2(b) / What is your approach short and long term for implementing culture of Quality excellence? Explain how does the unit/mine/organization develop and implement its quality policy, quality objectives and quality strategic plan
Note: Explain the process of establishing and implementing its quality policy, quality objectives and quality strategic plan minimum 2-year way forward
In addition, please attach the following:
i)Quality policy
ii)Quality objectives / Metrics (Key performance indicator)
iii)Quality Strategic Plan
2.2(c) / How do you ensure that quality risk management has been considered in your quality system?
Note: Quality risk management is a valuable component of an effective quality system. Provide an explanation of how you are identifying, assessing, mitigating and monitoring the risks associated with products/services, processes, regulations etc
2.2(d) / How do you identify areas of improvement or progressive Quality road map?
Like area of improvement will 1) Focus Area, 2) Differentiator, 3) Bench Marking, 4) Technology upgradation, 5) Initiatives for Quality Improvements (ZD, Six Sigma, Analytics, Quality Automation etc.)
-Closure of non-conformances observed in your products/services / processes?
Note: Attach Quality Strategic Plan and Progressive Quality road map with closure, Review mechanism, effectiveness, Cost Saving etc.
2.2(e) / How do you assess the effectiveness of your E2E Quality initiatives including details of reviewing mechanism through Audit/Assessment (both internal and external)?
Note: Provide details of process/internal audit on Quality/Zero Defect Audits including types of action taken on deviations and Internal / External Assessment, Survey etc.
Key Performance Outcomes
* As applicable / 3.1 / Please provide the following information (For Power & Mining sector please provide information on adding parameters as given in Annexures in addition to the listed below parameters)
Financial Year
2016-17 / Financial Year 2015-16 / Financial Year 2014-15
A / For main products/services: % of output/service meeting specification at
A1 - Initial inspection
A2 - Intermediate Inspection
A3 - Final Inspection
B / Re-work %/Reprocess%
(Main Product-wise)
C / Scrap/Wastage %
(Main Product-wise)
D / Orders/Projects not delivered on time in % age
E 1 / Warranty/expiry failures in %age
E 2 / No. of customer returns as a % of No. of product delivered or No. of returns per projects completed (in case of Construction & Infrastructure)
F / Number of customer complaints as a % of No. of product delivered or No. of customer complaints as a % of No. of projects completed (in case of Construction & Infrastructure)
G / Overall Equipment Effectiveness (OEE) for critical machines in %age
H / Mean Time Between Failures (MTBF) for critical machines in hours. (Attach Calculation sheet for arriving MTBF in all three years)
I / Mean Time to Repair (MTTR) for critical machines in hours. (Attach Calculation sheet for arriving MTTR in all three years)
J / Number of training hours per employee (on quality related topics)
K / No. of opportunities identified for improvement in your processes w.r.t product/service quality, customer satisfaction, process improvement (Provide the synopsis)
L / No. of improvements implemented w.r.t product/ service quality, customer satisfaction, process improvement (Provide the synopsis)
Key Performance Outcomes
* As applicable / Annexures 1: For Power Generation Plants
Financial Year 2016-17 / Financial Year 2015-16 / Financial Year 2014-15
A / Plant Availability
B / % of Output Plant Load Factor (PLF)
C / Plant Heat Rate
D / % Forced Outages
E / Man/MW Ratio
F / Specific Oil Consumption
G / % Cycle Make up water consumption
H / Plant make up water consumption in Cu.M/MW-Hr
Key Performance Outcomes
* As applicable / Annexures 2: For Power Transmission
Financial Year 2016-17 / Financial Year 2015-16 / Financial Year 2014-15
A / Transmission Line Availability
B / Transmission Line Losses
C / % Forced Outages
D / Man/Km Transmission Line Ratio
E / Average time of Transmission line fault level attendance & Rectification
F / Power Frequency variation
G / Voltage magnitude variation
Key Performance Outcome
* As applicable / Annexures 3: For Power Distribution
Financial Year 2016-17 / Financial Year 2015-16 / Financial Year 2014-15
A / Distribution Line / Network availability
B / Distribution Line Losses
C / % Forced Outage
D / Man/Km Distribution Line Ratio
E / Metering system availability in distribution network
F / Average time of fault complaint attendance & rectification
G / Power Frequency variation
H / Voltage magnitude variations
Key Performance Outcome
* As applicable / Annexures 4 : For Mining Companies
Financial Year 2016-17 / Financial Year 2015-16 / Financial Year 2014-15
A / Exploration carried out
(% age of potential mineralized area explored at G2 & G1 level)
B / % of Slimes/Tailing generated below threshold value*
C / % of Slime/Tailings generated below cut-off *
D / Blending of mineral reject/subgrade with high grade ore (% of subgrade/mineral reject utilization w.r.t. its generation in a year)
Growth Indicator / People, Execution & Sustenance / 4.1 / How do you plan the development of competence of your key group of personnel to improve quality of product and services?
How People talents are reviewed and encouraged for achievements?
Note: Provide details of
i)determination of competencies at various levels
ii)plan for closing gaps in competencies
iii) training need analysis
iv) provision of training and evaluation
v) Reward & Recognition Culture, SME etc.
4.2 / What is your approach (ways/tools/methods) & How are you establishing effective communication on quality systems in your organisation/unit/mine?
Note: Explain your policies and practices on communication amongst different levels of personnel about quality related issues including the coverage of deployment in the unit/organization/mine level
Lean Drive
(Value Stream Mapping, Lean Projects, 6 Sigma, Kaizen) / 5 / How employees are getting involved to the culture of excellence including empowerment and accountability?
Note: Project and participation, Kaizen, Quality Circle etc. involvement means kaizen vs Employees
Operational Improvement / 6 / Operational improvement initiative for day to day routine way and reduction in Waste (8 Waste)
Note: Operational improvement road map etc.
Critical Success Factors / PROCESS (Critical Success factor)
Automation (IoT, Industry 4.0, Quality Automation) / 7(a) / What approach are your following to create an centre of excellence drive in the organisation.
- To create Poka-yoke /Mistake proofing Culture
- Innovation Drive
- Simple use case of Automation
Note: Detail required of innovation culture, projects, level of e-information related to shop floor
7(b) / What kind of all other process followed for promotion of culture of excellence.
Note: Participation in conference, town hall, expo centres etc.
Analytics
(SPC, Predict & Prevent) / 8.1 / Are statistical methods used to measure process capability at various stages of conversion process?
Explanation: The purpose of any manufacturing plant/mine site/ service sector is to make/extract a product/service of consistent quality. Therefore, the way to measure its quality performance is to measure its consistency. All products/services have a specification agreed in some form with the customer & this has upper & lower limit. Good quality conscious organizations are routinely analysing the product quality parameters & plotting the specifications as distribution. This is normally measured through Statistical Process Control (SPC).
To achieve consistent product/service quality, the process is expected to operate at a consistent set of conditions which can be defined precisely and where a statistical band can be put around them. In fact, the control charts & process capability analysis (Cp & Cpk) are some of the proven methods to measures the consistency of unit/mine/organization operation & hence assure delivery of product/service consistently. This question asks you to explain the statistical methods that are deployed in yours process & also how you are determining process capability.
8.2 / How do you plan and ensure effective inspection, testing and calibration activities?
Note: Provide only a short description of your programme including how you are monitoring the effectiveness of the programme
8.3 / How do you ensure that your products/services comply with product/service liability, IPR, environment and other legal and statutory requirements?
Explanation: Compliance is a prevalent business concern for each business organization. There are ever increasing number of regulations that require organization to be vigilant and have a full understanding of the compliance requirement. It is important for the organizations to ensure that they can manage all compliance risks effectively. In this question, you have to explain how you are identifying the compliance requirement regularly, updating them and the kind of data you are collecting, storing etc. Apart from explaining the process you are also requesting to submit evidence of different compliance.
8.4 / What is the system of Product Recall in case there is a need for such recall/ controlling the non- conforming product? If there is no system of Recall in the Organization/unit/mine, then please provide details of traceability system followed in your Organization/unit/mine.
Explanation: a) Product recall is a request to return a product after the discovery of safety issues or product defects that might endanger the consumers or put the manufacturer/mining company at risk of legal action. The Product recall is an effort to limit liability for corporate negligence which can cause significant cost to company.
Controlling the Non-Conforming Product: Major Non-conformances if any in a product detected by customer or by the contractor can cause significant impact to the project or to the customer. The control of Non-Conforming product is an effort to limit the liability for organizationnegligence which can cause significant cost to the company
b) Traceability: - Explain the various steps taken by the unit/mine in case of a defect discovered at the customer/consumer end. The manufacturers/mining company must have a system in place to provide a trail of information that follows each item from manufacturing/mining to supply chain. To ensure product safety and quality, the manufacturers/ mining company must be able to quickly identify and locate potentially faulty items in the manufacturing/mining as well as supply chain. The traceabilityindicates the system you have in place for the above.
Smart Operation with dynamic fulfilment / 9.1 / How do you assess the performance of your channel trade partners?
Note:Distributor/Dealers are channel trade partners who act as a medium to ensure stock delivery/availability for the consumer across the geographies. The role of these entities is critical. Please provide a description of the assessment of the performance of the channel trade partners.
9.2 / Are you deploying the Quality by Design (QbD) concept in your design/ development and manufacturing/mining processes? If so, then please explain the process of deployment
Explanation:Quality by Design (QbD) is a scientific approach to ensure quality by developing a thorough understanding of the compatibility of the finished product to all the components and processes involved in manufacturing that product. Instead of relying on finished product testing alone, QbD provides insides upstream through the development & Manufacturing processes. As a result, a quality issue can be efficiently analysed and its root cause can be quickly identified. Through this question, you are requested to explain whether you are using any scientific approach of Quality by Design which may include identification of all critical attributes of product & process parameters as well as determining the extent to which any variation can impact the quality of finished product.
9.3 / How do you ensure that all critical processes are identified, validated and controlled?
Note: Describe your method of identification of all important process variables and related quality control measures, necessary data collection, monitoring and appropriate controls for the products and processes. Also, explain the process of validation of all critical process.
9.4 / Do you have a change control system? Are changes being evaluated before implementation?
Note: Attach description of your change control system.
9.5 / How do you ensure your facilities and equipment’s are appropriate for consistently manufacturing quality products or providing quality services?
Note: Please include a description of your current maintenance practices including technological up gradation, automation etc.
9.6 / How do you asses the quality systems adopted by your contractor?
Stakeholder Management / Stakeholder Expectation (Internal & External) / 10.1 / Are your capturing data for customer satisfaction? / o Yes
o No
If yes, provide the trend of customer satisfaction measurement over the last three years (provide the details with indices and attach calculation sheet for arriving the figures in all three Years)
10.2 / Are your capturing data for employee satisfaction? / o Yes
o No
If yes, provide the trend of employee satisfaction measurement over the last three years (provide the details with indices and attach calculation sheet for arriving the figures in all three Years)
10.3 / Are you capturing data for cost of poor quality? / o Yes
o No
If yes, provide the trend of cost of poor quality over the last three years (provide the details with indices and attach calculation sheet for arriving the figures in all three Years)
Explanation: The quality costingapproach is a proven means of tracking, guiding and motivating quality improvement. Scrap/Wastage, Rework/Reprocess, Reject, relevant terminology used in your sector and inspection accounts for about only 5% of wastes that occur in an organization. This is only a small part of the actual cost of poor quality. A good practice is to establish a data collection process to obtain necessary cost of quality information throughout including various departments, sections of the organization. The steps may be:
1. Identify the major categories of quality costing (for example prevention, appraisal with detailed cost element for each category)
2. Establish a method to collect data for each category mentioned above
3. Establish costs for the different categories mentioned above being tracked
4. Establish reporting format that can easily calculate total cost of poor quality
A realistic estimate of poor quality cost is an essential element of any effective quality system.
CUSTOMER Management
Internal Customer Satisfaction / 11.1 / What approach are you followed to share customers and suppliers feedback in your Organisation/Unit/Mine? Please provide the description of the same and explain how customer and supplier relationships are managed and enhanced (As part of Eco-system)
Note: Include descriptions of the processes for both customers and suppliers feedback sharing. Description shall include the trends offeedback
11.2 / How do you select and evaluate your supplier?
Note: Attach a description of supplier selection process and supplier evaluation criteria
11.3 / How do you monitor the quality of product(s) and service(s) of your sub suppliers?
Explanation: The quality performance of your final product/service may get affected due to your sub supplier poor quality of product(s)/service(s). So, through this question we want to know whether you are monitoring the quality of product(s)/service(s) of your sub supplier and if so what are the various ways
11.4 / What are the various interventions/supports you provide to ensure that your supplier capability will meet to your product and service requirements on continuing basis?
(For example, technical assistance, training, equipment selection, early supplier involvement etc. with specific reference to Quality System of the applicant unit/mine/organization)
Note: Attach list of above mentioned initiatives taken by the unit/mine/organization
11.5 / How do you assess the effectiveness of your customer related processes including customer complaints?
Note: Attach only the list of customer related processes along with a short description
Recognition / External Recognition / 12 / Detail all the external recognition and awards, receiving for your Organisation
Note: Awards details (Rajiv Gandhi, MT, ET, Industry body, Government Recognition etc.
Bench Marking / 13 / Do you have any process for Bench marking to achieve the next level of performance? If Yes
Note: Provide the details or are you participating in Best Practice sharing conference internal / External
Eco-System / 14 / How are you developing your Eco-System?
Note: CSR activities, Collaboration with other technical and non-technical partners etc.

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