5Th FICCI QUALITYSYSTEMS EXCELLENCEAWARDS FORINDUSTRY- 2016

5th FICCI QUALITYSYSTEMS EXCELLENCEAWARDS FORINDUSTRY- 2016

APPLICATION FORM

Terms and Conditions of the Awards:

• Scope of the Awards covers the following sectors :

Construction & Infrastructure

Manufacturing (including energy)

Mining

Power (including transmission, distribution and generation)

• 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 would be non-refundable.

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

Application evaluation

On site assessment after 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) for the three categories of the award for each of the four sectors i.e. Construction & Infrastructure, Manufacturing. Mining & Power covers under the scope of awards is as follows :

Rs. 17,250/- for small sizedorganization (Organizationhaving both turnover & investment excluding working capital both less than Rs 100 crore)

Rs.34,500/- for medium sized organization (Organization having either turnover orinvestment excluding working capital between Rs 100 crore to Rs 500 crore.If any one of the parameter crosses the higher limit of Rs 500 Crore then the organization falls in large sized organization)

Rs. 46,000/- for large sized organization (Organization having either turnoveror investment excluding working capital more than Rs 500 crore)

• 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 11,500/- 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. Only in case of Infrastructure & Construction, auditors would be deployed for both the organization (HO) and any one project site.

• In case any question is not applicable for your Organization/Unit then 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. 6 and beyond in the form

• Last date for receiving duly filled Application Form in FICCI Office is30thSeptember 2016 by close of business hour.

• In case of any query, please contact:

Mr Samir Mathur / Mr Aseem Khanna

;

011 - 2348 7269 (Direct) & 011 – 2348 7381 (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 / Mr Aseem Khanna

Manufacturing Division

FICCI, Federation House

Tansen Marg

New Delhi – 110001

Application forthe Fifth Edition of FICCI Quality Systems ExcellenceAwards for Industry

1. / Name of the Applicant Unit/Mine/Organization
2. / Address
Pin Code:
For the organization participating in Construction and Infrastructure sector, please furnish the below details also.
Name & Address of the Project 1 of the organization:
Name & Address of the Project 2 of the organization:
Name & Address of the Project 3 of the organization:
3. / Details of the Unit/Mine Head or Quality head of the organization and of Alternate Contact Person
Unit/Mine Head or Quality Head of the Organization Details :
Name :
Designation:
Office (Tel):
Mobile:
Email: / Alternate Contact Person Details :
Name:
Designation:
Office (Tel):
Mobile:
Email:
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 of the unit/mine and for the Organization as of whole
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 of the unit and for the Organization as of whole
6. / Main products produced/services provided by the applicant unit/mine/organization
1
2
3
7. / Main Customersof the applicant unit/mine/organization
1
2
3
8. / Number of Employees in the applicant unit/mine/organization
Regular employees in the unit/mine/organization:
Other than regular (Contractor/ Consultant etc) in the unit/mine/organization:
9. a) / Major sequence of conversion process involved in the applicant unit/mine (For example machining, welding, casting, forging, grinding, packaging, distillation, mining operation like drilling, blasting, excavation, hauling etc.)
Note: Attach process chart describing your conversion process
9. b) / Major equipment, facilities and technologies usedby applicant unit/mine/construction site
Note: Attach list separately for all the equipments other than major equipments
10 / QUALITY MANAGEMENT SYSTEM
10.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. Brief the Quality System and certification adopted in the Construction & Infrastructure project
(For example ISO 9001 & 14001, 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
10.b) / Explain the organisation structure for deployingqualitythroughout the organisation and the roles & responsibility of the QA/QC function?
Note: Attach the organisation structure and also provide a description of the roles and responsibilities of personnel towards producing quality products/services
10.c) / Explain the role of Managing Director/Business Head of organization and project head in quality management? Also, explain how do leaders understand and develop the underlying capabilities of the organization?
Note : Underlying capabilities – Strength, Weakness, Opportunities and Threat
10.d) / Explain how does the unit/mine/organization develop and implement its quality policy, quality objectives and quality plan
Note: Explain the process of establishing and implementing its quality policy, quality objectives and quality plan.
In addition, please attach the following:
i)quality policy
ii)quality objectives
iii)quality plan
10.e) / 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 the monitoring of the risks associated with products/services, processes, regulations etc
10.f) / How do you identify areas of improvement from non-conformances observed in your products/services / processes?
Note: Attach alongwith description reporting system for non-conformances
10.g) / How do you assess the effectiveness of your current quality systemincluding details of monitoring & Audit (both internal and external) plans?
Note: Provide details of process/internal audit on Quality/Zero Defect Audits including types of action taken on deviations
10.h) / What are the initiatives you have taken to improve quality?
Note: Provide a short description of your quality improvement process and attach list of quality improvement projects
10.i) / How do you evaluate the effectiveness of your improvement initiatives?
Note: Include a description of your system of planning and monitoring the quality improvement projects
11 / CUSTOMER & VENDOR MANAGEMENT
11.a) / Is there any mechanism to share customers and suppliers feedback in your Organisation/Unit/Mine? If yes, please provide the description of the same and also explain how customer and supplier relationships are managed and enhanced.
Note: Includedescriptionsof theprocesses of capturingboth customers and suppliersfeedback. Description shall include the trends of feedback
11.b) / How do you select and evaluate your supplier?
Note: Attach alongwith description of supplier selection and supplier evaluation criteria
11.c) / How do you monitor the quality of product(s) and service(s) of your sub suppliers?
Explanation: Sub suppliers are your Tier 2 suppliers or suppliers of your main supplier.
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 and also the kind of supports you are providing to them
11.d) / 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 Systemof the applicant unit/mine/organization)
Note: Attach list of above mentioned initiatives taken by the unit/mine/organization
11.e) / How do you assess the effectiveness of your customer related processes including customer complaints?
Note: Attach alongwith description only the list of customer related processes
12 / PEOPLE
12.a) / How do you plan the development of competence of your key group of personnel to improve quality of product and services
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
v)Evaluation of effectiveness of training
12.b) / 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
13 / PROCESS
13.a) / 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.
13.b) / 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
13.c) / How do you ensure that yourproducts/services complywithproduct/serviceliability, IPR, environment and other legal and statutory requirements?
Explanation: Compliance is a prevalent business concerned for each business organization. There are ever increasing number of regulations that required organization to be vigilant and also have a full understanding of the compliance requirement. It is important for the organizations to ensure that they are able to 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.
13. d) / What is the system of Product Recallin 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:Productrecall 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 organization negligence which can cause significant cost to the company
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 traceability indicates the system you have in place for the above.
13.e) / 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.
13.f) / 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 of 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 equation 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.
13.g) / How do you ensure that all critical processes are identified, validated and controlled?
Note: Describe your method of identification of all important process variablesand 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.
13.h) / Do you have a change control system? Are changes being evaluated before implementation?
Note: Attach description of your change control system. Change Control system is the deviation from your SOP’s (Standard Operating Procedure).
13.i) / How do you ensure your facilities and equipments 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.
13. k) / How do you asses the quality systems adopted by your contractor?
14. / Please provide the following information (For Power sector please provide information on adding parameters as given in Annexures in addition to the listed below parameters)
Financial Year 2016-15 / Financial Year 2015-14 / Financial Year 2014-13
A / For main products/services : % of output 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 / No. of warranty/expiry failures in %age
E 2 / No. of customer returns as a % of No. of product delivered or projects completed
F / Number of customer complaints as a % of No. of product delivered or project completed
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 implementedw.r.t product/ service quality, customer satisfaction, process improvement (Provide the synopsis)
Annexures 1 : For Power Generation Plants
Financial Year 2016-15 / Financial Year 2015-14 / Financial Year 2014-13
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
I / No. of customer complaints
Annexures 2 : For Power Transmission
Financial Year 2016-15 / Financial Year 2015-14 / Financial Year 2014-13
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
I / No. of customer complaints
Annexures 3 : For Power Distribution
Financial Year 2016-15 / Financial Year 2015-14 / Financial Year 2014-13
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
I / No. of customer complaints
15 / Are your capturing data for customer satisfaction? /  Yes
 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)
16. / Are your capturing data for employee satisfaction? /  Yes
 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)
17. / Are you capturing data for cost of poor quality? /  Yes
 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.

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