ficci.inficci.in/events/24496/Add_docs/LargeScaleApplicationFor… · Web viewConstruction & Infrastructure. Manufacturing (including oil ... Limit the answers to maximum of 400

8th FICCI QUALITY SYSTEMS EXCELLENCE AWARDS FOR INDUSTRY - 2019

APPLICATION FORM Large Sized Organization

Terms and Conditions of the Awards:

Scope of the Awards cover the following sectors: Construction & Infrastructure Manufacturing (including oil & gas) 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.

Limit the answers to maximum of 400 words unless it is very necessary to deviate from this word limit.

The application for the award is for a unit 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.

This time we have also introduced a Vendor Collaboration Award for Large size organization to promote growth and development of vendors.

A separate category for large sized organization has been created where the large size organization in collaboration with their respective vendors can apply for separate awards, i.e., VENDOR COLLABORATION AWARD.

This award has been institutionalised to promote growth and development of the Vendors of the organization and also to recognize the efforts of large player for bringing up quality system of their vendors.

Under this category, large player has to apply jointly with his/her vendor as a single group. Large player will be applying in the large category and its vendor will apply in the respective large/medium/small category. Maximum of 3 vendors can be included in the group.

In this category, if the unit is selected for on-site audit, the fee for the audit will be for each unit applying in the group.

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.

[Confidentiality Note: Information collected in the application will remain strictly confidential & intended for FICCI Quality systems excellence award assessment only]

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 & Fees will 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 (including oil & gas), Mining & Power covers under the scope of awards is as follows :

Rs 53,100/- inclusive of all taxes for large sized organization (Organization having either turnover or investment excluding working capital more than Rs 500 crore). Please share your unit/organization’s GST Number and state code while making payment as it is mandatory under GST regime.

In case you are applying for Vendor Collaboration Awards the fees is Rs 1,18,000/- inclusive of all taxes.

Unit/Organization that qualify for on-site assessment will have 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/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. 1.6 and beyond in the form

Last date for receiving duly filled Application Form in both soft and hard copy in FICCI Office is 20 th February, 2020 by close of business hour.

In case of any query, please contact:

Ms Ankita Sharma / Mr Suresh Subramanian [email protected] / [email protected]

011 - 2348 7269 (Direct) & 011 – 2348 7450 (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: Ms Ankita Sharma / Mr Suresh Subramanian

Manufacturing DivisionFICCI, Federation HouseTansen Marg


mailto:[email protected]

New Delhi – 110001 E-mail – [email protected] / [email protected]

Quality System Excellence Building Blocks

Application for the Eighth Edition of FICCI Quality Systems Excellence Awards for Industry

Excellence Pillars

1.1 Name of the Applicant Unit/Mine/Organization

Brief about O

rganisations

Organisation G

eneral Information

1.2 Address

Pin Code:

Sector Applying in: Manufacturing/Construction/Mining/Power(Transmission/Distribution/Generation)

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:


mailto:[email protected]

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/mine and 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/organization1

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 D

rivers

2 Development of Quality System Strategy

Developm

ent of Quality System

Strategy

2.1 What is your Quality Systems strategy for long term and short term? Explain how the organisation develops, its Quality Policy, Quality objectives and Quality culture. Note - Explain the Quality strategy, focus areas, goals and objectives

Please provide i) Quality Policyii) Quality Strategic Planiii) Quality Objectives

Note: Explain the process of establishing and implementing its quality policy, quality objectives and quality strategic plan minimum 2-year way forward

2.2 Explain the Quality Organisation structure including roles and responsibilities

Note: Attach the organisation structure and provide a description of the roles and responsibilities of personnel towards producing quality products/services

2.3 How top management is involved in shaping Quality vision? How do they demonstrate their commitment to Quality Systems? How they identify and develop the underlying capabilities of the organisation?

Note: Underlying capabilities – Capabilities, Strength, Weakness, Opportunities and Risk


3 Quality Systems

Quality System

s

3.1 Describe your present quality systems - implemented and certified?Explain key integration milestones of various management systems (e.g. EMS, OSHAS, EnergyMS, ISMS, etc.

Note: 1 – Attach Quality Manual as applicable (Do not attach Procedure Manual)

Note: 2 – Limit the above description within one page

3.2 How do you identify quality road map including focus areas, tools to be deployed, KPIs?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.

3.3 How do you ensure the risk management relevant to interested parties are being integrated in your quality systems?

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.

Stakeholder

4 Stakeholder Expectation

Stakeholder Expectation

4.1 How do you collect inputs, engage and manage stakeholder expectations?

Note - Stakeholders include interested parties.

4.2 How do you ensure that your products / services comply with the applicable legal and statutory, environmental 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.

4.3 How do you develop and collaborate across your eco system such as collaborations with technical partners, universities, society. If relevant, include your approach towards your CSR initiatives.

5 Benchmarking

Benchmarking

5.1 Do you have any process for benchmarking to achieve the next level of performance?Provide examples of benchmarking being used for target setting exercise

Note: Provide the details or are you participating in Best Practice sharing conference internal / External

5.2 How do you assess effectiveness of your End-to-End quality initiatives over long term including details of reviewing mechanisms e.g. Maturity assessments

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.

6 Surveys (External and Internal)

Surveys (External and Internal)

6.1 How do you measure customer satisfaction of your products / services? How does top management communicate the results - internally and externally?Provide details of Scale used, analysis of results and process improvements, frequency of the survey.

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)

6.2 How do you measure employee satisfaction? How does management review the results and communicate the results and measures?Provide details of employee satisfaction survey methodologies used, frequency of the same, improvement measures identified.

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)

Criti

7 Analytics


cal Success factors and growth indicators

Analytics

7.1 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.

7.2 How do you ensure your facilities and equipment are appropriate for consistently manufacturing quality products / providing quality services?Note: Please include a description of your current maintenance practices including technological up gradation, automation etc.

7.3 How do you plan and ensure effective collection of process data for analytics e.g. SMART sensors, IoT etc?

7.4 Describe how quality data is analysed and data analytics tools deployed e.g. SPC, Data Analytics and Artificial Intelligence.

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.

7.5 How do you manage and control changes within your operations?

Note: Attach description of your change control system / Change management process

8 Quality Systems tools for Operational improvements including Lean Drive

Quality

Systems

8.1 How do you measure cost of poor quality? Describe trend / analysis based on past 3 years of data.

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)


8.2 What is you approach to create a culture of excellence across the organisation?E.g. EFQM, Business Excellence, TQM, TPM, Lean Management

Note: Detail required of innovation culture, projects, level of e-information related to shop floor

8.3 How do you manage routine process variations and non-conformance management as part of day to day operations?

Note: Operational improvement road map etc.

8.4 How do you integrate quality in your processes e.g. Quality by Design?

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.

8.5 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

8.6 How have your organisation deployed system for monitoring of products in the field e.g. system of traceability to deal with non-conforming products / product recalls?


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 organization negligence 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 traceability indicates the system you have in place for the above.

8.7 How do you assess effectiveness of your customer support processes including customer complaints?Note: Attach only the list of customer related processes along with a short description

9 People execution and sustenance

People execution and sustenance

9.1 How do you plan the competence development of personnel deployed by you in product / service realisation (including those on contract or with outsourcing partners) to improve quality of products / services?How people talents are reviewed and encouraged for achievements?

Note: Provide details of i) Determination of competencies at various levels & plan for closing gapsii) Capability analysis / Skill Matrix iii) Training need identification & Analysisiv) Adopting Mentoring & Coaching practices v) Reward & Recognition Culture, SME etc.

10 Partner Ecosystem management - North side and Southside.

Partner Ecosystem

managem

ent - North

side and Southside.

10.1 How do you integrate your channel partners as part of quality systems? How do you assess the performance of the channel partners to your quality systems?

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.


10.2 How do you select and evaluate your suppliers? How do you assess the performance of the suppliers to your quality systems?

Note: 1) Attach a description of supplier selection process and supplier evaluation criteria 2) Suppliers audits

10.3 How do you monitor the quality systems and service levels 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 the various ways

10.4 What are the systematic support initiatives you have implemented 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

10.5 How do you assess the quality systems adopted by your outsourcing partners?

10.6 How do you integrate your suppliers and channel partners in the measures / initiatives based on customer feedback?

Note: Include descriptions of the processes for both customers and suppliers feedback sharing. Description shall include the trends of feedback

Recognition

11 Recognition

External Recognition

11.1 How does management recognise contribution of employees, channel partners and suppliers in achieving its quality system objectives / targets?

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

11.2 Detail all the external recognition and awards received by your organisation over previous 3 years?

Note: Awards details (Rajiv Gandhi, MT, ET, Industry body, Government Recognition etc.


Quality System

Results

12 Quality System Results

Key Perform

ance Outcom

es* A

s applicable

12.1 Please provide the following information (For Power & Mining sector please provide information on additional parameters as given in the respective Addendum in the table below in addition to the listed below parameters)

Financial Year 2018-19



A For main products/services: % of output/service meeting specification at

A1 - Initial inspectionA2 - Intermediate InspectionA3 - 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 Perform

ance Outcom

es* A

s applicable

Addendum 1: For Power Generation Plants Financial Year 2018-19



A Plant Availability B % of Output Plant Load

Factor (PLF)C Plant Heat RateD % Forced OutagesE Man/MW RatioF Specific Oil

Consumption


G % Cycle Make up water consumption

H Plant make up water consumption in Cu. M/MW-Hr

Key Perform

ance Outcom

es* A

s applicable

Addendum 2: For Power Transmission


Financial Year2017-18


A Transmission Line Availability

B Transmission Line Losses

C % Forced OutagesD Man/Km Transmission

Line Ratio E Average time of

Transmission line fault level attendance & Rectification

F Power Frequency variation

G Voltage magnitude variation

Key Perform

ance Outcom

e* A

s applicableAddendum 3: For Power Distribution




A Distribution Line / Network availability

B Distribution Line Losses

C % Forced OutageD 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 Perform

ance Outcom

e* A

s applicable

Addendum 4 : For Mining Companies




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)


Documents

ficci.inficci.in/events/24496/Add_docs/LargeScaleApplicationFor… · Web viewConstruction & Infrastructure. Manufacturing (including oil ... Limit the answers to maximum of 400