CANDO Pillar Audit Checklist

# Review Point 1 CANDO Structure Score Scoring Guideline 1 There is a formal structure & team laid down along with a CANDO board for the zone, with standard displays to be put on it - clearly identified 2 There is photograph displayed of the CANDO team along with the leader 3 Display of the team structure along with the skill level and brief profle of each team member 4 The CANDO structure displayed also lists down responsibility of each team member 5 Displayed CANDO team & responsibilities list is updated with - completeness of the responsibility along with dates 1 CANDO Pillar goals are set at broad plant level only and not communicated to the individual CANDO zones 2 There is tracking mechanism in place for goal achievement of each CANDO zone in the plant 3 Goals are set upto team & individual level and there is regular review of goals alongwith action plans for gap 4 CANDO team leaders conduct regular performance reviews, solicit input from the team on performance issues and identify action plans. 5 CANDO zone has been faring well (scoring more than 50% in CANDO audits conducted by Plant) and adhering to responsibilities regularly - reflecting in the CANDO audits conducted by Plant CANDO / ME Coordinators 1 All existing & potential leakage points have been identified, listed & displayed with date of identification mentioned and system is in place to track them regularly 2 Leakage and spillage points have been prioritized for the purpose of removal based on criticality 3 Root cause analysis of HTA (Hard To Access) & SOC (Source of Contamination) is initiated and over 20% of the cases of leakage, spillage, HTA & SOC points have been addressed and removed permanently using POKA YOKE (Mistake Proofing) measures etc. 4 Over 50% of the cases of leakage, spillage, HTA & SOC points have been addressed and removed permanently using POKA YOKE (Mistake Proofing) measures etc. 5 4 Problem solving (with the help of SD pillar) 1 2 3 There is clear visual identification/marking for such points and frequency of reviewing / inspecting defined through colour coding, symbols etc. CANDO team prepares a problem bank (including both existing & potential problems) on a monthly basis CANDO Leader identifies need for training and relevant topics for each CANDO member on a quarterly basis and ensures registering such requirements with the plant CANDO / ME Coordinators Over 60% of CANDO members have been trained on problem solving tools like LEAN for identification and elimination of wastes like MUDA (Wasteful activities), MURA (Inconsistency) & MURI (Physical Strain), 5-S, Differential Diagnosis, Autonomous Maintenance (AM), why-why analysis, Fishbone analysis etc. Training application on shop floor in the form of Kaizen / improvement project, validated by plant CANDO / ME Coordinator by atleast 50% of the trained members Training effectiveness is evident through 80% of problems being resolved (to be evaluated by CANDO leaders & Plant CANDO/ME coordinators) The scoring criteria is as follows Critical equipment benchmarks and standards laid down (min % of critical equipments covered) 1 2 3 4 5 1 2 Operator & asset care point training for critical equipments provided to operators (min % of critical equipments covered) Criteria - Evident teamwork and up to date display of the activities and progress of the CANDO zone Positive points Areas of Improvement Score

2 CANDO Pillar Goals (Strategic Planning, Goal Setting & Benchmarking)

- No. of internal reviews of goal achievement - On questioning, CANDO team member should be able to tell their respective goals, gaps and means to achieve

3 HK (House Keeping) & CANDO activities

- No. of cases found and addressed (can be registered as Kaizen if CAPA done) - Tidy looking Leak-free, Spillage-free, HTA & SOC free CANDO zones - Possibly reduction in housekeeping staff

4 5 5 Operator Asset care (with the help of SD pillar)

In last 3 months - No. of trainings undergone by each CANDO member (to be displayed on CANDO Board) - No. of Kaizen contributed by CANDO zone - % of problems resolved out of those listed in problem bank

6 Man-Machine allocation (Structure & Manning)

20% 20% 30% 30% 50% 50% 75% 75% 100% 100% Allocation of area & machine for the implementation of my/ our area, machine has been initiated for critical equipments. Fresh list of critical equipment as on 1/4/2010 to be referred Area & machine allocation has been completed for 20% of critical equipments along with SOPs/Guidelines displayed enabling operators to address minor stoppages or breakdowns along or call the right person for solving, depending on the level of problem Area & machine allocation has been completed for 30% of critical equipments along with SOPs/Guidelines displayed enabling operators to address minor stoppages or breakdowns along or call the right person for solving, depending on the level of problem Area & machine allocation has been completed for 50% of critical equipments along with SOPs/Guidelines displayed enabling operators to address minor stoppages or breakdowns along or call the right person for solving, depending on the level of problem. Fairly good level of visual control Area & machine allocation has been completed for 75% of critical equipments along with SOPs/Guidelines displayed enabling operators to address minor stoppages or breakdowns along or call the right person for solving, depending on the level of problem. High level of visual control applied by the CANDO member on/in his machine/area

Benchmarking has been done and equipment performance has been measured against: 1: Design performance 2: Outside performance 3: Industry performance 4: KNPL performance 5: My own best performance

- Increase in MTBF - % of cases where equipment failures were addressed by operator himself - Decreasing trend in MTTR (Excluding outliers) - Sufficient updated visual control near the allocated area

7 CANDO Zones covered under AETs towards zero breakdown (AET wise tracking)

5 8 Safety, Health & Hygiene (with the help of SD pillar) 1

2 3

4 5

9 Daily Management through CANDO

There are at least 20% critical equipments in the CANDO zone with 50 % reduction in no.of notifications in last 3 months & standard display on each equipment giving no. of days passed without any breakdown to be more than 30 days There are at least 30% critical equipments in the CANDO zone with 50 % reduction in no.of notifications in last 3 months & standard display on each equipment giving no. of days passed without any breakdown to be more than 45 days There are at least 50% critical equipments in the CANDO zone with 50 % reduction in no.of notifications in last 3 months & standard display on each equipment giving no. of days passed without any breakdown to be more than 60 days There are at least 75% critical equipments in the CANDO zone with 50 % reduction in no.of notifications in last 3 months & standard display on each equipment giving no. of days passed without any breakdown to be more than 75 days There is regular tracking of breakdowns for each equipment in the CANDO zone - status to be displayed on CANDO Board Formal training is initiated for CANDO members to explain safety behavior expectations and make them aware of health & hygiene issues and a formal system has been developed for the tracking of accidents, incident & nearmisses 50% of CANDO members have been given essential training on Safety, Health & hygiene (PPE, MSDS, Safe working norms, Raw material compatability etc.) All CANDO members have been given training on above mentioned aspects of Safety. Material is stored as per RM Compatability list. There is regular analysis and Corrective actions undertaken to address accidents, incident, Minor Injuries & nearmisses CANDO members are aware of the safety norms & practices and safety mechanisms provided by design and ensure they are intact for all equipments in use including MHEs etc. There are interlocks & fool proof mechanisms provided for prevention of accidents, incident, Minor Injuries & nearmisses. Such initiatives may be classified as Kaizen (subject to Kaizen coordinator's approval) Self audits by CANDO team CANDO members take decisions CANDO members are involved in members is conducted as for removal of A (green tag) & B problem analysis & prevention per the defined schedule (red tag) type abnormalities & (Ideally Monthly - using this are involved in removal of audit sheet upto point 10) abnormalities (from Autonomous Maintenance Training) Know-your-machine training Standards are implemented for CANDO members regularly and for key target groups has all equipments & equipments are effectiely participate in Kaizen in all been completed as per the standards CANDO Zones Visual controls for inventory Review , update of CLTI check norms list (as fallout of any BD maint, Kaizen , FIP done) Visual displays for preventive & breakdown maintenance

- Reduction in No. of notifications - Reduction in no. of breakdowns

- Reduction in no. of incidents/accidents/MI/near misses - Increase in no. of Safety kaizen from CANDO zones - Awareness among operators about use of PPE and other safety aspects (Operators to be questioned) - Compliance in use of PPE to be seen on shop floor

10 Over all Cleanliness, orderliness and asthetics of the facility

1 2 3 4 5 1 2 3 4

At least 1 element is implemented At least 2 elements are implemented At least 4 elements are implemented At least 6 elements are implemented At least 8 elements are implemented Abnormality register, list of HTA and possible Leakage /spillage points are available in all CANDO Zones and the same is visible on the shop floor Implementation of at least first 2 levels of 5-S (i.e. 1-S, 2-S) is evident through floor markings, search- Visual markings on shop free working etc. Standard search time allowed world over is 30 seconds. 3rd level (3-S) has been implemented and CANDO member incharge ensures aethetical appeal and not floor - Search-free working only clean equipments and floor but also usability and basic condition is restored There is no "NO MAN'S LAND". 5-S, Overall cleanliness and orderliness in the CANDO zones ,which does - Neat & tidy work area not fall under any AET are Visible. Also, other equipments like MHEs etc. are included. Point no. 1, 2 & - Clean equipments - No unwanted items seen 3 are also addressed effectively in these areas All the above points have been monitored & audited by plant CANDO Coordinators every month for 3 months (substantiated by comments by external auditors , HO members, Photographs sent to Corp ME Cell ) 25% of CANDO zones are at level 2 50% of CANDO zones are at level 2 75% of CANDO zones are at level 2 90% of CANDO zones are at level 2 All CANDO Zones are at level 2

11 CANDO team scores

1 2 3 4 5