ZED Articles

MCCIA's Sampada - July 2019 Issue - Challenges of ZED implementation focused on embedded electronics sector

MCCIA's Sampada - August 2019 - Team Dynamics for skill and performance management of Technology deployment in MSME

MCCIA's Sampada - September 2019 - CSR & Employee development using ZED

MCCIA's Sampada - October - November 2019 - ZED enhancing the global competitiveness for export promotion

MCCIA's Sampada - January 2020 - Gearing up for the Future with Quality as Foundation

Designing the road map for Paint industry through ZED implementation

The beginning is difficult. Being a pioneer is still difficult. And to be a successful pioneer in achieving a global benchmark is extremely difficult. But someone has to take it. We appreciate the achievement of Team Korrocoat, for being the First Paint manufacturing organisation in Maharashtra, and one of the top 3 organisations in India, irrespective of any State incentives like Gujrat, or without any MNC association. The global level innovations and practices are developed, in Pune, on our own. With a background of many other organisations giving up the projects during, or post OSA (OSA - Online Self-assessment), after knowing a long list of documents as part of system evidence and legal compliances, which are assessed during desktop & site assessment. To go for ZED without any business compulsion, demands, or state incentives, needs an exceptionally dedicated commitment. Although they were certified in the first week of September 2019, we are sharing this, after assessing the consistency for six months.

More than hundred documents, including the special emphasis on safety, was so meticulously done, that on the day of the site assessment, the lead assessor was tempted to click some of her photos with putting all the PPE as a memory. The assessors’ team appreciated the safety initiatives. The paint manufacturing is a typical process, wherein the environment and quality are very sensitive concerns. The dedication of team including, the management representative, Mr Gondhali, the customer education & satisfaction support by Mr Patwardhan, the R & D, QA team of Ms Kunda and Ms Gauri, and Supplier education and Purchase by Mr Yogesh, jointly with production & Stores team is a unique combination. Contribution from Everyone including the entry point induction by Mrs Sonal is very distinctive and impressive. The team together has put in a lot of efforts to make it feasible, especially on the background of most of the organisations in this sector not even opting for it, or just starting and then quitting… We are sure as a team, and their achievement - itself is a great motivation for all the remaining Industries.

ZED is a global benchmarking standard, everyone is not capable of adapting to the demanding and distinctive requirements. We are very proud to set a benchmark, which is only possible as every individual has a benchmark effort, we have now carved a path for rest to follow.

The credit must be given to the able leadership of Mr Yogesh Rasane, for initiating such a ‘mission impossible’ and granting resources to make it possible. Dr Archana Rasane is an added advantage to the team. She imparted training, & conducted the safety and health counselling while addressing the health & safety concerns of all stakeholders. Enjoying breakfast till dinner together was a fantastic motivation and involvement drive for all.

Being a part of TLC, Mr Rasane is focused on learning and employee development. The project was initiated almost one and half year back, but the real speed and rigour were demonstrated in concluding six months. The 5 S, lean culture has established the foundation of employee engagement. Beyond it are the Devine blessings Rasane Family has, by their Shirdi trusteeship. I am sure the last 15 days are the most memorable days and nights for all of us.

Team Korrocoat is to take up new challenges, such as: being the first NABL approved conformity assessment body in this area, Industry 4.0, ISMS …...

Carefully formulated - Mission, vision, KRAs and ERP system linked to IoT; the team will continue as Pioneers, in the pursuit of the excellence, for years to come.

Zero Defect Zero Effect (ZED) - Roadmap towards global competitiveness

As an Engineering student I was told to go to small scale industries to learn. Logically the most innovative, effective engineering and management is learnt from MSMEs. I owe the learning opportunities since 1982 till date I got from MSMEs, in India and Globally not only during my internships, but also when I did trainings & audits with DNV, and thereafter as a QCI registered trainer, assessor, auditor, consultant till date. MSME capacity building is my humble contribution back to society. ZED is the most effective scheme and method I have ever used.

Is ZED only for MSMEs? No, it is for all. MSME are supported for capacity building. while Large Scale Industries can minimise their audits and appraisal costs as well as supplier development efforts and costs, by getting their supplier base registered for ZED. Organisations like Mahindra have started their supplier sensitisation and other OEMs are taking up this initiative step by step. The supplier chain development is a major & most effective way of economic engine development through MSME, along with schemes benefits. The indirect control of QES, like incoming goods and services impacts the end product, so most of the Large setup, conduct supplier, subcontractors’ audits. The number of customers demanding number of certifications and their protocols, create lot of confusions and repetition, so even for such MSME and large organisation ZED can be a much-awaited solution.

The major problem in MSME is non-effectiveness and nonefficiency as the try and struggle for survival against all odds. The contribution in economic development is hampered due to uncontrolled wastages. If any effectiveness and efficiency drive is implemented on ZED guidelines this would result in employment generation and economic development for sure, so all of us should take this drive seriously.

India with their young manpower has all the potential to be global manufacturing hub, if the reliability and quality is taken care of. At the same time, we should aim at sustainable development, with energy and environment and safety in focus. Means enhance the competitiveness of Indian MSMEs and to ensure Zero Defect practices in their manufacturing and also ensure Zero Effect on the environment while manufacturing This Model. Also enjoys benefits of the new scheme viz. “Financial Support to MSMEs in ZED Certification. ZED is a unique & holistic certification model for MSMEs, that will assess, rate and handhold them, based on 50 well defined parameters of Production, Design, Quality, Safety, Environment etc., with special focus on the Defence sector. The tangible ladder of move MSME up in ZED Certification (Bronze-Silver-Gold-Diamond-Platinum) makes it very interesting.

Although based on elements of the best standards and practices like ISO 9001, ISO 14001, Lean Management, 5S, Kaizen, Six Sigma, IPR, Energy Management, Supply Chain Management etc. ZED is carefully developed taking care of MSME environment in Min. Thus, The ZED maturity assessment model is one of the most comprehensive assessment models for MSME. The limitation in standardising the certification process, the professional skills and deployment variations are controlled in ZED end to end use of technology for the entire process of ZED assessment and handholding. The site assessment is conducted by the assessors using a secured ‘ZED app’ on their mobile phones which has embedded features like ‘geo-tagging & geo-stamping’ making the process transparent and fool-proof.

The assessment provides a detailed report on every parameter on which the assessment is made thereby providing an opportunity to the enterprise to identify strengths and gaps for focused improvement to move up the ladder in the journey to become world class.

Some of my clients fully agree with ZED deployment they have achieved, Superior quality, reduced rejections & higher revenues through step by step focused planning & monitoring & improvisations. Organisations like BEL and Mahindra consider ZED as tool for credible vendor database for large enterprises, without multiple certification pressures. The promotion cost and effectiveness with existing media and methods like exhibition participation has limited impact, whereas, ZED has enhanced visibility and brand recognition, being on the ZED web page of QCI, making it visible as preferred associate globally. The capacity building and employee development drives synchronised with the best practices using e learning portal & newsletters and knowledge sharing forums through ZED is additional bonus for MSMEs. All this with responsive care and Reduced negative impact on environment, by Goal Zero commitment, ensures ZED is the ultimate choice.

Along with, technical, marketing and financial benefits, ZED is a most effective methodology for cultural change and motivating the employees. All other certifications are like go -and differed go gauges (never - no go) so, auditee does not know where organisation stands and what next. The subjectivity, professionalism, auditing skills hamper the learning and improvement processes.

In ZED the assessors are trained and calibrated to follow technology driven rating process, so the subjectivity is minimised. When I personally got involved in this model, I thought it is simplified IQRS – a dedicated excellence model by DNV. Soon I realised this is beyond quality, it not only includes all aspect of enablers and results but also all critical parameters for capacity building in a methodical way. It is a simple 4 step model with first two steps free registration, and free self-assessment, after that desk top review and Site assessment, to get the awarded.

I am asked - In spite of so many incentives and benefits of the scheme, why this is not popular? and till date why only 100 and odd organisations have gone for award? When I started discussing it with some known contacts, I got various responses such as – My MR is working on it… since past two years …. I tried for it, but it is too much of paperwork, we have given up… We will take it up by 2020… Maharashtra state has no benefits … If it is mandatory like ISO 9001 for tenders and otherwise only then we will do it, why spend money and efforts otherwise… We are financially strong independent organisation, why spend time for one more audit, globally QES is adequate…

I am sure some of them are correct but on wrong assumptions. MR is not the right authority to know and work for your cultural fine tuning… Sparing 2-3 hours and getting it done is easy- Do it yourself, do not delegate. The owner and all decision makers sitting for 2 hours can complete, first three steps, it does not take years, I have many examples where in we have along with the owner completed the same, in 2-3 hours. It needs no paper work, but is evidence driven, even audio and video works instructions and soft records are acceptable in the digitised form. Delaying an opportunity is delaying your success. May be even you end up in losing it permanently as only first 22222 MSME are getting subsidised payment benefits.

Individuals working for schemes are penny wise. The point is if we start any change the schemes may facilitate and help It, but the commitment cannot substitute the benefits, With or without state benefits, we should work, Implementation is entirely the owners or top management’s commitment. Process implementation is the benefit beyond any external benefit. One micro organisation with size of 7 individual and the top man, who is a technocrat, visionary and committed, told me, he cannot afford the 1,65,000/- handholding / consultancy charges, but if there is a way out for subsidized need driven support like specific training he wants to go for it. This is a rational approach, instead of saying the problem is too big, find a way out. Sort out what you need, then it may not appear so terrifying. Organisations that are certified will assure you, it is not very difficult.

Typical excuses are - I have substandard team, lot of operational issues and so do not have time for ZED. If one has substandard people, all the more reason one needs a strong system. The top management has to select appropriate 30 elements, for which any one of us or even I will extend support, then make 30 folders and start filling up all by the documents and records organisation already has, and soon almost 60-90 percent problem is solved. Allocate the 30 folders to the process owners to sustain and focus on remaining gaps, makes it simple. Almost any 9001-certified organisation easily reaches bronze level.

For remaining, either go to e learning portal or google it, or hire a trainer, it is focused and not very costly as anticipated. No matter whether Maharashtra State is offering any benefits, or it is mandatory for tenders or you are required no external funds, for sure implementation means a direction setting for your organisation which is SWOT driven, for achieving the global competitiveness.

It helps to be systematic, it means little extra efforts, it is like setting a system driven culture of sharpening and validating your tools, you may have to spend time on it, but it saves lot of non-effective, non-efficient wasteful efforts.

We are there for Extending all the necessary support in your journey of excellence, wishing you all the very best. So, do not wait, log in to ZED portal, if registered and have questions or even otherwise, write to us on drsanjeevanigogawale@gmail.com or zeninternationalsystems@gmail.com, sacchida222@gmail.com call me 8329155488 , 9422522322, 7020987263 or leave a text message. We are also with MCCIa organising small focused problem-solving sessions soon, so we can meet in person.

Zero Defect Zero Effect (ZED) - Energy Sector - 1st Silver in India

The name itself indicates the organisation is dedicated for energy solutions.

The owner is a hardcore design engineer with M.Tech. from IIT Kharagpur Mr. Apashankar.

His products are appreciated globally for the energy performance. The furnaces along with the vapour density meter are developments done in-house by the dedicated Engineering team.

The role of MR was handled by Dr. Khare and was supported by Ms. Kiran and Nilesh.

The production was handled by Mr. Pawar and the stores by Mr. Khare , the accounting support by their accountant Madam. Mr. Beldar handling the marketing and also the CEO of the team was really having a lot of documentation related to customer education, appreciations and U tube clipps that were really handy during XED implementation. The core team visited various ZED certified clients including their family business certified for ZED called Studcraft. The quest to learn and adapt to new skill level was demonstrated inthe vertual training and follow up on phone.

A time came when they were almost going to give up the project when some one tried to tell them -first go for ISO then ZED. Indeed the zeal and top driven commitment was so strong a small intervention and motivation charged them again.

The structural design was handled by Mrs. Apashankar, the team together was a unique combination of dedicated focused individuals with excellent teamwork and Support from the operators.

The employee engagement drives were very fruitful and suggestions were remarkable.

The international journeys business pressure and still the ZED persuit was a real challenge and was handled so good by the top management that they became the first ever silver certified unit in Energy sector.

So, it is the team Energy , synergy led by able innovative leadership matters more than any formal ISO certification was proven by them.

We are indeed very happy to be associated with them.

Zero Defect Zero Effect (ZED) with lightning speed

Meeting Manasi was a Divine planning. I first met her in RKM, Bhagini Nivedita 150 birth anniversary celebrations. She joined as woman entrepreneurs representative and I was an anchor that day. Before we could exchange any views, she left for her office, and I have to rush for next I introduction.

Second meeting with her was through one of my Research student. Same topic women entrepreneurs....

But this time she was keen in knowing ZED and had taken up the pursuit to achieve it before China Exhibition.

I was not very sure , because I was not aware of her driving leadership ability and commitment. Her office, & conference hall is full of many awards and appreciation letters for her. I personally interacted with Pradnya her HR manager , Mr. Manoj Bidkar, the R &D Mentor and Marketing Director. Her son Shubham now able to head the Research and development, Chaitrali the QA head, Mr.Bagaitkar and was relax. I knew the target was difficult but was not impossible.

We sat together and completed the OSA in two and half hours. The DA was done by her team, after completion of training.

The audit was to be witnessed by the QCI panel of Experts, so we were to face 4 assessee in all.

The team was ready, still the dedicated members use to call me, and get issues solved. It was indeed a great pleasure to see the engagement.

Pradnya has done her employee satisfaction survey and I was surprise to see, unedited transparent remarks.

Shall we not edit it,.. it is more of emotions than facts ..isn't it?...I asked. - Still some learning can be derived if not these are sensitive issues can be concluded. She replied.

The logical engineering approach forced me check for her background and indeed even she is an engineer...

When everything is right the results also have to be right. With in 15 days they received the award letter.

A super-fast excellence journey I ever witnessed but it suits and is just in tune with the driving speed of Manasi...

When I wanted to congratulate her , she strongly recommend my name to MCCIA and two more clients just walked in thanks to her. Till date the association of MCCIA is very fruitful for all of us.

Till date I am enjoying, being associated with the dedicated family and wonderful leadership. The drive is so contagious that even my other clients were excited, and motivated after meeting her.

I still feel fortunate that I met her in the holy campus of RKM on the auspicious day of Bhagini Nivedita Jayanti celebrations.

I am sure for years to come our association will flourish to contribute something unique for the Nation and the society as triggered by the Divine power, so, I never miss any opportunity to meet and interact with her. I feel excited just by talking to her and await for the ultimate realization for the Divine planning

Zero Defect Zero Effect (ZED) - Resources conservation drive at WBSPL