Slide 1

JISHU HOZEN Journey In Arihant From2011 to 2014

Arihant Spinning Mills, Malerkotla1

Vardhman

Vardhmanaims to be world class textile organization producing diverse range of products for the global textile market. Vardhmanseeks to achieve customer delight through excellence in manufacturing and customer service based on creative combination of state-of-the-art technology and human resources.Vardhmanis committed to be responsible corporate citizen.Massage From Chief Executive DeskMassage From CGM(Operation) Desk

3Dear All,

It Gives me immense pleasure and Satisfaction to release JH Manual I (JH Journey in Arihant From 2011 to 2014).On Group level we all are working hard on improving Productivity, Break-downs , Accidents, New Ideas, Man-Power Reduction, Complaints and Defects etc.JH Pillar is based on My Machine, I Maintain Concept. It enables Shop Floor Workers/Officers/Staff to think more rationally, Search for small-small improvements, innovate and bring more creative thinking in overall Working. JH Pillar while helping us to Control Proper functioning of our equipments, but also helps us in understanding working/proper Maintenance of equipments. This is a Self Development Exercise.I Congratulate JH Pillar Team in Compiling all the details which will guide all future participants in this movement.I Wish them Good Luck.

Kuldeep Jain(Chief Executive)

Dear All,

First of all I heartily Congratulate the efforts put by Arihant Team in brining together the Experiences of JH Journey in from of JH Manual. Vardhman always believes if Systematic during the Journey Through TPM Path.Jishu Hozen/Autonomous Maintenance is most important pillar among the Eight Pillars of TPM. My Machine-I maintain is the Key Mantra of Jishu Hozen.This Manual shares experiences Like: Steps being followed to bring involvement during JH, Procedure followed CLITA and Kaizens during CLITA etc.I wish all the success to Arihant Team in Achieving many more milestones in the years to come.

With Best Wishes,K.K.Lahiri(CGMO)

3IndexS.No.Topics CoverPage No.First Phase of JH Manual1.What is JH & Why JH?5 to 92.Enhancing Involvement10 to 123.JH Tree 13 to 184.Last Three years Trend19 to 225.Our present JH Activities23 to 40Second Phase of JH Manual6.One Points Lesson41 to 51Third Phase of JH Manual7.Kaizens Under JH Pillar52 to 668.Vote of thanks 674

What is JH??

5

First Phase of JH Manual6

This pillar is geared towards developing operators to be able to take care of small maintenance tasks, thus freeing up the skilled maintenance people to spend time on more value added activity and technical repairs. The operators are responsible for upkeep of their equipment to prevent it from deteriorating. JISHU HOZEN (Autonomous maintenance) :Policy : 1. Uninterrupted operation of equipments. 2. Flexible operators to operate and maintain other equipments. 3. Eliminating the defects at source through active employee participation. 4. Stepwise implementation of JH activities. JISHU HOZEN Targets: 1. Prevent the occurrence of 1A / 1B because of JH. 2. Reduce oil consumption by 50% .3. Reduce process time by 50% .4. Increase use of JH by 50%.

7Steps in JISHU HOZEN :

1. Preparation of employees. 2. Initial cleanup of machines. 3. Take counter measures 4. Fix tentative JH standards 5. General inspection 6. Autonomous inspection 7. Standardization and 8. Autonomous management.

8

TO MAKE OPERATOR EQUIPMENT COMPETENTTO ELIMINATE COST LOSSESTO ELIMINATE QUALITY DEFECTSTO ELIMINATE EQUIPMENT FAILURETO ESTABLISH BASIC EQUIPMENT CONDITIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO PREVENT EQUIPMENT DETERIORATIONWhy Jishu Hozen?TO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO PREVENT EQUIPMENT DETERIORATIONTO ESTABLISH BASIC EQUIPMENT CONDITIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO PREVENT EQUIPMENT DETERIORATIONTO ELIMINATE EQUIPMENT FAILURETO ESTABLISH BASIC EQUIPMENT CONDITIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO PREVENT EQUIPMENT DETERIORATIONTO ELIMINATE EQUIPMENT FAILURETO ESTABLISH BASIC EQUIPMENT CONDITIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO PREVENT EQUIPMENT DETERIORATIONTO ELIMINATE QUALITY DEFECTSTO ELIMINATE EQUIPMENT FAILURETO ESTABLISH BASIC EQUIPMENT CONDITIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO PREVENT EQUIPMENT DETERIORATIONTO MAKE OPERATOR EQUIPMENT COMPETENTTO ELIMINATE QUALITY DEFECTSTO ELIMINATE EQUIPMENT FAILURETO ESTABLISH BASIC EQUIPMENT CONDITIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO PREVENT EQUIPMENT DETERIORATIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO PREVENT EQUIPMENT DETERIORATIONTO ESTABLISH BASIC EQUIPMENT CONDITIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO PREVENT EQUIPMENT DETERIORATIONTO ELIMINATE EQUIPMENT FAILURETO ESTABLISH BASIC EQUIPMENT CONDITIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO MAKE OPERATOR EQUIPMENT COMPETENTTO ELIMINATE EQUIPMENT FAILURETO ESTABLISH BASIC EQUIPMENT CONDITIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO ELIMINATE QUALITY DEFECTSTO MAKE OPERATOR EQUIPMENT COMPETENTTO ELIMINATE EQUIPMENT FAILURETO ESTABLISH BASIC EQUIPMENT CONDITIONTO MAINTAIN EQUIPMENT IN OPTIMAL CONDTIONTO ELIMINATE COST LOSSESTO ELIMINATE QUALITY DEFECTSTO MAKE OPERATOR EQUIPMENT COMPETENTTO ELIMINATE EQUIPMENT FAILUREWhy9

JISHU HOZEN Journey Start with ENHANCING INVOLVEMENT10

In this noble concept machine has been owned by operator itself.

He / she takes care of the machine with brave slogan Yeh machine meri hai. M/C OWNERSHIP CONCEPT

11

OWNERSHIP CARD

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JH Tree Concept started in 2012 For branching more involvement & penetration of responsibility sharing throughout the 100% workforce in JH Activity .. 13Mr. Kuldeep Jain (Chief Executive)

JH Tree Mr. K.K.Lahiri (CGM Operation)Mr. Gurvir Bath (TPM Coordinator)PROD. MGR.- MR. KARTIK CH. KARProduction Manager - Mr. Anupam GangulyCHIEF. MGR.-BALBIR SINGHCHIEF. MGR.-BALBIR SINGHMR. RAMANDEEP SINGHCHIEF. MGR.-BALBIR SINGHMr.Harsimran Singh MR. ANUPAM SHARMAMR. SUMIT SINGH MR. CHARANJIT GOYAL1.. Mr. Gurtej Singh2.. Mr. Shyam Lal Jat3. Mr. Ajay Saxena4. Mr. Vinod Sharma

1.. Mr. OM Narayan2. Mr. Gagandeep Garg3. Mr. Anil Kumar4. Mr. Indresh Chran

1.Mr. Bhubaneshwar Das2.Mr. Mandeep Singh3. Mr. Sukhvir Singh4. Mr. Kanwaljeet Sharma

1.. Mr.Pushpender Singh2. . Mr. Sahil Bhatia3. Mr. Karan Singh4. Mr. Vijender Bendwal'1.. Mr.. UPINDER Singh2. Mr. Narayan Lal Jat3. Mr. Tanveer Salam4. Mr. Bijendra Bendwal

PROD. MGR.- MR. KARTIK CH. KAR

Unit No-1

JH Tree MembersMR. RAMANDEEP SINGH Shift A - MR.GURTEJ SINGH Shift B - MR.SHYAM LAL JATShift C - MR.AJAY SAXENAMR. VINOD SHARMARing Frame Dept JH Core Members Preparatory Dept JH Core MembersRing Frame Dept JH Core Members Preparatory Dept JH Core MembersRing Frame Dept JH Core Members Preparatory Dept JH Core MembersWINDING JH CORE TEAM1 .MR .PRAVEEN KUMAR 2.MR. BHIKHU PARSAD 4.MR. ARVIND 5.MR. AJAY SHARMA 7.MISS. LUBNA 8.MR. SHREE RAM 9. SHAYAM KISHAN 1.MR. ANIRUDH PARTAP 2.MR. SURYA NARAIN 3.MR. DINESH KUMAR 4. MR. SURESH SINGH 5.MR. PARMATMA SINGH 1.MR.PRAVEEN KUMAR 2.MR. AJIT KUMAR 3.MR. BIRENDER 4.MR. AJAY 5.MR. BABU LAL 6.MR. SUKH LAL 7.MR. SHIV BUSHAN PANDAY 8. MR.DHARMINDER 9. JITENDER PARSAD 1. AJIT DAS 2.MR.GURUPARSAD 3.MR. RAMESH KUMAR 4. MR. MAINUDEEN 1.MR.SURENDRA NITHARWAL 2. MR. BILAS YADAV 3.MR.RAMADEV 4.MR. MANOJ KUMAR 5.MR.RAMESH KUMAR 6.MR.RAMCHANDER 7.MR. VINOD KUMAR 8.MR. RAJDEV 9. KUNDAN KUMAR1.MR.GYANENDRA 2.MR. DINESH KUMAR 3.MR. JAGDISH PARSAD 4.MR. HEERA LAL 5. MR.JAI RAM 1. MR. DEEPAK SHARMA2. MR. BABU LAL3. MR. HAULDAR4. MR. DAWINDER5. MR. RAMSAREESH6. MR. MAHESH7. MR. VIJAY8. MR. RAMSAKAL9. MR. NAND LALProduction Manager - Mr. Anupam Ganguly

Unit No-2

JH Tree MembersMr. Harsimran SinghShift A - Mr. Bhubaneshwar DasShift B - Mr Mandeep SinghShift C - Mr. Sukhvir SinghMr. Kanwaljeet SharmaRing Frame Dept JH Core Members Preparatory Dept JH Core MembersRing Frame Dept JH Core Members Preparatory Dept JH Core MembersRing Frame Dept JH Core Members Preparatory Dept JH Core MembersWinding Department JH Core Members Juman KamalTarkeshwarChandeshwarRamuRanjeetSubashAmandeep KaurAbdulBahadurSatya NarayanManishMr. S.K. PareekKamleshAvadeshRam SumerBrijeshRam DarasRanjanMr. Om PrakashShiv BahadurOm PrakashBabluUma ShankarAnil GuptaRinkuMr. KuldeepChote LalSanjayRaj KumarKamakhya TiwariAnil PatelChandraprakashMr. KamalkantKapoor ChandKapil DevSurender SinghAvnishDesh RajShankarKrishnaLal BahadurRadhey ShyamKamleshJai NarayanHarishankarD. PandeyCHIEF. MGR.-BALBIR SINGH

Unit No-3,4

JH Tree Members MR. ANUPAM SHARMA Shift A - MR.PUSHPENDER Shift B - MR. SAHIL BHATIAShift C - MR.KARAN SINGHMR. VIJENDER BENDWALRing Frame Dept JH Core Members Preparatory Dept JH Core MembersRing Frame Dept JH Core Members Preparatory Dept JH Core MembersRing Frame Dept JH Core Members Preparatory Dept JH Core MembersWINDING JH CORE TEAM1 .MR .SHIRI RAM 2.MR. RAMU 3.MISS NAJIRA 4.MISS ANJU KUMARI 5.MISS. KULDEEP KAUR . 1.MR. SHIV JEE 2.MISS RAMANDEEP 3.MR. VISHNU 4. MR. BALKESHWAR 5.MR. BRIJ LAL 1.MR. AWDHESH 2.MR. RAJESH 3.MR. SANTOSH 4.MR. SATINDER 5.MR. AKHILESH 6.MR. JAIPRAKASH 1.MR.RAGHUNANDAN 2. MR.DEENANATH 3.MR.KANAHIYA LAL 4.MR. JAI SIMRAN 5. MR. UMESH 1.MR.KAMLESH 2. MR. RAJU 3.MR.SANTOSH 4.MR. VKEEL 5.MR.RAMKUMAR 6.MR.RAMU 1.MR.RAMASHANKAR 2.MR. DEVINDER 3.MR. RAVINDER PANDEY 4.MR. SHIVDHANI 5. SHIRIKANT 1 MR. SHAMSHER2. MR. RAJESH3. MR. VISHNU DAYAL4. MR. RAJESH5. MISS RANI17CHIEF. MGR.-BALBIR SINGH MR. CHARANJIT GOYAL Shift A MR.OM NARAYAN Shift B - MR. GAGANDEEP GARGShift C - MR. ANIL KUMARMR. INDRESH CHARAN Ring Frame Dept JH Core Members Preparatory Dept JH Core MembersRing Frame Dept JH Core Members Preparatory Dept JH Core MembersRing Frame Dept JH Core Members Preparatory Dept JH Core MembersWINDING JH CORE TEAM1 .MR .LAXMIKANT 2.MISS KAMALJEET 3.MISS MANDEEP 4.MR. RAJDEV . 1 .MR .MADAN 2.MRS SANGEETA 3.MRS SAPNA 4.MRS VIJENTI RANI . 1.MR. RAM REKHA 2.MR. SALUNDER 3.MR. PRAMOD 1.MR.SANTOSH 2.MR.RAM LAL 3.MR.KANAYA 4.MR. ARJUN1.MR.RAMAKANT YADAV 2. MR. KIRPASHANKAR 3.MR. RAMJI 4.MR. PRAMOD1.MR.MADAN 2.MR. RAGUNADAN 3.MR. AWIDESH 1 MR. DAVINDER2. MR. RADHYSYAM3. MR. RAMESH4. MISS RANI

Unit No-5

JH Tree Members

Unit Wise Machine Details Last 3 Years Trend

19Jishu Hozen Pillar S.NoActivitiesTarget 11-12Achieved 11-12Target 12-13Achieved 12-13Target 13-14Achieved 13-141Total Nos of M/cs 8512Total A & B Grade m/cs ( Area wise ) 3Completion of A & B grade m/c up toJH Step-1525520574570625615JH Step-2525518574568625612JH Step-35255185745706256154Develop One Point Lesson (OPLs) section wise 10000840880006366600055215Develop Kaizens during J.H activities10065150681501246Total no. of Training classes conducted regarding JH and total no. of people covered.201540(500)38(402)45(500)41(415)7 % of worker involvement in JH activities100%68%100%89%100%92%8Develop expert workers for fuguai identification70558062807020Total Nos of M/cs -- 851Total Nos of M/cs Area wise Sr No Dept / Area U1,6U2U3,4U5Total No's of M/cs 1Blow room / carding902277232122Preparatory543345221543Spinning672555291764Post spinning159129455Ch wdg / TFO1116129576Ring Doubling19----4237Reeling29----14438Packing6556229H-Plant15101064110Maintenance714673411Work shop131312Engg ( Compressors / DG )DG - 5 COMPRESSOR - 81313 R&D151514Waste packing3321

Completion of A & B grade m/c up to Step 322S. No Activity Timing Frequency1Routine CLITA15 Mins before Shift start Thrice Daily2CLITA Day Celebration15 Mins before Shift start

Monthly3JH awareness Training Program 4.00 PM Monthly (On every 3rd Tuesday )4JH WEEK 3.30 PM TO 4.30 PM ( Daily during the week ) Yearly

5Regular Meeting of Core committee 4.00 PMTwice /Month (Extra meeting as per need)OUR PRESENT JH ACTIVITIES

23CLITA DAY CELEBRATION

CLITA STANDS FOR C CLEANINGL LUBRICATIONI- INSPECTIONT- TIGHTENINGA- ADJUSTMENT

24CLITA DAY One day In the 1st Week of every month. Timing - 15 Mins before Shift end . Participants : outgoing shift operators Operators from every department participates. In sections with large no of M/cs (i.e Ring Spinning ) operator groups are formed , Each group is made owner of their allocated set of m/cs . Fuguai noted in M/c wise fixed format . Later this data is stored in PC . Shift Electrician , Maint fitter also present during this period to attend faults .

25

CLITA Day Celebration

2626Some common Fuguai ---Found During CLITA Activity

27

FUGUAI FOUND AT M/CS

Cut mark on Detaching cotsBurn roll at Draw frame Door safety bypass Improper color of Doff buttonImproper wire dressing 28

FUGUAI FOUND AT M/CS

Worn out TapeWorn out Top Clearer Cloth

Cut on Apron

Cut on cots

Broken Separator Holder

Broken Cradle

Broken ABC Ring

Broken Separator

Broken Spacer

Bend Needle Bearing Cap

Damaged Fly Catcher 29

Opaque screenGlass window brokenIndication board brokenCrack at exhaust pipeOHB nozzle disturbedJam at suction arm mouthFUGUAI FOUND AT M/CS 30

Most common Fuguai ( found on CLIT day ) :Fuguai TypeApr13 May13Jun13July13Aug13Sept13Oct13Nov13Dec13Jan14Feb14Mar14Damaged Apron152812910121091110810Damaged Cots51722121514101712864Worn out Daffy cloth1421201718121417118105Grease from Bearing512811874810650Loose/ Worn out Tape1481112101214109764Broken Separator668452643582Loose/ DisturbedLappet hook212002002100Bend needle Bearing Cap5251250243

0131Fuguai TypeApr13 May13Jun13July13Aug13Sept13Oct13Nov13Dec13Jan14Feb14Mar14Indication lamp Prob574224013201Stop motion 659757543421S/X Saddle gauge out462001011020S/x cots pressed9128108109119624Worn out Twist master/ Flyer finger312000102000S/X Clearer cloth not working5564224

52424B/R Waste pipe leakage625322212211Suction pipe crack2400001101

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Most common Fuguai ( found on CLIT day ) :32 JHAWARENESS PROGRAMME ONEVERY 3RD TUESDAY

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Training on Wheels34JH WEEK CELEBRATION

35

JH Rally & Inauguration 36

37

Poster competition38

JH Gallery Prashna Manch

39

CLIT Competition40

Second Phase of JH Manual41ONE POINT LESSON Department wise best OPL s Sorted & Displayed .

Product specific OPLs

Safety OPLs

OPLS displayed at some common places (Canteens, entrances etc)

42

AreaPre-combing

Actual ResultsDate ExecutedTeacherStudentONE POINT LESSONX

XBasic KnowledgeImprovement casesTrouble caseskRIl bRykyj hony pr lwebr ipis