jk paper jk paper limitedlimited - iqems india...2018/12/13 · suport to jishu hozen activities...

JK PAPER JK PAPER LIMITEDLIMITEDUnit: JK Paper Mills, Unit: JK Paper Mills, JaykaypurJaykaypur

J K PAPER …….Creating Lasting Impressions

Smart Safety-Industry Best Practices

Presenter : L M RAO

Date : 03.11.2018

ABOUT THE COMPANY

J K PAPER …….Creating Lasting Impressions Slide No. 1

Role of Leadership in Building &

Sustaining Safety Culture


INDUSTRIAL REVOLUTION 4.0


Definition : The full integration of information and communication

technology and automation technology in the "factory of the future” with

traditional manufacturing processes.

Slide No. 3

CostCost ComplexityComplexity� Eliminate waste & losses

� Eliminate hidden cost

� Cost reduction

� Sub-Nano technology

� Cyber Physical System

� Exponential technologies

INDUSTRY 4.0: WHY WE NEED IT?


CustomerCustomer CompetitionCompetition

� Personalize

� Fast, Cheap, Quality

� Total Customer Satisfaction

� Digitalization

� Increase competitiveness

� Globalization

Slide No. 4

High Skilled Technical (Engineer)High Skilled Technical (Engineer)

Mid Skilled Mid Skilled

(Technician)(Technician)

CURRENTCURRENT INDUSTRY 4.0INDUSTRY 4.0

LocalLocal

F iF i

High Skilled Innovator (Engineer)High Skilled Innovator (Engineer)

Mid Skilled Mid Skilled

(Specialist)(Specialist)

Local (Existing)Local (Existing)

Local Local

INDUSTRY 4.0: WORKFORCE TRANSFORMATION


Low SkilledLow Skilled

(Operator)(Operator)

LocalLocal

ForeignForeign

ForeignForeign

Low SkilledLow Skilled

(Operator)(Operator)

RoboticsRobotics

AutomationAutomation

(Upgrade)(Upgrade)

� Industry 4.0 will eliminate our dependency on Foreign labour workforce

� Industry 4.0 will provide platform for job upgrade on existing local workforce

Slide No. 5

COMPANY POLICY


SHE MANAGEMENT SYSTEM

Unhygienic

working

conditions

Incidents

Poor solid waste

disposal system

Noise Water

Lack of

Safety

Awareness

systems

SAFETY, HEALTH

& ENVIRONMENT

RELATED PROBLEMS Dust

Pollution

Concept & Objective

Back Ground


Pollution Pollution

To establish a

full proof safety management system &

its implementation

To establish a

systematic approach to

address Noise, Dust,

Discharge water, solid

waste & create pollution

free environment

To improve the

methodology of health checkup & treatment

ZERO ACCIDENT

IMPROVEMENT IN HEALTH & HYGIENE CONDITION OF

EMPLOYEESZERO POLLUTION

Concept & Objective

Slide No. 7

PROACTIVE

We work on the problems that we still find

GENERATIVE

SHE is how we do business round hereCulture LadderCulture Ladder

Successful Safety Management

REACTIVE

Safety is important, we do a lot every time we have an


CALCULATIVE

We have systems in place to manage all hazards

PATHOLOGICAL

Who cares as long as we’re not caught

accident

Slide No. 8

Technology

and standards

SHE

Management

Systems• Engineering improvements

• Behaviour

• Visible leadership / personal

accountability

• Shared purpose & belief

• Aligned performance commitment &

external view

• SHE delivers business value

Successful Successful Safety ManagementSafety Management

SHE SHE Performance over timePerformance over time


Time

Incid

ent r

ate

Improved

culture

g g p

• Hardware improvements

• Safety emphasis

• E&H Compliance

• Integrated SHE-MS

• Reporting

• Assurance

• Competence

• Risk Management

Slide No. 9

Establishing Safety System

Suport to Jishu

Hozen Activities

Safety Patrolling

Analysis of

Accidents

Training on importance of Safety during Initial

cleaning with Safety Checklist

- Preparation of Route Map

- Identification & Elimination of Hazards

- Human action related accidents

- Equipment related accidents

- Preventive Measures

- Implementation of various permit systems

- Evaluation of Safety performance through

Safety

ittINTEGRATED

Sample of Safety Checklist

Support to Jishu Hozen



Near Miss

Accidents

Safety Audit &

Supervision

Safety Awareness &

Training

Emergency

Preparedness &

Response

- Recording all Near Miss cases

- Analysis & Prevention

- Internal Audit & External Audit

- Supervision by Deptl.heads & Safety

stewards

- On the job Practical Training

- Shop floor Training

- Site safety instruction with OPL

- Display of Safe Operating Procedures.

- Celebrations & Competetions

- Mock Drills for Toxic release & Fire

INTEGRATED

SAFETY

ACTIVITY

Elimination Process Of the Identified Hazard

Slide No. 10

Analysis of AccidentsSafety Pyramid

INVESTIGATION

ELIMINATED

ROOT CAUSE

ANALYSIS

IMPLEMENTATION OF

COUNTER MEASURES

EVALUATION OF

INCIDENTSREOCCURRENCE

REVIEW

ACCIDENT

Accident Investigation Flow Chart


Reportable Accidents (Absenting

> 48 hrs)

Non-Reportable Accidents

(Absenting < 48 hrs)

First Aid Cases (Absenting < 3

hrs)

Near Miss

Cases

U/A

Kn

ow

led

ge

Ab

ility

Mo

tiva

tio

n

De

sig

n

Ma

inte

na

nce

Actio

n o

f

oth

ers

Re

active

ap

pro

ach

Pro

-a

ctive

ap

pro

ach

La

gg

ing

Ind

ica

tors

Le

ad

ing

Ind

ica

tors

U/C


Accident Status – (2017-18)

GOOD

Slide No. 11

0 0 0 0 0 0 0 0 0 0 0 00

1

2

3

4

5

APR MAY JUN JULY AUG SEP OCT NOV DEC JAN FEB MAR

No

s

MONTH

REPORTABLE ACCIDENT-2017-18

GOOD

Total-0

143 151168 167

147

197174 180 184 182

162 162

0

50

100

150

200

250


NEAR MISS CASES-2017-18GOOD

Total-2017

25 6

3 34

3 47 6 5

23

2

1 23

2 20 3

01

0

5

10

15

20

25

30


CONTRACTOR COMPANY

FIRST AID CASES-2017-18

58 8

4 57

5 67

95

3

GOOD

Total-72

K M

305

480

305

480

0

100

200

300

400

500

600

Unsafe Act Unsafe Condition

Chart Title

Identified Rectified

Capturing of Unsafe Act & Conditions-2017-18

46

551

896

401

54 72

347

46

551

896

401

54 72

347

0100200300400500600700800900

1000

Ext

.Sa

fety

Au

dit

Int.

Sa

fety

Au

dit

Se

lf S

afe

ty A

ud

it

Sp

eci

fic

Sa

fety

Au

dit

Sr.

Off

icia

l S

urp

rise

Au

dit

Sr.

Mg

mt.

Nig

htA

ud

it

Da

ily

Ob

s. B

y

Sa

fety

Off

ice

rs

No.of Observations

SAFETY AUDIT COMPLIANCE STATUS 2017-18

SAFETY PERFORMANCE FOR THE YEAR 2017-18


33 35 37 47 42 42 39 41 40 43 46 49

582

776846

952

606 596 597539

617

867948

1025

0

200

400

600

800

1000

1200

Ap

r.1

7

Ma

y.1

7

Jun

.17

Jul.

17

Au

g.1

7

Se

pt.

17

Oc

t.1

7

No

v.1

7

De

c.1

7

Jan

.18

Fe

b.1

8

Ma

r.1

8

Tr. Conducted Participants

SAFETY TRAINING (CLASS ROOM)-2017-18

Tr. Prog-494

Participants -8964

22 23 28 16 26 9 29 7 18 18 16 9 21 23 9220283 329 403 292 416

263452

184 263472

251 173385

571256

3971

0

500

1000

1500

2000

2500

3000

3500

4000

Safe

ty M

anag

em

en

t Sy

ste

m

Use

of

PP

Es

Wo

rk P

erm

it S

yste

m

Inci

de

nt R

ep

ort

ing

Syst

em

Ne

ar M

iss

Cap

turi

ng

Be

hav

iou

r B

ase

d S

afe

ty

Eme

rge

ncy

Pre

par

ed

en

ess

Pla

n

Co

nfi

ne

d S

pac

e S

afe

ty

Ch

em

ical

Saf

ety

Traf

fic

Safe

ty M

anag

em

en

t

He

igh

t W

ork

Saf

ety

Ho

t W

ork

Saf

ety

Lift

ing

Too

ls &

Tac

kle

s

Mat

eri

al H

and

ling

HIR

A

SOP

s /

SMP

s

Tr.Programme Participants

SAFETY CLASS ROOM TRAINING FOR THE YEAR 2017-18

No.of Trainings-494

No.of Particpants-8964

Slide No. 12

SAFETY PERFORMANCE FOR THE YEAR 2018-19

0 0 0 0 0 00

1

2

3

4

5

APR MAY JUN JULY AUG SEP OCT NOV DEC

No

s

Month

MONTH WISE TREND OF REPORTABLE ACCIDENT-2018-19

GOOD

0 0 0 0 0 00

1

2

3

4

5


No

s

Month

MONTH WISE TREND OF NONREPORTABLE ACCIDENT-2018-19

GOOD


Company-03

Contractor-11

Total-14

GOOD Total-261Total-458

52 3 3 3

33

2 2 1 00

5

10

15

20

25

30


Contractor Company

MONTH WISE TREND OF FIRST AID ACCIDENT-2018-19

8

3 5 5 4 3

GOOD

207228 234 222

177

249

0

50

100

150

200

250

300


NEAR MISS CASES-2018-19

GOODTotal-1317Company-9

Contractor-19

Total-28

Slide No. 13


Unsafe

Condition, 22

Unsafe Act, 50

CAUSE WISE ANALYSIS OF FA-2017-18


Head, 9

Trunk, 4

Upper

Limb, 32

Lower

Limb, 23

Both

(UL&LL), 2Misc, 2

Injury Wise Analysis of FA-2017-18

EMERGENCY PREPAREDNESS

EMERGENCY

ON-SITE

EMERGENCYOFF-SITE

EMERGENCY

NATURAL

HAZARDS


TOXIC

HAZARD

FIRE

HAZARD

EARTHQUAKE,

etc.

CYCLONE FLOOD

Slide No. 15

IDENTIFICATION OF MOST CREDIBLE HAZARD SCENARIO

� Identification of Hazardous Chemicals:

1. Chlorine :Toxic & Threshold Quantity

� Analysis Of Hazard:

1. Spread of Chlorine

2. Concentration

3. Distance to travel

� Mitigation Plan

1. Emergency Preparedness Plan

2. PPE

Geographical Analysis by

DGFASLI, Mumbai

The following chemicals have been

identified as hazardous chemicals used

in our mills.

Chlorine ( Cl2 )

Chlorine Dioxide ( ClO2 )

Sulphur Dioxide ( SO2 )

Caustic Soda lye ( NaOH )

Hydrogen Peroxide ( H2O2 )

Hydrochloric Acid. ( HCl )

Sulphuric Acid (H2SO4)

Out of these Chlorine (Cl2) is the most

hazardous chemical used in our mill.


M/s Sun

Consultancy, Bhubanes

war


Activation & Closing Procedure for Toxic & Fire

Fire Training Fire Mock Drill

Emergency Training On-Site Chlorine Mock Drill

Mock Drill during the year 2017-18

Ext Int

Fire 1 123

Toxic 2 12

Hydrant Motor Pump Tr. on use of SCBA

Slide No. 16

Off-Site Chlorine Mock Drill Presentation of Emergency Plan in DCG Meeting Off-Site Emergency Plan

Steps taken to reduce the potential hazard



A. Initially when plant started, chlorine was stored in 2 storage tanks of capacity 40 MT each.

B. After the Bhopal gas tragedy , one of the above storage tank has been isolated.

C. The storage quantity in the second tank has been reduced from 40 MT to 25 MT.

D. And later on, the potential has been further reduced by isolating both the storage tank 1&2.

E. We have again modified the unloading system by connecting 900 Kg tonners directly and being

consumed in the process.

F. We have provided 4 nos. of chlorine sensors in the Chlorine Storage Shed. If leakage occurs, it

is indicated on the control panel which is located in Incident control room / Operator room.

H. One sensor has been installed at our unloading bank to sense the chlorine leakage during

unloading.

I. One more sensor has been provided in the gasifier room to sense the leakage of chlorine.

J. 4 nos. of Chlorine sensors have been provided at Chlorine Dioxide Plant.

Slide No. 17

TABLE OF CONTENTS

SL. NO. DESCRIPTION PAGE NO.

1.0 General Information about the factory 03-07

1.1 About Organization 01-01

1.2 Company & Unit Profile 01-02

1.3 Manufacturing Process & Mill Design 02-07

1.4 Paper Making Process Flow 07-07

2.0 Product / Bi-product 08-08

2.1 Product Profile 08-08

2.2 Bi Product Profile 08-08

3.0 Identification of Hazard 09-16

3.1 Possible Causative Factor 09-09

3.2 Consequence Analysis for Hazard Scenario 09-15

4.0 Emergency Command Structure 16-16

5.0 Role of key persons 17-18

5.1 Role of Works Main Controller (WMC) 17-17

5.2 Role of Site Incident Controller (SIC) 17-17

5.3 Role of Chief Safety Co-ordinator(CSC) 17-18

5.4 Role of Combat Team 18-18

Unit: JKPM, Jaykaypur, Dist: Rayagada, Odisha -765017 EMERGENCY PLAN FOR NATURAL HAZARD- 2014- -

EMERGENCY PLAN



5.5 Role of Rescue Team 18-18

5.6 Role of Auxiliary Team 18-18

6.0 Action plan for On-Site Emergency Plan 19-20

7.0 Silent Hour Command Structure 21-21

8.0 Activation & Closing procedure 22-22

ANNEXURE

SL. NO. DESCRIPTION PAGE NO.

1.0 Emergency Contact Numbers 24-25

1.1 Important Local Admn. Telephone Nos. 24-24

1.2 Telephone nos of Key Persons of the factory 24-25

1.3 Others Persons Telephone Nos. 25-25

2.0 Instruction Sheet 26-27

FOR NATURAL HAZARDS

JK PAPER LTD (UNIT – JKPM)

At/PO-JAYKAYPUR, DIST- RAYAGADA ODISHA – 765017

Do’s & Don’ts

Before the Cyclone season:

� Check the building; secure loose tiles and carry out repairs of doors and windows

� Remove dead branches or dying trees close to the building; anchor removable objects such as

lumber piles, loose tin sheets, loose bricks, garbage cans, sign-boards etc. which can fly in

strong winds

� Keep some wooden boards ready so that glass windows can be boarded if needed

� Demolish condemned buildings

When the Cyclone starts

� Listen to the radio (All India Radio stations give weather warnings).

� Keep monitoring the warnings. This will help you prepare for a cyclone emergency.

� Pass the information to others.

� Ignore rumours and do not spread them; this will help to avoid panic situations.

� Believe in the official information

� When a cyclone alert is on for your area continue normal working but stay alert to the radio

warnings.

� Stay alert for the next 24 hours as a cyclone alert means that the danger is within 24 hours. � Do not delay and run the risk of being marooned

� Provide strong suitable support for outside doors.

� If you do not have wooden boards handy, paste paper strips on glasses to prevent splinters.

However, this may not avoid breaking windows.

� Get extra food, which can be eaten without cooking. Store extra drinking water in suitably

covered vessels.

� Small and loose things, which can fly in strong winds, should be stored safely in a room.

� Be sure that a window and door can be opened only on the side opposite to the one facing the

wind.

� If the centre of the cyclone is passing directly over plant, there will be a lull in the wind and rain

lasting for half an hour or so. During this time do not go out; because immediately after that,

very strong winds will blow from the opposite direction.

� Switch off the electrical supply.

� Remain calm.

When Evacuation is instructed

� Head for the proper shelter or evacuation points indicated by the plant authority.

� At the shelter follow instructions of the person in charge.

� Remain in the shelter until you are informed to leave

Post-cyclone measures

� Strictly avoid any loose and dangling wires from lamp posts.

� If you have to drive, do drive carefully.

� Clear debris from the area immediately.

Do’s & Don’ts:

What to Do Before an Earthquake

� Repair deep plaster cracks in ceilings and foundations.

� Anchor overhead lighting fixtures to the ceiling.

� Follow BIS codes relevant to your area for building standards

� Fasten shelves securely to walls.

� Place large or heavy objects on lower shelves.

� Brace overhead light and fan fixtures.

� Repair defective electrical wiring and leaky gas connections. These are potential fire risks.

� Secure water heaters, LPG cylinders etc., by strapping them to the walls or bolting to the floor.

� Identify safe places indoors and outdoors.

� Know emergency telephone numbers (such as those of doctors, hospitals, the police, etc)

� Educate all

Help your community get ready

� Publish a special section in your local newspaper with emergency information on earthquakes.

Localize the information by printing the phone numbers of local emergency services offices

and hospitals.

� Conduct week-long series on locating hazards in the home.

� Work with local emergency services and officials to prepare special reports for people with

mobility impairment on what to do during an earthquake.

� Provide tips on conducting earthquake drills

� Interview representatives of the gas, electric, and water companies about shutting off utilities.

What to Do During an Earthquake

Stay as safe as possible during an earthquake. Be aware that some earthquakes are actually foreshocks and a larger earthquake might occur. Minimize your movements to a few steps that reach a nearby safe place and stay indoors until the shaking has stopped and you are sure exiting is safe.

If indoors

� DROP to the ground; take COVER by getting under a sturdy table or other piece of furniture;

and HOLD ON until the shaking stops. If there is no a table or desk near you, cover your face

and head with your arms and crouch in an inside corner of the building.

� Protect yourself by staying under the lintel of an inner door, in the corner of a room, under a

table or even under a bed.

� Stay away from glass, windows, outside doors and walls, and anything that could fall, (such as

lighting fixtures or furniture).

� Stay in bed if you are there when the earthquake strikes. Hold on and protect your head with a

pillow, unless you are under a heavy light fixture that could fall. In that case, move to the nearest

safe place.

� Use a doorway for shelter only if it is in close proximity to you and if you know it is a strongly

supported, load bearing doorway.

DO’s & DON’Ts of Cyclone DO’s & DON’Ts of Earthquake

Slide No. 18

Cl2 STORAGE SHED FRP FUNNEL SAFETY VALVE Cl2 SENSORS

INFRASTRUCTURE AVAILABLE

LIME BAG STORE


FRP HOOD

SNIFFER SYSTEM

CAUSTIC PIT

TAPPING POINT UNIVERSAL RING SYSTEMCHAIN & YOKE SYSTEM

CAUSTIC TANKWARNING SYSTEM SAFETY TIPS

PPE ROOM

Slide No. 19

Internal :

• Specific Safety Audit by Safety Officer

• Bimonthly Self Safety Audit by Department

• ISO internal Audit once in a quarter

• Six months Cross Functional Safety Audit

• Sr. Executive Plant Visit

• Sr. Executive Night Surprise Visit

External :

• Once in two years by accredited External Agency

• ISO Audit in every six month

• Annual Inspection by Asst. Director, Factories &

Boilers, Rayagada Zone

Safety Audit Safety Audit

AUDITS


TRAININGS & AWARENESS


SAFETY PROMOTIONAL ACTIVITIES

Road Safety Week

Observance of National Safety Day / Week


Obse a ce o at o a Sa ety ay / ee

Observance of National Disaster Prevention Day

Observance of Fire Safety Week

Observance of World Environment Day

Slide No. 22

LEVEL 7

LEVEL 6

LEVEL 5

EVE 4 TPM OE/CI ERP

TPM-CONSISTENCY AWARD

TPM COMMITMENT AWARD

OHSAS: 18001

TPM SPECIAL AWARD

GROWTH PLAN


LEVEL 4

LEVEL 3

LEVEL 2

LEVEL 1

1980-1985 1986-1990 1991-1995 1996-2000 2001-2005 2006-2010 2011-2020

QUALITY CIRCLE

ISO 14001 ENVIRONMENT SYSTEM

TPM, OE/CI, ERP

SUGGESTION SCHEMES

ISO 9001 QUALITY SYSTEM

Slide No. 23

TPM ORGANISATION

Mr.Biswajeet DwivediMr. Biswajit Deb

Chairman : Mr. PK Suri

Labour Union

Mr. L.M. RaoMr. A. Tripathy

Mr. G.V. Joga RaoMr Ch. V. Ramana

TPM APEX COMMITTEE

TPM Secretariat

1 Kobetsu KaizenP

SUB COMMITTEES


Pulp Mill, Paper

Machines, Recovery

ElectricalMechanica

lInstrumentation

Boilers, Turbines,

Water Supply

Purchase, Sales,

Stores, Accounts

28 4 11 56

Personnel, HRD,

Welfare

Total TPM Circles (54)

HeadManufacturing

HeadMaintenance

HeadCommercial

HeadUtilities

HeadPersonnel &

Admn. 2 Jishu HozenMr. CSR Appa Rao

3 Planned MaintenanceMr. MRKM Rao

4 Quality MaintenanceMr. GS patnaik

5 Initial Flow ControlMr. P. Suryanarayana

6 Education & TrainingMr. Dibyendu Basu.

7 Office ImprovementMr. Biswajit Dwivedi

8 Safety, Health & EnvironmentMr. S. Mohanty

9 LogisticsMr. S Gaikwad

1 Kobetsu KaizenMr. AK Mishra

PR

OCESS

INNO

VATION

Total TPM Circles consists of 1481 Members 10 New Product DevelopmentMr. Susants Nayak

Slide No. 24

Relationship between KMI, Policies, KPI & KAIKMI BACKGROUND & CHALLENGES POLICY PILLAR POLICY KPI KAI IMPROVEMENT GRAPHS

1. SPEED LOSS

2. PLANNED SHUT LOSS

3. MANAGEMENT LOSS

4. EQUIPMENT FAILURE LOSS

5. DEFECT FILURE LOSS

6. YIELD LOSS

7. CHEMICAL CONSUMPTION LOSS

8. ENERGY LOSS

9. INVENTORY LOSS

1. WHY-WHY ANALYSIS

2. PM ANALYSIS

3. BOTTLENECK ANALYSIS

4. COUNTER MEASURES

5. KAIZEN REGISTRATION

6. KAIZEN IMPLEMENTATION

1. REDUCTION IN C,L,I & T TIME

2. KAIZENS RELATED TO SOURCES OF CONTAMINATION

3. KAIZENS RELATED TO INACCESSIBLE AREA

4. MINOR STOPPAGES

5. BREAKDOWN DUE TO BAD OPERATION

6. BREAKDOWN DUE TO DETERIORATION OF BASIC CONDITION

7. BREAKDOWN ATTENDED BY JISHU HOZEN

8. OME POINT LESSONS

1. WHITE TAGS

2. RED TAGS

3. KAIZEN SHEETS

4. OPL SHEETS

5. WHY-WHY

6. TRAINING

1. A RANK EQUIPMENTS MAJOR FAILURE

2. A RANK EQUIPMENTS MEDIUM FAILURE

3. A RANK EQUIPMENTS MINOR FAILURE

4. A RANK EQUIPMENTS TOTAL FAILURE

5. TOTAL FAILURE HOURS( A RANK)

6. MTBF

7. MTTR

8. MAINTENANCE COST

9. LUBRICATION COST

1. WHY/ WHY

2. COUNTER MEASURES

3. TBM COMPLIANCE

4. CBM COMPLIANCE

5. CORRECTIVE MAINTENANCE

6. MP SHEETS

7. KAIZENS

8. OPL's

9. TRAINING

1. CUSTOMER COMPLAINT

2. IN-PROCESS REJECTION

3. RE-WORK LOSS

1. 4M CONDITION COMPLAINCE

2. WHY-WHY ANALYSIS

3. COUNTER MEASURE

4. OPLS

4. TRAININGS

5. KAIZENS

6. 4M CONDITION REVISED

7. VISUAL CONTROL

8. POKE-YOKE

RELATIONSHIP BETWEEN KMI POLICIES,KPI AND KAI

MACHINE

STRENGTH:

1.QUALITY & TECHNOLOGY

2.GOOD CONFIGURTION

3.SUITABLE TO CERTAIN QUALITY OF PAPER

WEAKNESS:

1.SPACE OCCUPANCY OF MACHINE

2.MANPOWER OPERATIG IS NOT SKILLED

3.SLOW SPEED & AGED MACHINE

OPPORTUNITY:

1.LOW COST LABOR

2.GSM VARIATION IS HIGH

3.WIDE RANGE OF PAPER

THREATS:

1.ENVIRONMENT REGULATION

2.HUMAN INJURIES

3 WATER AVAILABILITY IS LOW

MAN

STRENGTH:

1.OPERATIONAL EFFICIENCY

2.DISTRIBUTION NETWORK

WEAKNESS:

1.RAW MATERIAL

OPPORTUNITY:

1.AVAILABILITY OF TRAINED MANPOWER

THREATS:

1.RAW MATERIAL & COST

VISION

(KMI)

TO BE

DYNAMIC

BENCHMAR

K LEADER IN

INDIAN

PAPER

INDUSTRY

TPM POLICY

In our continuous pursuit for organizational excellence we are

committed to:

1. Customer delight by providing world class product &

services

2.Be a dynamic benchmark and leader in pulp & paper

industry through process innovation in the entire business

chain.

3.Develop pride for all stake holders including society around.

4.Build a culture of intellectual honesty and professional

integrity

TPM POLICY


committed to:

1. Customer delight by providing world class product & services

2.Be a dynamic benchmark and leader in pulp & paper industry

through process innovation in the entire business chain.



integrity

TPM POLICY


committed to:


services



chain.



integrity

TPM POLICY


committed to:


services



chain.



integrity

TPM POLICY

In our continuous

pursuit for

organizational

excellence we are

committed to:

1. Customer delight

by providing world

class product &

services

2.Be a dynamic

benchmark and

leader in pulp &

paper industry

through process

innovation in the

entire business chain.

3.Develop pride for

all stake holders

including society

around.

4.Build a culture of

intellectual honesty

and professional

integrity

QUALITY POLICY

"To provide customer

delight- both internal

land external through

our products and

services at lowest

cost by continuous

improvement in

processes,

productivity, quality

and management

systems"

QEHS POLICY

We manufacture and

supply Pulp Paper

KK POLICY

AIMING TO MAXIMIZE THE OVERALL

EFECTIVENESS OF EQUIPMENT & PROCESS

THROUGH LOSS & COST MINIMIZATION

THROUGH KAIZENS & IMPROVING OEE

JH POLICY

TO PREVENT EQUIPMENT DETERIORATION BY

MAINTAINING SET OPERATING CONDITION

PM POLICY

TO FOCUS ON MTBF & MTTR AND THEREBY

IMPROVING EFFICIENCY OF MAINTENANCE

SYSYTEM AND REDUCTION OF MAINTENANCE

COST

QM POLICY

TO ACHIEVE REDUCTION IN CUSTOMER

COMPLAINT BY ENSURING QUALITY AT THE

VERYBEGINNING OF PRODUCTION PROCESS

KMI, POLICIES, KPI & KAI


1. NEW EQUIPMENT

2. NEW PROCESS

3. NEW PROCEDURE

4. INNOVATION

5. NEW PROJECT DEVELOPMENT

6. NO. OF INITIAL FLOW DEVELOPMENT

7. NO. OF TRAINING TO OPERATOR OF NEW PLANT

8. LOW COST AUTOMATON

1. MP SHEETS

1. TRAINING MANDAYS

2. SKILL UPGRADATION

3. SUGGESTIONS / KAIZENS

4. MULTISKILLING

5. COMPETENCY DEVELOPMENT OF EXECUTIVES

1. NO. OF TRAINING

2. SKILL ENHANCEMENT

3. SAFETY & HEALTH TRAINING

4. NO. OF KAIZENS / SUGGESTIONS

5. REWRD & RECOGNITION

1. ADMINISTRATION COST REDUCTION

2. INVENTORY CARRYING COST

3. INTERNAL LEAD TIME (PR TO PO CONVERSION COST)

4. ON-TIME DELIVERY

5. SAVING IN BOUGHT OUT

6. LABOUR PRODUCTIVITY (PER TON OF PAPER)

1. WHY-WHY ANALYSIS

2. COUNTER MEASURES

3. KAIZENS

4. JOB STANDARDIZATION

5. SYSTEM IMPROVEMENT

6. VENDOR DEVELOPMENT

7. ALTERNATE RESOURCE

1.REPORTABLE INCIDENTS

2.NON-REPORTABLE INCIENTS

3.FIRST AID INCIDENTS

4.NEAR MISS INCIDENTS

5.OCCUPATIONAL HEALTHCHECKUPS FOR EMPLOYEES

6.REDUCTION IN USAGE FOR OF EAR-PLUG IN NOISE PRONE AREA

7.REDUCTION IN USAGE FOR OF NOSE-MASK IN NOISE PRONE AREA

8.REDUCTION OF BIOCHEMICAL OXYGEN DEMAND (BOD) IN DISCHARGED EFFLUENT

9.REUCTION OF SUSPENDED SOLIDS

10.USE OF TREATED DOMESTIC EFFLUENT

11.USE OF TREATED EFFLUENT

1. WHY-WHY ANALYSIS

2. COUNTER MEASURES

3. KAIZENS & OPLs

4. STANDARDIZATION

5. LOW COST AUTOMATION

6. IMPROVEMENTS

7. RESOURCE CONSERVATION

1. PROCUREMENT LOGISTIC COST

2. INTERNAL LOGISTIC COST

3. SALES INTERNAL LOGISTIC COST

4. SALES OUTBOUND LOGISTIC COST

1. WHY-WHY ANALYSIS

2. COUNTER MEASURES

3. KAIZENS & OPLs

4. LOW COST AUTOMATION

5. IMPROVEMENTS

COMPETITION

STRENGTH:

1.BRAND

2.PRICE LEADERSHIP

WEAKNESS:

1.GROWTH

OPPORTUNITY:

1.HIGH GROWTH OF MARKET SEGMENT

2.LIMITED PRESENCE OF ORGANISED PLAYER IN

HIGH PAPER VALUE

THREATS:

1.POSSIBLE ENTRY OF MNCs

2.INCREASING COMPETITION FROM NON-

INTEGRATED PRODUCTS

SUPPLIER

STRENGTH:

1.LOCATION OF SUPPLIER

2.MARKET SHARE IN BRANDED PAPER

WEAKNESS:

1.FIXED COST

2.JKPM LOCATION

OPPORTUNITY:

1.LARGE MARKET IN WESTERN MARKET

2.HIGH DEMAND OF PACKAGING BRAND(ITC

DOMINANT)

THREATS

1.FALLING IMPORT TARRIF

3.WATER AVAILABILITY IS LOW

TO BE

DYNAMIC

BENCHMARK

LEADER

IN INDIAN

PAPER

INDUSTRY

TPM POLICY


committed to:





4.Build a culture of intellectual honesty and professional integrity

TPM POLICY


committed to:





4.Build a culture of intellectual honesty and professional integrity

TPM POLICY


committed to:


services



chain.



integrity

TPM POLICY


committed to:


services



chain.



integrity

TPM POLICY


committed to:


services



chain.



integrity

supply Pulp, Paper

and Paper Board for

Photocopying,

Printing and Writing

applications.

At JK Paper Limited,

Unit : JK Paper Mills,

we are committed to

adding value for our

stake holders and

achieve sustainable

growth through :

1.Manufacture and

supply of consistent

quality products

complying with

customer’s

requirements,

2.Protection of the

environment

including prevention

of pollution,

3.Prevention of

human injury and ill

health,

4.Ensuring fulfillment

of compliance

obligations

5.Complying with the

requirements of

applicable

management system

standards and

integrating them with

our Business

Strategies,

6.Continual

improvement of

Quality,

Environmental and

Occupational Health

& Safety

Management systems

and their

performance,

7.Adoption of

cleaner technologies,

processes and

resource conservation

8.Afforestation

through social and

farm forestry by

clonal technology,

This Policy is

communicated within

our organization and

is made available to

the relevant

interested parties, as

appropriate.

IFC POLICY

AIMIMG DEVELOPMENT AND MAINTAINING

OF HIGH EFFICIENT EQUIPMENT AND

FOCUSSING ON RELIABILITY OF EXISTING

EQUIPMENT

E&T POLICY

TO DEVELOP INDIVIDUAL SKILL THROUGH

FOCUSSED TRAINING PROGRAMS TO IMPROVE

COMPANY'S BUSINESS RESULT AND MORALE

OF THE WORKFORCE

OTPM POLICY

AIM TO ELIMINATE LOSSES IN OFFICE BY

IMPROVING OFFICE FUNCTIONAL EFFICIENCY &

SUPPORTING PRODUCTION DEPT.

SHE POLICY

TO WORK IN A SAFE, POLLUTION FREE &

CLEAN ENVIRONMENT WITH ZERO ACCIDENT

LOGISTIC POLICY

TO REDUCE THE COST ASSOCIATED WITH

PROCUREMENT BOTH INTERNAL LOGISTIC

COST & SALES LOGISTIC COST

Slide No. 25

KMI / KPI / KAI Improvement Sheet

KMI, KPI & KAI


JK

PM

NE

W P

RO

DU

CT

ION

SY

ST

EM

(NP

S)

Co

ntin

uo

us

Op

era

ting

Pla

nt

Custo

me

r

De

light P

lant

No

Sto

ck

Pla

nt

Fix

ed

Co

st

Pla

nned

Shutd

ow

n

Varia

ble

Co

st

Ze

ro In

terru

-

ptio

n P

lant

Cu

sto

me

r

Sa

tisfa

ctio

n

Em

plo

ye

e

Sa

tisfa

ctio

n

Lo

we

st C

ost

Pla

nt

Lea

d

Tim

e

Raw

mate

rial

Cost

Pow

er &

Fuel

Cost

Chem

ical

Cost

Logis

tic

Cost

No

Sto

ppage

No

Tro

uble

Sm

all L

ot

Pro

ductio

n

Inte

gra

ted

Lin

eIn

vento

ry

JK

PM

NE

W P

RO

DU

CT

ION

SY

ST

EM

IMA

GE

TR

EE

Man

Pow

er

Cost

Over-

heads

Cost

No. o

f

Shutd

ow

n

Dura

tion

Per

Shutd

ow

n

Cost P

er

Shutd

ow

n

mprovement

Raw Material

ntation

e Chemical

iciency

nate Fuel

n of linkage coal

te purchase

t feeding

mode of despatch

abour productivity

sourcing

und Management

g of S/D jobs

fe enhancement

ce planning

in tools & tackles

cal path method

ous Spares

sourcing

breakdown

adjustment

ess stoppage

nor stoppage

Speed loss

ect rate

Adjustment

t piece

ocess in tandem

lenecking

Crew Multiskilling

Material

WIP

ed Goods

ew Products

roved Products

Customer

me delivery

Maintenance

New

Pro

duct

Serv

ices

So

cia

l

Sa

tisfa

ctio

n

Glo

ba

l

Sa

tisfa

ctio

n

& Development

e Infrastructure

er Consumption

Discharge to River

Sequestration

er Harvesting

J K P

APER

…….C

reating L

asting Im

pression

s

LO

WC

OS

TP

LA

NT

CO

NT

INU

OU

S

OP

ER

AT

ING

PLA

NT

NO

ST

OC

K P

LA

NT

CU

ST

OM

ER

DE

LIG

HT

PLA

NT

•L

ow

co

st a

uto

ma

tion

•R

eso

urc

es c

on

se

rva

tion

•W

aste

utiliz

atio

n

•E

limin

atio

n o

f Mu

ltiple

ha

nd

ling a

ctiv

ities

•L

oss e

limin

atio

n

•Z

ero

de

fect

•E

limin

atio

n o

f Bre

ak

do

wn

•R

ed

uce

d p

lan

t sh

ut

do

wn

s

•M

ain

tain

ed e

quip

ment

ba

sic

co

nd

ition

•E

ffectiv

e p

lan

ne

d

ma

inte

nan

ce

•R

ed

uctio

n in

inve

nto

ry

leve

l

•E

nh

ancin

g O

PE

to

red

uce

WIP

•F

IFO

an

d ju

st in

time

follo

we

d

•W

ork

ing o

n firs

t pie

ce

righ

t pie

ce

.

•Z

ero

incid

en

t

•S

afe

ty b

ud

die

s

Slid

e N

o. 2

7

Yield Im

Alternate R

Plan

Alternate

Effic

Alterna

Maximization

Proximat

Direct

Alternative mo

Increase in lab

Outso

Innovative Fu

Clubbing

Equipment lif

Advance

Improvement i

Use of critica

Indigeno

Outso

Zero br

Setup & a

Zero proce

Zero mino

Zero Sp

Defe

Setup & A

First

Bring the proc

Debottl

Operational Cr

Raw M

W

Finishe

No. of Ne

No. of Impro

Visit to

On Tim

Chance M

Training &

Work Place

Fresh Water

Treated Effluent D

Carbon Se

Rain Wate

JK PAPER MILLS :: RAYAGADA

SAFETY IMPROVEMENT DEPARTMENTWISE For the Year 2017-18

Sl No. Department No. of ImprovementsHierarchy of Control hazard

Elimination Substitution Engineering Administrative PPE

1 PM1-5 11 5 0 6 0 0

2 PM#6 11 2 1 8 0 0

3 Pulp Mill 36 8 7 18 0 3

4 Power Block 15 0 0 15 0 0

5 R 18 8 0 7 1 2

IMPROVEMENTS


5 Recovery 18 8 0 7 1 2

6 FH Old 8 0 0 6 2 0

7 FH#6 20 6 10 4 0 0

8 Quality 9 2 1 4 1 1

9 Sales 8 1 0 1 6 0

10 Stores 10 1 0 6 2 1

11 Environment 38 0 0 38 0 0

12 Instrument 11 0 3 8 0 0

13 Civil 4 0 1 1 0 2

14 Electrical 37 20 3 12 1 1

15 Mech.Workshop 4 0 0 4 0 0

240 53 26 138 13 10

Slide No. 28

IMPROVEMENTS

Auto ignition system for HCl

synthesis

Installed a bag filter at limekiln to

localize lime dust Dust collecting through vacuum

unit at pet coke storage area


Provided sprinkler system at

coal yardInstallation of heat exchanger to

prevent emission HCl fumes

Pneumatic break provided to stop

free rotation of roller

Slide No. 29

Activity KK JH QM PM SHE OTPM IC ET

*

Result Area P Q C D S M

1

(illustration with sketch) (illustration with sketch) 2

3

4

Benefits:

KAIZEN IDEA - SHEET

S

Plant : FINISHING HOUSE PM 6 Machine: SHEETER

Theme:- LIFTING TABLE AREA FOUND MORE GAP

ACCIDENT MAY HAPPENED Idea: SUPPORTING PLATE MAKE AT LIFTING TABLE AREA

Problem / Present status Countermeasure: Benchmark ZERO BREAK DOWN

(in words) Target 30.04.2017

LIFTING TABLE HAVE MORE GAP GAP SHOULD BE COVERED OR SUPPORTED

BY PLATE

Kaizen start 15.04.2017

Kaizen finish 15.05.2017

Team members

BINOD PATTNAIK

DILLIP KUMAR

SANTOSH PRADHAN

TAPAN KU DAS

AFTER PROVIDING THE SUPPORT THE PLATE AT LIFTING

TABLE ACCIDENT NOT HAPPING & MACHINE WILL BE

SAFE

JKPM-TPM



1

2

3

4

5

KAIZEN IDEA - SHEET

Plant : FINISHING HOUSE PM 6 Machine: KICKER MACHINE

Theme:- KICKER HUTTER NOT AVAILABLE Idea: - HUTTER TO BE PROVIDED

Problem / Present statusCountermeasure:

Benchmark ZERO BREAK DOWN


REEL ASRS KICKER HUTTER NOT

AVAILABLE

HUTTER TO BE PROVIDED AT REEL ASRS

KICKER



Team members

TAPAN KUMAR DAS

(illustration with sketch) (illustration with sketch) BISWAJIT DAS

SANTOSH PRADHAN

BINOD PATTNAIK

BISWAJIT PRADHAN

Benefits:

JKPM-TPM



1

(illustration with sketch) 2

3

4

KAIZEN IDEA - SHEET

Plant : FINISHING HOUSE PM 6 Machine: PALLETIZER SECTION

Theme:- PROFILE CHECK ERROR BY THE MAZDOOR AT

PALLETIZER SECTION .Idea: COMPACTER TYPE MACHINE TO BE INSTAL AT CONVEYOR NO 5102 & 5103

Problem / Present statusCountermeasure:

Benchmark


MAN POWER USING FOR CORRECT THE

PROFILE CHECK ERROR .

MAN POWER REDUCE BY USING

COMPACTOR .



Team members

SATISH BELE

(illustration with sketch) DILIP BEHERA

KEDAR NATH MAHARANA

SANTOSH PRADHAN

JKPM-TPM

SAFETY IMPROVEMENT KAIZENS



Problem / Present status: Countermeasure:

Abhishek Tiwari, Sourav Banerjee, Manoranjan Sahu

Team members:

(lllustration with sketch)

it becomes difficult to control the HCl fume arranged Kaizen start 23.08.2017

emissions Kaizen finish 25.08.2017

Kaizen Theme:

Provision of water spraying arrangement at the top of HCl filters

for safety during any leakage at HCl filter area.

Idea:

Provide a spray shower with DM water supply

Benchmark

During sudden leakages of HCl filter Emergency spray shower system to be Target

KAIZEN IDEA - SHEETJH

S

Plant : ClO2 Plant Machine: HCl filter

JKPM-TPM


Result Area P Q C D S MKAIZEN IDEA - SHEET

SAFETY

Plant : FINISHING HOUSE PM 6 Machine: SHEETER

Theme: -SHEETER IDLER ROLLER MOVING FREELY Idea: BRAKE ARRANGEMENT FOR THE IDLER ROLLER FOR STOPPING WHENEVER

THE PAPER BREAKS AT SHEETER.

Problem / Present status Countermeasure: Benchmark ZERO ACCIDENT


WHILE PAPER THREADING IN

BETWEEN THE WEB GUIDE ROLLER



JKPM-TPM


Analysis: Results:

(Why-why analysis) (illustration with sketch)

Sl

No

M/c

NoStatus

SAFE

LIFTING TABLE HAVE MORE GAP AFTER PROVIDING THE SUPPORT THE

PLATE AT LIFTING TABLE ACCIDENT NOT

HAPPING & MACHINE WILL BE SAFE

1 WHY - ACCIDENT WILL BE

HAPPENED

2 WHY - THERE IS MORE GAP IN

LIFTING TABLE

3 WHY - THERE IS NO SUPPORTING

PLATE

Scope & Plan for Horizontal Deployment

Target

dateResponsibility

0

0.5

1

APR-17 MAY-17 JUNE-17 JULY-17 AUG-17

ACCIDENT

Sl

No

M/c

NoStatus

THERE IS NO CHANCE TO ACCIDENT AT REEL ASRS

KICKER .

Analysis: Results:

WHILE THE REEL KICK FROM KICKER AT

THAT TIEM THERE IS NO ALERT . IT CAN

BE AN ACCIDENT .

THERE IS NO CHANCE TO ACCIDENT AT

REEL ASRS KICKER .


1 WHY - KICKER HUTTER NOT AVAILABLE

2 WHY - HUTTER TO BE PROVIDED .

3 WHY -


Target

dateResponsibility

0

0.5

1

1.5

APR-17 MAY-17 JUNE-17 JULY-17 AUG-17

NEAR MISS

5

Analysis: Results:


Sl

No

M/c

NoStatus

AJIT JAIN

Benefits:

AFTER INSTALATION OF COMPACTOR ONE MAN POWER

REDUCE FROM PALLETIZER SECTION .WHEN THE PALLET ERROR AT

PALLETIZER SECTION AT THE TIME ONE

MAZDOOR USING FOR CLEAR THE ERRO

R.

Complete

ONE MAN POWER REDUCE FROM

PALLETIZER SECTION AFTER INSTALATION

OF COMPACTOR .

1 WHY - THE PROFILE CHECK ERROR IN

PALLETIZER SECTION

2 WHY - COMPACTOR NOT AVAILABLE

3 WHY -


Target

dateResponsibility

12.11.17

1. SATISH BELE

2. AJIT JAIN

3. KEDAR NATH MAHARANA

4. SANTOSH PRADAN

5. DILLIP BEHERA

Slide No. 30

Benefits:

Analysis: Results:

Sl

No

M/c

NoStatus

31.08.17 Abhishek Tiwari


Target

dateResponsibility

( )

1) Hazardous free environement

2) No leakage of HCl.

1 1

Emission effect towards surrounding reduced, So

number of safety incidents reduced.

3) No production stoppage

3

00

0.5

1

1.5

2

2.5

3

3.5

Before After

No. Of Near miss incidents

More emmision of Hazardous

HCl fumes

Leakage from Hcl filter

Damage from filter body and

cover due to excess heat as it is

exposed to sun.

Why

Why

1

2

3

4

5

Sl

No

M/c

NoStatus

AT SHEETER SECTION,ACCIDENT MAY

HAPPENED (HAND MAY CONTACT

WITH THE IDLER ROLLER.

BRAKE SYSTEM TO BE PROVIDED Kaizen finish 25.05.2018

Team members

SANTOSH RAO

(illustration with sketch) (illustration with sketch) ANAND RIWARI

Benefits:

AFTER PROVIDE THE BRAKING SYSTEM AT IDLLER

ROLLER THE ROLLER STOPS DURING PAPER BREAK AT

SHEETER.ACCIDENT ELEMINATED.

Analysis: Results:

THERE IS NO BRAKING SYSTEM TO

STOP THE IDLLER ROLLER.

AFTER PAPER BREAK THE BRAKE ACTIVED

& STOP THE ROLLER & THE OPERATOR

CAN PASS THE PAPER EASYLY.


ANKIT KUMAR

BINOD PATTNAIK

SANTOSH PRADHAN

1 WHY - SHEETER IDLLER ROLLER

MOVING FREELY.

2 WHY - IDLLER ROLLER MOVEMENT

IS FREE

3 WHY - THERE IS NO SAFETY COVER

& STOPPER .

4 WHY - BRAKING SYSTEM NOT


Target

dateResponsibility

2

SHE

ETE

R

LINE

1

25.07.2018

1. SARIF (MECH)

2. ANKIT (MECH)

3. ANAND TOWARI (MECH)

4. BINOD PATTNAIK(PROCES)

PENDING

1

0 0 00

0.5

1

1.5

MAY-18 JUNE-18 JULY-18 AUG-18

ACCIDENT

Focus Area-Yard Department

SAFETY IMPROVEMENTS AT YARD

MECHANIZATION OF WOOD HANDLING STACKING AREA

4

5

REPORTABLE ACCIDENT

GOOD

4

5

NON REPORTABLE ACCIDENT

GOOD


0 0 00

1

2

3

2016-17 2017-18 2018-19(Up to Sept.)

No

s

Year

0 0 00

1

2

3

2016-17 2017-18 2018-19(Up to Sept.)

No

s

Year

241

298

156

0

50

100

150

200

250

300

350

2016-17 2017-18 2018-19(Up to Sept.)

No

s

Year

NEAR MISS CASES

GOOD26

9

00

5

10

15

20

25

30

2016-17 2017-18 2018-19(Up to Sept.)

No

s

Year

FIRTST AID CASES

GOOD

Speed LimitSeparate Entry & Exit Road for vehicles

ROAD SAFETY

Convex mirrors at blind

corners


Designated Truck Parking Area Separate safe path provided for pedestrianTemporary gate provided at rly crossing

area

Slide No. 32

• We have prepared on-site emergency plan for toxic release and fire & explosions.Periodically as per scheduled mock drills (dry & wet) are conducted. Gaps & lapsesobserved during the drills are noted and rectified.

• All Near miss incidents are captured; analyzed and suitable corrective & preventivemeasures are taken.

• Daily Safety pledge by all employees is carried out in all the departments at the beginningof all shifts (A,B,C,& General)

• At J K Paper Mills, National Safety Day/Week, Fire Safety Week, Environment Day,

Odisha Disaster Preparedness Day and National Day for Disaster reduction &Chemical Disaster Prevention Day are celebrated in the mills by good gathering .Safetypromotional activity like Quiz, Essay, Slogan, Posters, Skit & etc. competitions wereconducted and suitably recognized & rewarded.

• Inside the mills safety slogans, cautions boards, signs boards, assembly points andambulance points are identified and displayed.

• All lifting tools, lifting machines, and pressure vessels are tested and inspected as perFactories Act and Orissa Rules.

• Continuous training on different best safety practices (List of various training programmesenclosed in the Annexure-II)

• Noise levels and Dust emission levels are measured in all the areas of the mills. Suitablekaizen themes are generated and implemented on continual basis to reduce minimumpossible.

• All best possible measures are taken to eliminate heat, humidity, fumes, etc in ordercreate a safe work environment.

• We have 10 nos. of training centers to educate all the employees in order to improve skill,knowledge, and positive attitude towards improvement of safety.

• We are generating operational related standards to eliminate minor injuries in materialhandling areas.

• Health check up for all the employees are conducted and treated if any abnormality foundwith the employees health.

• Occupational health check ups were conducted by external specialist and suitablemeasures are taken.

• We also carry out best safety practices in Fire safety, Electrical safety, Chemical safety,and etc.

• In addition to all above activities we have started implementation of focused safetymanagement in all the departments, in order to involve all the employees in the safetyactivities to eliminate incidents.

Environment, Occupational Safety & Health Profile

JK PAPER MILLS with its dedicated efforts and strong commitment has been continuously improving its performance in the areas of Safety, Health and Environment. The systems and practices introduced by the Mill have led to its being the first In Indian paper mill to receive ISO 14001 Environment Management Certification in 1998 and the „Greenest Paper Mill‟ Award of CSE in 1999 and Top 2 Paper Mills for getting 3-leaves award from CSE, New Delhi in 2004. 2nd Best Pollution Control Excellence Award for implementing effective Pollution Control Measures and adopting good environmental management practices during 2004 by Orissa Pollution Control Board, Bhubaneswar. JK Paper Mills has won numerous National and International Awards for Safety and Occupational Health

J K PAPER MILLS JAYKAYPUR

“BEST SAFETY PRACTICES AT OPERATING PLANT”

J K Paper Mills is an ISO-9001(2008); ISO-14001(2004) and OHSAS-18001(2007) certifiedcompany and all the system procedures were implemented as an integrated management systemto improve the performance in the areas of Safety, Health and Environment & Quality. JKPM hasestablished a Best Safety Management System and followed strictly.

Best Safety Management System at JKPM: • All Statutory and legal requirements are complied.

• All accidents / incidents are investigated, analyzed and suitable corrective & preventivemeasures taken.

• Preparation of Incident analysis for every first aid cases in power point mode consisting ofthe following slides and organizing sharing sessions to employees of the other areas toincrease the awareness :

� Incident details � What happened? � What went wrong? � Prevention of reoccurrence.

• Job safety analysis is carried out for each critical activity.

• Hazard Identification and Risk Assessment is carried out and reviewed periodically.

• Work permit system (Height work, Hot work, Confined space, Excavation, EquipmentIsolation, etc.) is strictly followed.

• We have four safety committees as following : � Central safety co-ordination committee(monthly), � Departmental safety committees(monthly), � Safety Steward Committee(Six month) and � Contractors Safety Committee (six months).

All the observations made during the period are reviewed in the above committeemeetings and action plan are made by the concern for implementation.

• All the safety related matters are reviewed in our daily morning departmental meetings.

• Audits both (internal and external) are carried out and observations made are rectified.

• We carry out theme based patrolling with the help of a route map by different levels: - Shop floor supervisor and workmen daily during Jishu Hozen activity - Safety officer daily - Safety steward weekly - Cross functional teams monthly - Head of the departments monthly All the observation made during the patrolling are analyzed and eliminated bygenerating suitable kaizens and one point lessons.

• JKPM has enforced without helmet and shoes employees are not allowed into the Factory.

• JKPM has identified all relevant PPE’s required by employees were identified, distributedand ensured by monitoring frequently and also periodically, safety officer checks the PPE’sregister and its use.

• Standard operating procedures and safe maintenance procedures are generated andfollowed. And all the SOP’s are displayed near the equipments.

B t S f t P ti F d S f t M t S t

Day Time Programme Venue Resource Person

03-06-2017 8:00 AM Inagural ceremoney Store Office Department In-charge

03-06-2017 4.00 PM Safety Awareness Training Mecha.(Work Shop) SafetyDept.

06-06-2017 4.00PM Material Handling Mecha.(Work Shop) Mr.T.R. Rathor

10-06-2017 4.00 PM

Work Instruction/SOP trng.for loading unloding of CL2

cylinders. Mecha.(Work Shop) Mr.N.Panda

10-06-2017 4.00 PM training on hazarious chemical Mecha.(Work Shop) SafetyDept.

13-06-2017 4.00 PM

Work Instruction/SOP trng.for loading unloding of Sulphate

bags. Mecha.(Work Shop) Mr.Ramesh Kumar.

17-06-2017 4:00 PM Eargonomics Mecha.(Work Shop) Safety Dept.

17-06-2017 4.00 PM Work Instruction/SOP trng.for issue of materials. Mecha.(Work Shop) Mr. D.P.Baidya

19-06-2017 4.00 PM Use Of PPEs Mecha.(Work Shop) Safety Dept.

22-06-2017 4.00 PM HIRA Review Mecha.(Work Shop) Mr.KK. Tripathy

24-06-2017 10.00 AM Audit Chemical Area by Cross Functional Team Mecha.(Work Shop) Safety Dept./ Stores Dept.

24-06-2017 4.00 PM Work Instruction/SOP trng. On packing material handling Mecha.(Work Shop) Mr. KK Tripathy

27-06-2017 4.00PM Accident Investigation & Reporting Training Mecha.(Work Shop) Safety dept.

03-07-2017 4.00PM Work Instruction / SOP Training.for chemical issue. Mecha.(Work Shop) Mr. Ramesh

05-07-2017 4.00PM Behavioral Safety Mecha.(Work Shop) Mr.L.M.Rao, DGM (Safety)

08-07-2017 4.00PM First aid Mecha.(Work Shop) Dr. M.C. Lenka

08-07-2017 10.00 AM Audit Packing Area by Cross Functional Team Mecha.(Work Shop) Safety Dept.

11-07-2017 4.00PM Fire fighting Mecha.(Work Shop) Mr.D.K.Samal, MGR (Security)

14-07-2017 10.00 AM Audit of material yard by cross functional team. Store Office Safety Dept. & Stores Officer

14-07-2017 4.00 PM Work Instruction/SOP trng. On stores equipement handling Mecha.(Work Shop) Mr.P.R. Barik

17-07-2017 4.00PM Last quarter accident analysis. Safety Dept.

20-07-2017 10.00 AM Equipment Safe to Run certification audit. Store Office Safety Dept & Store Officers

20-07-2017 4.00PM Safe handling of compressed cylinder. Mecha.(Work Shop) Mr. Sameer Behera

23-07-2017 4.00PM Safety in Mechanical & Manual Handling. Mecha.(Work Shop) Safety Dept

26-06-2017 4.00PM Review of Statutory Requirement Mecha.(Work Shop) Safety dept.

28-07-2017 4:00 PM

Work Instruction/SOP trng.for heavy material, O2 & DA

cylinders. Mecha.(Work Shop) Mr. Sameer Behera

29-07-2017 4.00PM Closing Ceremoney Store Office Department In-charge

FOCUSED SAFETY MANAGEMENT SYSTEM

STORE MONTH OF JUNE & JULY

BEST SAFETY PRACTICES

J.K.PAPER MILLS : JAKAYPUR

FOCUSED SAFETY MANAGEMENT SYSTEM

Department: Stores Month – June- 2017

1) Identification :- a) Unsafe act. b) Unsafe condition. c) Near miss capturing. d) Dos & Don’ts generation e) Rectification of the above.

2) Safety Suggestions. 3) Training :-

i) General Safety. a) Use of PPE’s. b) Work permit system. c) Incident reporting /Investigation with root cause analysis. d) Behavioral Safety. e) Ergonomics. f) First Aid g) Fire Fighting

ii) Work Instruction & SOP Trainings. a) Loading, Unloading of CL2 cylinders . b) Loading, Unloading of Sulphate bags. c) Heavy materials O2 & DA Cylinders. d) Issue of Materials.

iii) Work Instruction / Safe operating procedure.

4) Revisiting of system procedure review of HIRA. 5) Good House Keeping.

6) On the job training (Pep talk). 7) Cross Functional Audit.

8) Safe to Run. 9) Statutory compliance.

10) Job Safety Analysis.


CENTRI-

CLEANER

DRIER

WIRE

PART

MG

CYLINDER

PRE

DRIER

CUTTER

ROPE

REEL

ROPE

REEL

SIZE

PRESS

POST

DRIERCALENDER

POPE

REEL

PRESSAPPROACH

FLOW

PD

PLANT

PAPER M/C.

I, III, IV & V

PAPER M/C.

II

Best Safety Practices Focused Safety Management System

Rout Map for Safety Patrolling Rout Map & Patrolling Checklist HAZOP Study

Slide No. 33

Hazard Identification &

Risk AssessmentWork Permit System Scaffolding Tag Vehicle Inspection



Award / Reward Violation Memo Training Passport Emergency Card

Slide No. 34

Caution board and Hooter to alert during movement of trainProhibited area



Restriction on usage of mobile phone Instruction for Drivers displayed at entry gate, truck parking area and drivers rest shed

Slide No. 35

Pneumatic & Battery operated Reel Pusher to prevent occupational hazards eliminating

manual shifting

Instead of inserting hand, Paper puller is

used to remove loose broke.



Paper Cartons palletized by Robots

Slide No. 36

Before After

Customized Guard Fabricated and installed in the chain saw

Lifeline arranged to untie rope on truck & Collecting sample from Tanker



Safety Skit by Employees CCTV Camera and Monitoring Display at Strategic Locations in the plant


Safety Trainings on various topics


Various Safety Competitions involving school students to increase awareness

Awarding Safety conscious employees, Members of Mahila Mandal & School children on different occasions

Slide No. 38

Skill Development Programme




Safety Pledge at workplaceTool Box Talk Caution Displayed at Chemical zone


Safety & Health Policy displayed in Odia &

English near biometric punching machine

Caution at Robot working zone Safety Instructions for Reel ASRS

PICTORIAL AWARENESS ON SAFETY

Lay out of Fire Fighting

Equipment's in Departments

Display of Exit Route Usage of PPE & Tips for Winder

Operation

Emergency Contact Numbers at

workplaces


5 “S” Status Boards at every

Department

Display on Good Housekeeping Display on walls Caution at work

Display on speed limit Display of Ambulance PointsDisplay on containers

Slide No. 42

SAFETY WITHOUT WORDS


HEALTH CARE CENTRE

Chlorine Inhalation & Burn Treatment JK Medical Centre CC Unit


Vertigo Test arrangementBeds for Treatment Audiometry Chamber

Different Lab Instruments

Slide No. 44

Health Awareness Training Awareness on Occupational Health

HEALTH & HYGIENE

Awareness on Hygiene at Shop floor


Hygiene Committee Meeting

Internal Health Check Up External Health Check Up Blood Donation Camp

Free Health Camp at 3 Villages Free camp for Cataract Treatment

Slide No. 45

Noise Level Reduction Dust Level Reduction

ENVIRONMENT


Counter Measures Counter Measures

1 Coal Yard Tolerable L2Spriklers for Dust

suppression providedSatisfactory L3

2 Chipper House Tolerable L2Spriklers for Dust

suppression providedSatisfactory L3

3 Lime Handling Tolerable L2 Back filters provided Satisfactory L3

4 Guest House Satisfactory L3 Satisfactory L3

sl no Identified areas Previous level Counter Measures Present level

Sewage Treatment PlantEffluent Treatment Plant

After

(mg/l)

Before (mg/l)CT

Facility for Treatment / Disposal of Effluents / Wastes

BOD – 150 - 200

COD – 250 - 300

TSS - 300 - 500 BOD – 06 - 08

COD – 20 - 22

TSS - 04 - 06


Scientific Land Fill for disposal of HW Front View of Scientific Land Fill

Sewage Treatment PlantEffluent Treatment Plant

Slide No. 47

RAIN WATER HARVESTING PROVISION AT DIFFERENT PLACES


SOLID WASTE MANAGEMENT

Particulars Utilisation / Disposal

Chipper Dust/PithUsed in our Coal Fired Boilers

along with Coal.

Fly Ash 100% generated fly ash is being

used for making fly ash brick by

brick manufacturer.

Bottom Ash Land filling

ETP Primary SludgeUsed by outside Agency for

manufacturing of Cartons & Egg

Tray.

ETP Secondary SludgeDisposed in landfill.

Fly Ash

Brick Mfg.

JKPur Market

Building in Fly Ash

Brick


Lime Sludge Lime Sludge - Out of total

generation 98% is being re-burnt

in Lime Kiln Plant and generate

lime is used in our process & 2%

use for filling up low laying areas.

Ash and inert from lime

kiln

Land filling

Dregs and Grits from recovery

Repairing of Road & Road

Making.

Plastics - HDPE Bags Selling to Authorized Recyclers

Pvt. Building in

Reclaimed Land

A nearby village on

Reclaimed Land

Slide No. 49

• Installed Methanol Plant for distillation of foul condensate from evaporator and used as fuel in Lime Kiln

Plant as a result the emission of SOG eliminated and Odour reduced drastically.

• Installed & commissioned a new Sewage Treatment Plant.

• Treated Sewage water is being again used in our process since three year

• Introduced On-line sprinklers at Coal Yard & Chip Conveyors.

• 100% fly ash is being utilized for manufacturing bricks.

• Use of bio-mass in Coal Fired Boiler for resource conservation.

• Adopted latest environment friendly processes and technologies in Pulp Mill, Recovery, Power Plant &

Lime Kiln in 2013.

ENVIRONMENT INITATIVES


• Water consumption per ton of paper reduced from 72m³ to 36.15m³.

• AOx level in treated effluent reduced from 0.6 to 0.14 kg/t.

• Augmented the existing ET Plant with latest technology to increase the treated effluent quality. As a result,

the quality parameters are far below the prescribed norms.

• Pet coke is being used as fuel in place of Producer Gas since 2015.

• On-line emission monitoring of Air & Water for better control of Pollution.

• Promoting social and farm forestry using clonal technology with a target of planting 12000 hectares every

year.

Slide No. 50

SPECIFIC POWER CONSUMPTION, KWH/T SPECIFIC STEAM CONSUMPTION,T/T

SPECIFIC WATER CONSUMPTION M³/T % OF UTILIZATION OF RENEWABLE ENERGY

1403

12721211

1140 1130

1000

1100

1200

1300

1400

1500

20

13

-14

20

14

-15

20

15

-16

20

16

-17

20

17

-18

SE

C K

wH

/T

Year

8.37.4

6.1 5.8 5.75

0

2

4

6

8

10

20

13

-14

20

14

-15

20

15

-16

20

16

-17

20

17

-18

Sp

eci

fic

ste

am

con

sum

pti

on

t/m

t

Year DISPLAY OF AIR PARAMETERS

NEAR THE MAIN GATE

SPECIFIC CONSUMPTION (ENVIRONMENT)

GOOD GOOD


SPECIFIC WATER CONSUMPTION, M³/T % OF UTILIZATION OF RENEWABLE ENERGY

61.91

40.31 37.47 38.61 36.10

0

10

20

30

40

50

60

70

20

13

-14

20

14

-15

20

15

-16

20

16

-17

20

17

-18

Sp

.Wa

ter

Co

nsu

mp

tio

n

Year

40.46

52.8 53.8162.6 60.89

0

10

20

30

40

50

60

70

20

13

-14

20

14

-15

20

15

-16

20

16

-17

20

17

-18%

of

ren

ew

ab

le e

ne

rgy

YearAMBIENT AIR QUALITY

MONITORING STATION

GOODGOOD

Slide No. 51

METHANOL PLANT IN PLACE OF SOG

Methanol Plant


SOG System

� 20% Conc. of Methanol in SOG

� Requires support fuel to fire

� Due to High volume in gas, can’t be

stored

� Water vapours not utilized

� Any interruption in LK operation, results

in odour in nearby area

Methanol System

� 80% Conc of Methanol

� Need support fuel but energy conserved.

� Saves on fuel demand for LK

� Liquid Methanol can easily be stored

� Condensate can be recovered

� During LK shut, Methanol can be stored,

hence no odour.

Slide No. 52

NEW INITIATIVES


A Mobile Safety APP has been lunched for

instant capture and communication of Unsafe

Acts, Unsafe Conditions & Nearmiss cases for

quick action

Slide No. 53

Our ClO2 plant has become the model plant in the

mills and considered as Safety Aaina where all the

Safety measures has been taken care with priority.

NEW INITIATIVES

Safety Buddies of 10 nearby Industries CGM (Mfg) addressing Safety Buddies Awareness Training to Safety Buddies

SAFETY BUDDIES


Visit to nearby Safety Buddies Industry to improve Safety Culture

National Level :

� National Safety Awards 2016 (Winner) for Accident Free Year

� Prime Minister Shram Award-2015

State Level :

� Best Performance in Safety, Health & Environment-2016 (1st Prize)

Lowest Weighted Frequency Rate of Accidents 2017 (1St Prize)

Reward & Recognitions

Achieved

27.26

Million Safe


� Lowest Weighted Frequency Rate of Accidents-2017 (1St Prize)

� State Shrama Awards-2014, 2015, 2016 & 2017

� CII SHE Excellence Awards 2016-2017 (Certificate of Appreciation)

� CII SHE Excellence Awards 2017-2018 (Certificate of Appreciation)

� Greentech Gold Safety Award for the year 2016

� Best Factory Medical Officer for Occupational Health-2015

Slide No. 55

Million Safe

Man Hours

(since 21st

July 2015 to

till date)

SHE Excellence Appreciation Award 2017-18 from CII (ER)

SAFETY AWARDS

National Safety Award for Accident Free Year 2016


First Prize in “Lowest weighted

Frequency Rate of Accidents” in the

State for the year 2017

Best Performance in

Safety, Health and

Environment in the State for

the year 2016

Best Occupational Doctor 2017SHE Excellence Appreciation

Award 2016-17 from CII (Easter

Region)

Shrama Award 2014Shrama Award 2014Shrama Award 2014Greentech Gold in 2016

Slide No. 56

Greentech Silver in 2011Greentech Silver 2012Greentech Silver 2013 National Safety Award 2012

SAFETY AWARDS


Sword of Honour from BSC

Slide No. 57

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