ASHISH GUPTA CN3343 THT2(WEAVING)

TPM is our way of life

TPM

April 15, 2023 1

To Reduce Short Terry In Weaving From 1210 PPM To 968 PPM in THT-

2, Till 08th August, 2014

Ashish Kumar GuptaCN 3343

THT-2, Weaving/Production


TPM

April 15, 2023 2

Crack10%

Cheera25%

Float13%

Lining3% Short Terry

17%

Selvage damage9%

Others13%

C-grade10%

Average percentage contribution to total downgrade from FF-2 ,THT-2 for BSC-1, BSC-2 & BSC-3

Grand Total downgrade = 3.46%Total FF-2 downgrade = 0.68%

Short terry = 0.12%


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April 15, 2023 3

Why this project is being undertaken?

Short terry is one of the major problem of terry towel. It contribute 17% of total downgrade percentage which is second highest downgrade in FF-2, THT-2.


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April 15, 2023 4

STEP-0


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April 15, 2023 5

TPM KK Project Registration

Unit THT - 2 Loss Loss 7: Quality loss

Project Name To reduce short terry in weaving from 1210 PPM to 968 PPM in FF-2, THT-2, till 08 August, 2014

Project Leader Ashish Kumar Gupta Project Guide Mr. Ajit Parandekar

Team Members

Member Name Mr. Taj Afzal (Weaving)

Mr. Prabhat kumar

(Weaving) Mr. A.P. Singh (Maintenance)

Mr. Sunil Arora

(R&D)

Mr. Narottam kumar

(Weaving)

Mr. Iqbal Singh (Maintenance)

Sal. Code M30858 P04114 A37951 S49640 n43437 I43032

Baseline (Primary Metric) 1210 ppm Target (Primary Metric ) 968 ppm

Financial impact Calculation Method/Formula =(Baseline - Actual/Target)% * CSP Packed production * Downgrade Cost ₹150

Project Start Date 09/06/2014 Target Completion Date 08/08/2014

Remarks & Sign.Unit Head

Remarks & Sign.Project Leader

Remarks & Sign.KK Pillar Head

Remarks & Sign.MIS & Costing Representative

Mr. Lalit Kaushal

Ashish Kumar Gupta Amit Mandal Deepak Garg

L06158 CN3343 A52202 D06799

Step 0.1


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April 15, 2023 6

KK Project Team Details

Project Name :To reduce short terry in weaving from 1210 PPM to 968 PPM in,THT-2, till 08, August 2014 Team Leader : Ashish Kumar Gupta

Team Members :- S No. Member Name Responsibility Description

1 Mr. A.P. Singh

To give an incite into the details of the looms, to impart thorough knowledge about the machines

1) To understand and reach to the minute details and settings of the air jet looms 2) To understand the machine related causes of the defects and to achieve standardized settings

2 Mr. Taj Afzal To understand the whole process from production point of view

1)To understand the production process as a whole 2) To understand hurdles and bottlenecks in the process3) To conduct trials to eliminate abnormalities

3 Mr. Prabhat KumarTo provide all weaving related data

To give the data and day to day downgrade detail and other weaving related information.

4 Mr. Sunil Arora

To give an incite into the quality of the raw materials, to get predictions and to help understand quality matrix

To help study, analyze and understand the data to identify quality related issues causing defects

5 Mr. Narottam Kumar To understand the weaving process

To understand the weaving mechanism and defect related to terry towel.

6 Mr. Iqbal SinghTo understand the maintenance related aspects of the machinery

1) To conduct maintenance and machine related trials 2) To identify the flaws in maintenance process causing defects

Step 0.2


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April 15, 2023 7

TPM KK Activity Plan Project Name : To reduce short terry in weaving from 1210ppm to 968ppmOwner Name :Ashish Kumar Gupta Week (BSC) -->S No. Activity Week 11 Week 12 Week 13 Week 14 Week 15 Week 16 Week 17 Week 18 Week 19

Step 0 1) Select and register topic

P A

2) Form project team

P A

3) Plan activities

P A

Step 1

1) Identify bottleneck processes

P A

2) Measure failure/defects and other losses

P A

3) Use baseline (bench mark) to set targets

P A

Step 2

1) Thoroughly study ,expose and eliminate abnormalities

P

A

2) Establish basic conditions equipment

P A

Step 0.3


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April 15, 2023 8

TPM KK Activity Plan Project Name : : To reduce short terry in weaving from 1210ppm to 968ppmOwner Name :Ashish Kumar Gupta Week (BSC) -->S No. Activity Week 11 Week 12 Week 13 Week 14 Week 15 Week 16 Week 17 Week 18 Week 19

Step 3

1) Stratify and analyze the causes

P A

2) Apply analytical methods

P A

3) Conduct experiments –see if root causes are applicable or not

P A

Step 4 1) Implement improvements

P A

2) Perform tests and trial runs

P A

3) Provide instructions to work on improved equipments, operating conditions

P A

Step 5

1) Evaluate results with time as improvement project goes on

P A

2)Check whether target has been achieved or not/if not start from step 3 again

P A

Step 0.3


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April 15, 2023 9

TPM KK Activity Plan Project Name : : To reduce short terry in weaving from 1210ppm to 968ppmOwner Name :Ashish Kumar Gupta

Week (BSC) -->S No. Activity Week 11 Week 12 Week 13 Week 14 Week 15 Week 16 Week 17 Week 18 Week 19

Step 6

1) Evaluate Results against target

P

A

2) Check whether target has been achieved or not

P

A

Step 7

1) Prepare inspection and work standards

P A

2) Make drawings and feed into DM Pillar

P

A

3) Train members to sustain results

P

A

Step 0.3


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April 15, 2023 10

STEP-1


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April 15, 2023 11

Flow ChartProcess Name : Weaving Date : 18/06/2014

Conclusion/ Way Forward : Weaving is the bottleneck for formation of Short terry. And further study based on mainly weaving.Prepared By : Ashish kumar gupta Approved By :Mr. Ajit Parandekar

Step 1.1

Winding Warping

Creeling of warper beam

If, stripe pattern/dyed

yarn

Weaver beam prepared

Sow box

Sectional Warping

Direct Warping

No

Yes

Cloth doffing Weaving Knotting

Grey folding

Bottle neck


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April 15, 2023 12

Step 1.2Check-Sheet

Process Name : Weaving Name of the investigator : Ashish Kumar GuptaLocation of Data Collection : R&D Date & time: From 1st week to 13th weekWhy this data is collected : To know about all the weaving defect

Defect Type/Event Occurance Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11 Week 12 Week 13 Average

# 1 Cheera 1403 1000 1128 1179 1158 2029 1797 1568 1285 2419 2032 2292 1590 1606

# 2 Short terry 790 957 591 534 304 1377 1299 1181 1544 1990 1551 1844 1772 1210

# 3 Crack 544 659 394 374 314 826 847 881 1240 1204 823 1717 841 820

# 4 Float 439 701 139 239 280 515 672 306 234 535 443 394 639 425

# 5 Lining 44 100 43 306 265 940 141 188 758 336 144 1158 627 388

# 6 Others 904 922 1006 605 1340 1683 1412 793 1215 1390 1539 1303 1133 1172

FF-1 GRAND TOTAL 4124 4339 3300 3238 3661 7369 6169 4916 6277 7874 6532 8709 6603 5623

* All the data taken in PPM

Conclusion/ Way Forward : : Short terry is one of the major defect generated in the weaving. Further study will be based on this defect.

Prepared By : Ashish Kumar Gupta Approved By : Mr. Ajit Parandekar


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April 15, 2023 13

KK Project Target Setting

S No. Failure/Defect/Cause Description UOM Baseline Target

1. Short terry ppm 1210 968

Step 1.3


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April 15, 2023 14

STEP-2


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April 15, 2023 15

Step 2.1टी�. पी�. एम. फु� गई रजि�स्टीर (TPM Fuguai Register)1. मा�मा�ली� खरा�बी� 2. अधू�रा� बी�नि�या�दी� हा�लीत 3. दुर्ग�मा स्था�� 4. सं�दूषण स्रो�त 5. र्ग�णवत्ता� दी�ष स्रो�त 6. अ��वश्याक औरा र्ग$रा जरूरा� वस्त� 7. असं�राक्षि)त जर्गहा1. Minor Flaws 2. Unfulfilled Basic Conditions 3. Inaccessible Places 4. Contamination Source 5. Quality Defect Sources 6. Unnecessary & Non Urgent Item 7. Unsafe Places

क्रमा��क

ढूँ�,ढूँ�- क. त�रा�ख

ढूँ�,ढूँ�- व�ली� असं�मा�न्यात� (Fuguai) निववराण असं�मा�न्यात� क- प्रक�रा

आसं�मा�न्यात� टे-र्ग

(ली�ली/संफे- दी)निवभा�र्ग संहा� करा�- व�ली� जव�बी� उपा�या / क�रा�व�ई

सं�धू�रा क. त�रा�ख (लीक्ष्या)

सं�धू�रा क. त�रा�ख (व�स्तनिवक)

ली�डरा द्वा�रा� टिटेप्पाण�

Sl. No

Date of Detectio

n

Name of Detector

“Abnormality” (Fuguai) description

Abnormality Type

(1/2/3/4/5/6/7)

“Abnormality tag”

(Red / White)

Department (Mech./ Elec./ Instr./ Tool/ Process)

ExecutorName

Counter Measure / Action Taken

Target Date of

Rectification

Actual Date of

RectificationRemarks

1. 23/06/14 Ashish Short terry at left side of fabric loom no.96 5 Red Mechanical Rakesh Gripper changed 23/06/14 23/06/14 Ok

2. 23/06/14 Balaram Short terry occurs at left side on loom no. 146 5 White Weaving Balaram Clean the gripper and tighten it 23/06/14 23/06/14 Ok

3. 24/06/14 Tribhuvan Formation of Sort terry due to tension variation in pile

beam at loom no. 1335 Red Weaving Dhiran Replaced the load cell and zero

setting done 24/06/14 24/06/14 Ok

4. 24/06/14 VirendraShort terry occurs on right

side of the fabric at loom no. 16

5 Red Mechanical jagvir Change the jammed relay nozzle valve by new one 24/06/14 24/06/14 Ok

5. 25/06/14 Ashish Negative pile beam length (-825m) on loom no. 36 5 Red Weaving Surendra Enter the correct beam length in

ICS setting (1850m) 25/06/14 25/06/14 Ok

6. 25/06/14 Tribhuvan Short terry occurs at right side temple 5 Red Maintenance Dayal Loose the temple and reduced the

temple angle below 90 degree 25/06/14 25/06/14 Ok

7. 25/06/14 Dhiran Short terry formed full width of cloth 5 White Weaving Dhiran Tension of pile warp beam reduces 25/06/14 25/06/14 Ok

8. 26/06/14 DineshTension variation in pile warp beam due to faulty load cell

at loom no.185 Red Mechanical Prafful patil Change the load cell 26/06/014 26/06/14 Ok

9. 26/06/14 Bambam Short terry occurs at left side of loom 5 White Weaving Bambam Clean the accumulated fluff and

tighten the gripper 26/06/14 26/06/14 Ok

10. 27/06/14 Sonu Fluctuation in tension of pile beam on loom no. 123 5 Red Electrical Khushpreet Change the electrical pile let-off

card 27/06/14 27/06/14 Ok

11. 27/06/14 Basant Gripper side short terry formed on loom no.113 5 White Maintenance Basant Open the gripper remove the

broken weft & fluff and reset 27/06/14 27/06/14 Ok

12. 28/06/14 Dayal Short terry formed full width of fabric 5 White Maintenance Dayal Reduced the pile warp beam

tension 28/06/14 28/06/14 Ok

13. 28/06/14 Ashish Wrong feed diameter of pile warp beam at loom no. 103 5 White Weaving Ashish Enter the correct diameter of pile

warp beam 28/06/14 28/06/14 Ok


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April 15, 2023 16

Step 2.2S No. Activity Identification

date Target Date Completion Date

Responsibility

(Member Name)

Review Date Review by Remarks

1. Formation of Sort terry due to tension variation

in pile beam at loom no. 133 24/06/14 24/06/14 24/06/14 Dhiran25/06/14 A. P. singh

Replaced the load cell and zero setting done

2.Short terry occurs at right side temple 25/06/14 25/06/14 25/06/14 Dayal

25/06/14 A. P. singh

Loose the temple and reduced the temple

pulling below 90 degree

3.Tension variation in pile warp beam due to

faulty load cell at loom no.18 26/06/14 26/06/014 26/06/14 Prafful patil 27/06/14A. P. singh

Change the load cell

4. Fluctuation in tension of pile beam on loom no.

123 27/06/14 27/06/14 27/06/14 Khushpreet 27/06/14 Gurpreet

singh

Change the electrical pile let-off card


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April 15, 2023 17

STEP-3


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April 15, 2023 18

Step 3.1Stratification & Analysis of Causes

S No. Failure/Defect/Cause Description Stratification Tool Analysis Tool

1. Short terry Flow chart,

Fish-boneCheck list,

Pareto analysis


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April 15, 2023 19

Weaving start

Loom start

Loom continuously

run

Short terry formation

Loom running

Attend the loom

Loom stopped due to any reason

Attend the short terry

Stop the loom

NO

NO

YES

YES

* Tension variation* Gripper problem* Relay nozzle direct* Negative beam length* Temple setting * Wrong dia. fed

Step 3.1Short terry generation in weaving

PROCESS FLOW CHART


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April 15, 2023 20

Step 3.1Problem Phenomena : Short terry Date : 27/06/14

Fish-bone diagram

Short terry

ManMachineMaterial

Environment

Method

Measurement

Temple setting

Sticky ends

Tension variation in pile beam

Relay nozzle direct

Faulty terry motion

Temple ring Jam

Temple pulling


Wrong feeding

of pile beam

diameter

Improper

gripper

setting

Improper sub valve timing

Pile ratio

variation

. Negative

beam length

Operator poor skill

Fitter negligence

Software problem

Wrong beam diameter

Wrong pick finding

Wrong beam length

Variation in beam hardness

Wrong method of load cell connecting

Weft quality

Wrong method of knotting pass


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April 15, 2023 21

Step 3.1Process Name : Short terry Name of the investigator : Ashish Kumar GuptaLocation of Data Collection : Loom shed Date & time: 27/06/14 to 08/07/14 & 9:00AM to 6:00PMWhy this data is collected : To find out the causes for the short terry

Defect Type/Event Occurance 27/06/14 28/06/14 30/06/14 01/07/14 02/07/14 03/07/14 04/07/14 05/07/14 07/07/14 08/07/14 TOTAL

Pile beam tension variation III II II III II III III II III III 26

Gripper setting II III II II I II I III II II 20

Relay nozzle direct I II II I III I II I II I 16Negative beam

length II I I I II I I I 10

Temple setting I I I I I I I 7Wrong diameter

fed I I I I 4

Weft yarn rupture I I I I 4Variation in beam

hardness I I 2

TOTAL 10 9 9 8 7 9 10 9 9 9 89Conclusion/ Way Forward : Pile beam tension variation, gripper setting, relay nozzle directed & negative beam length are major problem for generation of short terry defect.



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April 15, 2023 22

Step 3.1Problem Phenomena :Short terry Date : 09/07/14

PARETO-ANALYSIS

Prepared By: Ashish Kumar Gupta Approved By: Mr. Ajit Parandekar

Conclusion/ Way Forward : 80%age cause responsible for generation of short terry are pile beam tension variation, gripper setting, relay nozzle directed & negative beam length.

Pile beam te

nsion va

riation

Gripper s

etting

Relay nozzl

e directe

d

Negative beam le

ngth

Temple setting

Wrong diameter f

ed

Weft ya

rn rupture

Variation in

beam hardness0

10

20

30

40

50

60

70

80

90

100

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

2620

1610

74 4 2

29%

52%

70%

81%

89%93%

98% 100% 100% 100% 100%

Frequency/ Qty. Frequency/ Qty.Causes -->

Freq

uenc

y/ C

ontr

ibuti

on o

f Cau

se

% C

umul

ative

Con

trib

ution


TPM Step 3.2

April 15, 2023 23

TPM WHY-WHY ANALYSIS

Report Date: 09/07/14

Area : Weaving Equipment : Toyota Air jet loom Subsystem/ Component:

Gripper

Breakdown/ Physical Phenomenon Short terry formation.

What is your final action? sufficient torque applied to gripper bolt & checking of it once in a week.

After final action, is it okay? YES Why do you take above action Action

Why 1 Short terry observed on loom stop the loom

Why 2 Gripper standard position not ok Gripper position check

Why 3 Gripper found loose Tighten the gripper

Why 4 Due to vibration in loom

Why 5 Design of loom

Root cause is one of the following 5 items Action Planned AM/ JH PM Design E&T1 Poor basic condition CLRI

2 Poor operating condition OPL, SOP

3 Deterioration PM Schedule

4 Weak Design Redesign, MP sheet

5 Poor Skill Training, OPL

CC

Kaizen idea : Upper portion of gripper is tightly cover to reduce vibration effect.


TPM Step 3.2

April 15, 2023 24

TPM WHY-WHY ANALYSIS

Report Date: 12/07/14

Area : Weaving Equipment : Toyota Air jet loom Subsystem/ Component:

Relay nozzle, sub-valve

Breakdown/ Physical Phenomenon Short terry formation.

What is your final action? Solenoid valve change.

After final action, is it okay? YES Why do you take above action Action

Why 1 Short terry observed at four sub-nozzles Sub-nozzles checking

Why 2 Relay nozzle direct(continuous air supply) Valve open & checking

Why 3 Solenoid valve piston jam Changed the valve.

Why 4 Rust with air supply

Why 5 Due to mild steel pipe line

Root cause is one of the following 5 items Action Planned AM/ JH PM Design E&T1 Poor basic condition CLRI

2 Poor operating condition OPL, SOP

3 Deterioration PM Schedule

4 Weak Design Redesign, MP sheet

5 Poor Skill Training, OPL

CC

Kaizen idea : To change the mild steel pipe line by galvanised iron’s pipe line to avoid corrosion.


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April 15, 2023 25

Step 3.2Application of Analytical Techniques

S No.Applicable Root Causes/

Vital Few CausesKaizen Idea

Countermeasure/ Action Plan

1. Pile beam tension variation Standardize the tension of pile beam as per quality.

2. Gripper setting

Gripper should be covered with a support to reduce vibration effect & misalignment.(Before: DSC01195.JPG, After: DSC011944.jpg) Once in a week checking of gripper setting(Gripper position & deterioration) .

3. Relay nozzle direct Sub-valve piston cylinder of relay nozzle should be changed.

4.Negative beam length &

diameter(Software problem)

Checking of negative beam length & diameter per day and where ever found negative again length & diameter to be entered.


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April 15, 2023 26

Step 3.3Conduct Experiments/ Develop Prototypes

S No.Kaizen Idea

Countermeasure/ Action PlanExperiment Done/ Prototype

Developed

1. Standardize the tension of pile beam as per quality.

Standard tension chart prepared according to the quality & distributed to the fitter. Tension reading.xlsx Run the trial on loom no.123(TG4949) according to standard tension & no full width short terry found when doff checked.

2.Gripper should be covered with a support to reduce vibration effect & misalignment.

A covered gripper use on loom no. 54(TG 4949) & 55(TG 5691).Gripper position does not disturbed when it is covered and hence chances of loosening is reduced.

3.Checking of negative beam length & diameter per day and where ever found negative again length & diameter to be entered.

Checking of negative beam length & diameter started per day and it is corrected whenever it go to negative.


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April 15, 2023 27

STEP-4


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April 15, 2023 28

Step 4.1Make Improvement Proposals

S No.Kaizen Idea

Countermeasure/ Action Plan Improvement ProposalApproved by

HOD?

1. Standardize the tension of pile beam as per quality. Std tension.xlsx

When the new quality run their standard tension should be add in the standard tension list. YES

2.

Gripper should be covered with a support to reduce vibration effect.Once in two week checking of gripper setting(Gripper position, deterioration).

Gripper covered with a tight support to reduce vibration effect of loom & misalignment of gripper. YES

3.Sub-valve piston cylinder of relay nozzle should be changed.

Sub-valve piston of relay nozzle should be changed. YES

4.Checking of negative beam length & diameter per day and where ever found negative again length & diameter to be entered.

Checking of negative beam length & diameter per shift and where ever found negative again length & diameter to be entered. YES


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April 15, 2023 29

Step 4.2Compare Cost Effectiveness & Make Budget

S No.Kaizen Idea

Countermeasure/ Action Plan Approved by HOD? Budget Required

1. Standardize the tension of pile beam as per quality. YES NIL

2.

Gripper should be covered with a support to reduce vibration effect & misalignment of gripper. YES NIL

3. Sub-valve piston cylinder of relay nozzle should be changed. YES ₹1100/piston cylinder

4.

Checking of negative beam length & diameter per shift and where ever found negative again length & diameter to be entered. YES NIL


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April 15, 2023 30

Step 4.3Check for Possible adverse Effects

S No.

Kaizen IdeaCountermeasure/

Action PlanApproved by

HOD? Budget RequiredAny adverse

Effect?

1. Standardize the tension of pile beam as per quality. YES NIL NO

2.

Gripper should be covered with a support to reduce vibration effect & misalignment of gripper. YES NIL NO

3.

Sub-valve piston cylinder of relay nozzle should be changed. YES

₹1100/piston cylinder NO

4.

Checking of negative beam length & diameter per shift and where ever found negative again length & diameter to be entered. YES NIL NO


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April 15, 2023 31

STEP-5


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April 15, 2023 32

Countermeasures implementation planProject Name : : To reduce short terry in weaving from 1210ppm to 968ppm

Owner Name : Ashish Kumar Gupta Week (BSC)-->

S No. Countermeasure Week 16 Week 17 Week 18 Week 19

1. Standardize the tension of pile beam as per quality.

P

A

2.Gripper covered with a support to reduce vibration effect.

P

A

3. Sub-valve piston cylinder of relay nozzle should be changed.

P

A

4.

Checking of negative beam length & diameter per shift and where ever found negative again length & diameter to be entered.

P

A

P

A

Step 5.1


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April 15, 2023 33

KK Project Results Review

S No. Failure/Defect/Cause Description UOM Baseline Target

Actual(From 1st to 6th

Aug)Status

(Ok/ Not OK)

1. Short terry ppm 1210 968 1117 OK

Step 5.2 Perform tests & trial runs


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April 15, 2023 34

Step 5.3TENTATIVE STANDARD OPERATING PROCEDUE (SOP)

Business : Towel Location/ Unit : FF-2/THT-2 Machine Name/ Process Name : Weaving loom

Process : Beam knotting SOP during beam change

SOP for knotter during beam change

1. Take charge of knotting machine and frame from previous shift worker.2. Check the availability of beam as per requirement and preparatory section officer in case of non-

availability of beams.3. Unload the previous beam from the loom and do proper cleaning of the machine.4. Load the new beam as per detail written on the slip.5. Check the beam ends and do proper dressing of the yarn sheet.6. Use correct needles as per count of yarn in the beam.7. Start knotting as per required pattern and ensure for no yarn end breakage during knotting process.8. Also, ensure for no crossing ends during knotting.9. Finish the knotting and unmounts the knotting machine from the frame.10. Keep the knotting waste in its proper place during knotting process.11. Measure the accurate diameter of beam by using scale and feed it into loom system(computer).12. Temple cover should be open to prevent temple ring jam during passing the knotting.13. Handover the loom to weaver after passing knotting from reed area.

(Prepared By)

Ashish Kumar Gupta(Approved By)

Mr. Ajit Parandekar Format No.:/ Issue Date: Page __ of __Revision No. & Rev. Date:


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April 15, 2023 35



Process : Fitter working SOP during quality change

SOP for fitter during quality change

1. Take the round of loom in starting 15 minutes of shift and check quality change looms for incomplete work.2. Ensure that there should no jammed temple ring or ring with blunt spikes.3. Check temple pulling.4. Check gripper condition.5. Check all relay nozzle work properly and no one will be directed.6. Feed the pile and ground warp tension according to the standard tension.7. Check other settings like air pressure, detect angle, weft arrival timing etc.8. Before starting the loom ensure all setting are correct and work properly.9. Start quality change looms by feeding parameters given on quality card.10. Check performance of loom breakage and attend any major deviation on loom.11. To attend the looms with low efficiency allotted by shift officer.12. Check the high weft breakage looms and attend the loom.13. In case of major problem on quality, attend the loom with the help of maintenance team.

(Prepared By)


Mr. Ajit ParandekarFormat No.:/ Issue Date: Page

__ of __Revision No. & Rev. Date:


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April 15, 2023 36

STEP-6


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April 15, 2023 37

Evaluation of Result of Project (Primary Metric)Target Vs Actual

BSC 1 BSC 2 BSC 3 BSC 4 1st Aug to 6th Aug0

500

1000

1500

2000

2500

3000

686

1350

1789

2749

1117

Actual Base line Target

1210

968

Booking of jail material in

between 15th to 31st july


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April 15, 2023 38

Step 6.2

KK Project Results Review

S No. Primary Metric UOM Baseline TargetActual

(From 1st to 6th Aug)

Status(Ok/ Not OK)

1. Short terry ppm 1210 968 1117 OK

*In BSC 4, from 15th July to 31st July ,short terry defect has been rapidly increased due to regular booking of Jail material and now actual downgrade from 1st August to 6th August is under control i.e. in between given baseline and target.


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April 15, 2023 39

STEP-7


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April 15, 2023 40

Step 7.1 STANDARD OPERATING PROCEDUE (SOP)


Process : Beam knotting SOP during beam change

SOP for knotting during beam change

1. Take charge of knotting machine and frame from previous shift worker.2. Check the availability of beam as per requirement and preparatory section officer in case of non-

availability of beams.3. Unload the previous beam from the loom and do proper cleaning of the machine.4. Load the new beam as per detail written on the slip.5. Check the beam ends and do proper dressing of the yarn sheet.6. Use correct needles as per count of yarn in the beam.7. Start knotting as per required pattern and ensure for no yarn end breakage during knotting process.8. Also, ensure for no crossing ends during knotting.9. Finish the knotting and unmounts the knotting machine from the frame.10. Keep the knotting waste in its proper place during knotting process.11. Measure the accurate diameter of beam by using scale and feed it into loom system(computer).12. Temple cover should be open to prevent temple ring jam during passing the knotting.13. Handover the loom to weaver after passing knotting from reed area.

(Prepared By)


Mr. Ajit Parandekar Format No.:/ Issue Date: Page __ of __Revision No. & Rev. Date:


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April 15, 2023 41



Process : Fitter working SOP during quality change

SOP for fitter during quality change

1. Take the round of loom in starting 15 minutes of shift and check quality change looms for incomplete work.2. Ensure that there should no jammed temple ring or ring with blunt spikes.3. Check temple pulling.4. Check gripper condition.5. Check all relay nozzle work properly and no one will be directed.6. Feed the pile and ground warp tension according to the standard tension. Std tension.xlsx7. Check other settings like air pressure, detect angle, weft arrival timing etc.8. Before starting the loom ensure all setting are correct and work properly.9. Start quality change looms by feeding parameters given on quality card.10. Check performance of loom breakage and attend any major deviation on loom.11. To attend the looms with low efficiency allotted by shift officer.12. Check the high weft breakage looms and attend the loom.13. In case of major problem on quality, attend the loom with the help of maintenance team.

(Prepared By)


Mr. Ajit ParandekarFormat No.:/ Issue Date: Page

__ of __Revision No. & Rev. Date:


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April 15, 2023 42

Step 7.2Daily tracing of worst operator

1. Collect the data of damages produce per loom from damage report of grey folding.

2. Select those looms on which more than 9 damages are produced.3. Trace the operator name of those looms.4. Record those worst operator name in “Damage observation” register.5. Council those worst operator that they do not produce as much damage

and also worn them if their name repeated more than three times in that list, they will be punished.


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Step 7.3

Negative beam length cause let-off synchronization error.

Beam length should be correct for let-off synchronization.

Ashish Kumar Gupta

Beam length should be correct.

10/7/14

Surendra rawat

11/7/14Mr. Ajit parandekar

Loom shed, THT-2

Subedar Sanjay


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April 15, 2023 44

Step 7.3

Here temple cover is closed while knotting pass which cause chances

of jamming of temple rings.

Here temple cover is open while knotting pass so no chances of temple

rings jamming.

Ashish Kumar Gupta

During knotting pass temple cover should be open.

4/7/14

Ashish Kumar Gupta


Sushil Arun

Loom shed, THT-2

Sarwan singh Sunil


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Step 7.3

Here temple rings are jammed with fluff which creates short terry in

towels

Here temple ring is clean so no chance of short terry due to temple.

Ashish Kumar Gupta

Temple ring should be always clean

27/6/14

Ashish Kumar Gupta


Rakesh Arun

Loom shed, THT-2

Jagat negi Ananjay


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Step 7.3

Fluff accumulated in between gripper and its platform which cause loose gripping of picks.

Gripper should be always clean & free from Fluff accumulation for

proper gripping of picks.

Ashish Kumar Gupta

Gripper should be clean.

21/6/14

Ashish Kumar Gupta


Amandeep Soni kaur

Loom shed, THT-2

Ratandeep Rani


TPM Step 7.3KAIZEN IDEA - SHEET

Activity KK JH QM PM SHE OTPM DM ET Loss No./ Step

5

Result Area P Q C D S M

Plant/ Function : THT-2 Machine/ Area : Toyota Air jet/Loom shed Muskaan/ Kaizen No : Kaizen theme : To reduce short terry generation due to gripper.

Idea : Give additional support to gripper to reduce loom vibration effect. KPI UOM DataBenchmark/ Baseline NA NA NA

Countermeasure : The upper portion of gripper is tightly covered which reduce the vibration effect also nullify the chance of damage of reed & main cutter due to misalignment of gripper.

Target NA NA NAProblem/present status : short terry formation due to gripper. Due to vibration in running loom gripper loose frequently & hence resulting short terry formed.

Kaizen start 14 07 2014

Before condition (Photograph/Sketch) :

After condition (Photograph/Sketch) : Kaizen Finish OngoingTeam members

Name Salary Code

Dept/ Functi

on

Ashish kumar gupta

CN3343 Weaving

Taj afzal

M30858 Weaving

Iqbal singh I43032 Maintenance Benefits:

P Description (Before) :Less contact portion of gripper hence effect of loom vibration is more & it loose easily.

Description (After) :Upper portion of gripper tightly covered hence loosening of gripper reduces by loom vibration.

Q

C

Analysis why - why analysis : Results (Bar Chart of before & after of the problem metric) : S Problem Phenomena : Short terry formation

M Tangibl

e

In-tangible

Approved Savings in Rs.

Why 1 : short terry formation due to gripper

Approved by: Department Champion/ Muskaan Co-ordinator:

Taj afzal Why 2 : Gripper become loose.

Unit Champion: Unit Costing Team:

Why 3 : Vibration in running loom Scope & plan for Horizontal Deployment Yes/ No

S no M/c No.Target date

Responsibility StatusWhy 4 :Weak design

1. 55 24/7/2014

Iqbal singhok

Root Cause : Weak design of gripper support.

Befor After

00.5

11.5

22.5

33.5

44.5

Shor

t ter

ry in

doff


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Consolidating gainsDate CSP Prod in

MTActual Short terry in PPM

Base line (Week 1 to 13)

Target in PPM

1-Aug 40.2 1309

1210 968

2-Aug 38.28 605

3-Aug 50.26 792

4-Aug 38.24 1306

5-Aug 37.22 1133

6-Aug 37.61 1560

Average 40.30 1118 1210 968

(Base line-Actual)%*CSP packed production*₹150Reduction(Base line-Actual) =0.1%

Average production from 1th Aug to 6Th Aug = 40.30MTSaving(1st Aug to 6th Aug) = ₹3355


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April 15, 2023 49

ASHISH GUPTA CN3343 THT2(WEAVING)

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