JISHU HOZEN Journey In Arihant From

2011 to 2014

Arihant Spinning Mills,

Malerkotla

Vardhm
an
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 stateof-the-art
technology
and
human
resources.Vardhmanis committed to be

Massage From Chief Executive

Dear 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)

Massage From CGM(Operation) D

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

Inde
x
S.No.

Topics Cover

Page No.

First Phase of JH Manual

1.

What is JH & Why JH?

5 to 9

2.

Enhancing Involvement

10 to 12

3.

JH Tree

13 to 18

4.

Last Three years Trend

19 to 22

5.

Our present JH Activities

23 to 40

Second Phase of JH Manual

6.

One Points Lesson

41 to 51

Third Phase of JH Manual

7.

Kaizens Under JH Pillar

8.

Vote of thanks

52 to 66
67
4

What is JH?

First Phase of JH
Manual
6

JISHU HOZEN (Autonomous maintenance) :

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.
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%.

Steps in JISHU HOZEN :

1.
2.
3.
4.
5.
6.
7.
8.

Preparation of employees.
Initial cleanup of machines.
Take counter measures
Fix tentative JH standards
General inspection
Autonomous inspection
Standardization and
Autonomous management.

?
n
e
z
o
H
u
h
s
i
J
Why

Why

TO PREVENT EQUIPMENT
DETERIORATION
TO MAINTAIN EQUIPMENT IN OPTIMAL
CONDTION
TO ESTABLISH BASIC EQUIPMENT
CONDITION
TO ELIMINATE EQUIPMENT FAILURE
TO MAKE OPERATOR EQUIPMENT COMPETENT
TO ELIMINATE QUALITY DEFECTS
TO ELIMINATE COST
LOSSES

JISHU HOZEN Journey

Start with

ENHANCING INVOLVEMENT
10

M/C OWNERSHIP CONCEPT

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.

11

OWNERSHIP CARD

12

H Tree Concept started in 2012

- For branching more involvement & penetration of
responsibility sharing throughout the 100% workforce
in JH Activity ..

13

JH Tree

Mr. Kuldeep Jain (Chief

Executive)
Mr. K.K.Lahiri (CGM
Operation)
Mr. Gurvir Bath (TPM
Coordinator)

PROD. MGR.MR. KARTIK CH.

KAR

1.. MR.
Mr.
Gurtej
RAMANDEEP
Singh
SINGH
2.. Mr.
Shyam
Lal Jat
3. Mr. Ajay
Saxen
a
4. Mr.
Vinod
Sharm
a

Production
Manager Mr. Anupam
Ganguly

1.Mr.
1.Mr.

Bhubanes
Mr.Harsimran
Bhubanes
hwar
hwar Das
Singh

2.Mr.
Mandeep
Singh
3.
Sukhvir
3. Mr.
Mr. Sukhvir
Singh
Singh
4.
4. Mr.
Mr.

Kanwalje
et Sharma
Sharma

CHIEF. MGR.BALBIR
SINGH

MR. ANUPAM
SHARMA

CHIEF. MGR.BALBIR
SINGH
CHIEF. MGR.BALBIR
SINGH

1..
.. Mr.
Mr. OM
OM

MR. SUMIT SINGH

1..
1..

2.
2.
3.
3.
4.
4.

Mr.Pushp
Mr.Pushp
ender
ender
Singh
Singh
.. Mr.
Mr. Sahil
Sahil
Bhatia
Bhatia
Mr.
Mr. Karan
Karan
Singh
Singh
Mr.
Mr. Vijender
Vijender
Bendwal'
Bendwal'

MR. CHARANJIT
GOYAL

1..
1.. Mr..
Mr.. UPINDER
UPINDER
Singh
Singh
2.
2. Mr.
Mr. Narayan
Narayan Lal
Lal
Jat
Jat
3.
3. Mr.
Mr. Tanveer
Tanveer
Salam
Salam
4.
4. Mr.
Mr. Bijendra
Bijendra
Bendwal
Bendwal

Narayan
Narayan
2.
Mr.
2. Mr.
Gagandee
p
p Garg
Garg
3.
3. Mr.
Mr. Anil
Anil
Kumar
Kumar
4.
4. Mr.
Mr. Indresh
Indresh
Chran

Unit No-1

JH Tree
Members
Shift A MR.GURTEJ
SINGH

PROD. MGR.MR. KARTIK CH. KAR

MR. RAMANDEEP
SINGH

Shift B MR.SHYAM LAL JAT

Ring Frame Preparatory

Preparatory
Ring Frame
Dept JH
Dept JH
Dept JH
Dept JH Core
Core
Core
Core
Members

Members
Members
Members

1 .MR .PRAVEEN
1.MR. ANIRUDH
KUMAR

PARTAP

2.MR. SURYA

2.MR. BHIKHU
NARAIN

PARSAD
3.MR.
4.MR. ARVIND
DINESH
KUMAR
5.MR. AJAY
4. MR.
SHARMA
SURESH SINGH
7.MISS. LUBNA
8.MR.
5.MR.

SHREE RAM
PARMATMA
9. SHAYAM
SINGH
KISHAN

1.MR.PRAVEEN
KUMAR
2.MR.
AJIT KUMAR
3.MR. BIRENDER
1. AJIT DAS
4.MR.
AJAY
2.MR.GURUPARS
5.MR. BABU LAL
AD
6.MR.
3.MR.
SUKH LAL
RAMESH
7.MR. SHIV
KUMAR
BUSHAN PANDAY
4. MR.
MAINUDEEN

8.
MR.DHARMINDER
9. JITENDER
PARSAD

Shift C MR.AJAY SAXENA

Ring Frame
Dept JH
Core
Members

Preparatory
Dept JH
Core
Members

1.MR.GYANEND

RA
2.MR.
DINESH KUMAR
3.MR.
1.MR.SURENDRA
JAGDISH
NITHARWAL
2. MR. PARSAD
4.MR.
BILAS YADAV
3.MR.RAMADEV HEERA LAL 5.
MR.JAI RAM

4.MR.
MANOJ KUMAR
5.MR.RAMESH
KUMAR

MR. VINOD
SHARMA

WINDING JH CORE
TEAM

1.
2.
3.
4.
5.
6.
7.
8.
9.

MR.
MR.
MR.
MR.
MR.
MR.
MR.
MR.
MR.

DEEPAK SHARMA
BABU LAL
HAULDAR
DAWINDER
RAMSAREESH
MAHESH
VIJAY
RAMSAKAL
NAND LAL

Unit No-2

JH Tree
Members
Shift A - Mr.
Bhubaneshwar
Das

Production Manager - Mr.

Anupam Ganguly

Mr. Harsimran
Singh

Shift B - Mr
Mandeep Singh

Ring Frame
Dept JH
Core Members

Preparatory
Dept JH
Core
Members

Ring Frame
Preparatory
Dept JH
Dept JH Core
Core
Members
Members

Juman

Kamal

Tarkeshwar

Subash

Amandeep
Kaur

Chandeshwa
r

Abdul

Bahadur

Kamlesh

Avadesh

Ram Sumer Brijesh

Shiv
Bahadur

Om
Prakash

Bablu

Chote Lal

Sanjay

Kapoor
Chand

Kapil Dev

Uma
Shankar
Kamakhya
Raj Kumar
Tiwari
Surender
Avnish
Singh

Shift C - Mr.
Sukhvir Singh

Mr.
Kanwaljeet
Sharma

Ring Frame
Preparatory Dept
Dept JH
JH Core Members
Core Members

Winding
Department JH
Core Members

Ramu

Ranjeet

Satya
Narayan

Manish

Mr. S.K. Pareek

Ram Daras

Ranjan

Mr. Om Prakash

Anil Gupta

Rinku

Mr. Kuldeep

Anil Patel

Chandraprakas
h

Mr. Kamalkant

Desh Raj

Shankar

Krishna

nit No-3,4

JH Tree
Members

Shift A MR.PUSHPENDER

CHIEF. MGR.-BALBIR
SINGH
MR. ANUPAM
SHARMA

Shift B Shift C MR. SAHIL BHATIA MR.KARAN SINGH

Ring Frame Preparatory

Ring Frame
Preparatory
Dept JH
Dept JH
Dept JH
Dept JH Core
Core
Core
Members
Core Members

Members
Members

1 .MR .SHIRI 1.MR. SHIV

RAM
JEE
2.MISS
2.MR. RAMU RAMANDEE
P
3.MISS
3.MR.
NAJIRA
VISHNU
4.MISS
4.
ANJU
MR.
KUMARI
BALKESHW
5.MISS. AR
KULDEEP
5.MR. BRIJ

1.MR.
AWDHESH
2.MR.
RAJESH
3.MR.
SANTOSH
4.MR.
SATINDER
5.MR.
AKHILESH
6.MR.

1.MR.RAGHUN

ANDAN
2.

MR.DEENANA

TH
3.MR.KANAHI

YA LAL

4.MR. JAI

SIMRAN
5. MR.

UMESH

Ring Frame
Preparatory
Dept JH
Dept JH Core
Core
Members
Members

MR.
VIJENDER
BENDWAL

WINDING JH CORE
TEAM

1.MR.RAMAS

1.MR.KAMLE HANKAR

SH
2.MR.

2. MR.
DEVINDER

RAJU
3.MR.

3.MR.SANTO RAVINDER

SH
4.MR. PANDEY

VKEEL
4.MR.

5.MR.RAMKU SHIVDHANI
MAR
5.

6.MR.RAMU SHIRIKANT

1 MR. SHAMSHER
2. MR. RAJESH
3. MR. VISHNU
DAYAL
4. MR. RAJESH
5. MISS RANI

17

Unit No-5

JH Tree
Members

Shift A
MR.OM NARAYAN

CHIEF. MGR.-BALBIR
SINGH
MR. CHARANJIT
GOYAL

Shift B MR. GAGANDEEP

GARG

Shift C MR. ANIL KUMAR

Ring Frame Preparatory

Preparatory
Ring Frame
Dept JH
Dept JH
Dept
Dept JH
Core
Core
JH Core
Core Members
Members
Members
Members

MR. INDRESH
CHARAN

WINDING JH CORE
TEAM

Ring Frame
Dept
JH Core
Members

Preparatory
Dept JH
Core
Members

1 .MR
1 .MR
.LAXMIKAN
.MADAN
T

2.MRS

2.MISS
SANGEETA

KAMALJEET

3.MRS
3.MISS

SAPNA
MANDEEP

4.MRS
4.MR.

VIJENTI
RAJDEV
RANI
.

1.MR. RAM
REKHA
2.MR.
SALUNDER
3.MR.
PRAMOD

1.MR.SANTOS

2.MR.RAM

LAL

3.MR.KANAYA

4.MR. ARJUN

1.MR.RAMAK

ANT YADAV
1.MR.MADAN

2.MR.

2. MR.
RAGUNADAN
KIRPASHANK

3.MR.
AR 3.MR.

AWIDESH
RAMJI

4.MR.

PRAMOD

1
2.
3.
4.

MR. DAVINDER
MR. RADHYSYAM
MR. RAMESH
MISS RANI

Last 3 Years
Unit Wise
Machine
Trend
Details

19

Jishu Hozen Pillar

Target
S.N
o

Activities

1112

Total Nos of M/cs

Total A & B Grade m/cs ( Area wise )

Achieve
d
1112

Target
1213

Targe
Achieve t
Achieve
d

1213

1314

1314

851

JH
Step-1

525

520

574

570

625

615

Completion of A & B grade m/c JH

up to
Step-2

525

518

574

568

625

612

JH
Step-3

525

518

574

570

625

615

10000

8408

8000

6366

6000

5521

Develop One Point Lesson (OPLs)

section wise

Develop Kaizens during J.H activities

100

65

150

68

150

124

Total no. of Training classes conducted

regarding JH and total no. of people
covered.

20

15

40
(500)

38
(402)

45
(500)

41
(415)

100%

68%

100%

89%

100%

92%

70

55

80

62

80

70

7
8

% of worker involvement in JH activities

Develop expert workers for fuguai
identification

20

Total Nos of M/cs -- 851

Total Nos of M/cs Area wise
Sr No

Dept / Area

U1,6

U2

U3,4

U5

Total No's
of M/cs

Blow room / carding

90

22

77

23

212

Preparatory

54

33

45

22

154

Spinning

67

25

55

29

176

Post spinning

15

12

45

Ch wdg / TFO

11

16

29

57

Ring Doubling

19

--

--

23

Reeling

29

--

--

14

43

Packing

22

H-Plant

15

10

10

41

10

Maintenance

14

34

11

Work shop

12

Engg ( Compressors / DG )

13

R&D

15

14

Waste packing

13
DG -

13
COMPRESSOR - 8

13
15

21

Completion of A & B grade m/c up to Step 3

22

OUR PRESENT JH ACTIVITIES

S. No

Activity

Timing

Routine CLITA

15 Mins before Shift

start

CLITA Day
Celebration

15 Mins before Shift

start

JH awareness
Training Program

Frequency
Thrice Daily

Monthly
Monthly
(On every 3rd

4.00 PM

Tuesday )
4

JH WEEK
Regular Meeting of

3.30 PM TO 4.30 PM
( Daily during the week )
4.00 PM

Yearly

23

Twice /Month
(Extra meeting

CLITA DAY CELEBRATION

CLITA STANDS
FOR
C
L
ITA-

CLEANING
LUBRICATION
INSPECTION
TIGHTENING
ADJUSTMENT

24

CLITA 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

26

Some common Fuguai

---Found During CLITA
Activity

27

FUGUAI FOUND AT M/CS

Cut mark on
Detaching cots

Improper color of Doff button

Burn roll at Draw

frame

Door safety bypass

Improper wire
dressing

28

FUGUAI FOUND AT M/CS

Worn out
Tape

Broken Separator
Holder

Broken
Spacer

Cut on
Apron

Worn out Top Clearer

Cloth

Broken Cradle

Cut on cots

Broken ABC Ring

Bend Needle
Bearing Cap

Broken Separator

Damaged Fly
Catcher

29

FUGUAI FOUND AT M/CS

Opaque screen

Crack at exhaust
pipe

Glass window
broken

OHB nozzle
disturbed

Indication board
broken

Jam at suction arm 30

mouth

Most common Fuguai ( found on CLIT day )

Fugua
i
Type

Apr13

May1
3

Jun13

July
13

Aug13

Sept13

Oct13

Nov13

Dec13

Jan14

Feb1
4

Mar14

Damaged
Apron

15

28

12

10

12

10

11

10

10

Damaged
Cots

17

22

12

15

14

10

17

12

Worn out
Daffy cloth

14

21

20

17

18

12

14

17

11

10

Grease
from
Bearing

12

11

10

Loose/
Worn out
Tape

14

11

12

10

12

14

10

Broken
Separator

Loose/
Disturbed
Lappet
hook

Bend
needle
Bearing
Cap

31

Most common Fuguai ( found on CLIT day )

Fuguai
Type

Apr1
3

May1
3

Jun13

July13

Aug1
3

Sept1
3

Oct13

Nov1
3

Dec13

Jan14

Feb14

Mar14

Indication
lamp Prob

S/X Saddle
gauge out

S/x cots
pressed

12

10

10

11

Worn out
Twist
master/
Flyer finger

S/X Clearer
cloth not
working

B/R Waste
pipe leakage

Suction pipe
crack

Stop motion

32

JHAWARENESS PROGRAMME
ONEVERY 3RD TUESDAY

33

Training on Wheels

34

JH WEEK CELEBRATION

35

JH Rally &
Inauguration

36

37

Poster competition

38

JH Gallery

Prashna
Manch

39

CLIT Competition

40

Second Phase
of JH Manual
41

ONE POINT LESSON

Department wise best OPL s Sorted & Displayed .
Product specific OPLs
Safety OPLs
OPLS displayed at some common places (Canteens, entrances
etc)

42

ONE POINT LESSON

Area
Pre-combing

kRIl bRykyj hony pr lwebr ipis<g joV sy joV

imlwkr kry [

Basic
Knowledge

Improvement
cases

Trouble
cases

Actual
Results

XX

Date Executed
Teacher
Student

43

ONE POINT LESSON

Area
Simplex

PK1550 twp Awm~ sy joVw inkwlqy smX Holfr

ipn pRys kry [
Basic
Knowledge

Improvement
cases

Trouble
cases

Actual
Results

XX

Date Executed
Teacher
Student

44

ONE POINT LESSON

Area
Compact Spg

lyits EpRn jwm lgw huXw nhI clnw cwihXy [

Basic
Knowledge

Improvement
cases

Trouble
cases

Actual
Results

XX

Date Executed
Teacher
Student

45

ONE POINT LESSON

Area
Compact Spg

bwiP<g ky bwd Eilt kt Aor PRwNt kt fwXw cyk krY

Basic
Knowledge

Eilt kt Aor PRwNt kt fwXw kw Anupwq 1.36

rKnw HYY , qwik tyNsn fRwPt 1.05 rhy [

Actual
Results

esilXy bwiP<g ky bwd Eilt kt Aor PRwNt kt

fwXw cyk krY [ kts` cy<j ky bwd ir<gPRym
ryip<g
j}r cyk kry ]

Date Executed
Teacher
Student

46

ONE POINT LESSON

Area
Compact Spg

kRIl pr lwt lyXr kw mwl n clwXy< [ 1.5-2 lyXr mwl

rhqy huXy bYc cy<j kry ]

Basic
Knowledge

Improvement
cases

Trouble
cases

Actual
Results

XX

Date Executed
Teacher
Student

47

ONE POINT LESSON

Area Milange

fw~k Aor lwe~t Syf swQ swQ n clwXy [

Basic
Knowledge

Improvement
cases

Trouble
cases

Actual
Results

X
X

Date Executed
Teacher
Student

48

ONE POINT LESSON

Area Milange

e~Njy#tw lb mSIn pr gwe~f dono Dwgy ky syNtr pr

rhnw cwihXy]

Basic
Knowledge

Actual
Results

Date Executed
Teacher
Student

49

ONE POINT LESSON

Area
Power House

VCB inkwlqy smX tRwlI kw eqymwl kry< [

Basic
Knowledge

Improvement
cases

Trouble
cases

Actual
Results

XX

Date Executed
Teacher
Student

50

ONE POINT LESSON

Area
Work Shop

gRwe~iNfg ky smX syPit g^ls kw pRXog kry< [

Basic
Knowledge

Improvement
cases

Trouble
cases

Actual
Results

XX

Date Executed
Teacher
Student

51

Third Phase
of JH Manual

At Unimix waste suction pipe installed to prevent Dropping waste

falling under beater .

53

ERM Duct Mouthpiece modified to prevent Duct

chocking

54

Handle provided at Top clearer Box , To avoid

clearer cloth setting disturbance .

55

SB2

Coiler zone hood made in two parts

SB2 Draw-frame front hood was very heavy to open , After Cutting
this cover in two parts it became easy for operators to open & clean this
area .

Benefits :
Cleaning & inspection made easy .
Cover piston failure reduced & life increased .
56

At Simplex LF1660 Cover safety stop motion installed .

This prevents m/c to start when Front hood over flyer not closed

57

Proximity sensor placed at Unilap Yoke for Over

doff protection

58

Limit switch attached at SB2 Draw frame can delivery point

which automatically resets length counter to Zero while
Full doff taken out ,
( eliminated manual counter
reset activity after every doff ) .

59

Kota stone flooring at both U/laps trolley rail zone to avoid minor
stoppages due to Trolley sensing problem ( leveling disturbance ) .

60

At S/X LF1660

OHB Waste box height lowered for easy

removal of waste.

61

Steel clip support Provided with

separators

62

Stair given to D-typer Auto-coner for facilitating operators work

Before

After

63

Cleaning made Easier

New Battery operated cleaning Gun at TICO Compact

R/Frs
At TICO Compact R/frs it was difficult to clean narrow drafting
area with cleaning stick . For this cleaning Battery operated
cleaning gun provided . Then two gun joined as a single unit for
further cleaning time reduction .

Before

After

Benefits :
Better cleaning of drafting system
Cleaning Time reduced from 20 Mins /Side to 12 mins/side .

64

Tightening Made Easier

Tool designed for
ratchet of Combers

proper tightening of feed roll

65

Lubrication Made Easier

Bearing Greasing Point created for X shaft in LC 300
A Card

Before

No Greasing Point
Available

No Capillary
Available

After

Greasing Point
created
Capillary Created with in the
66
shaft

VOTE OF THANKS

At the outset, we would like to express our sincere thanks to Honorable CMD Sir, Mr.
Sachit Jain & Mr. Neeraj Jain to give us the inspiration , encouragement guidance &
direction for working in future.
We gratefully acknowledge the help & valuable suggestions received from Mr. I. M. J. S
Sidhu (Director & TPM Head) & Mr. Sanjeev Sharma (TPM Consultant).
Finally, We would like to thank the Mr. Kuldeep Jain(Chief Executive) & Mr. K. K.
Lahiri (CGM Operation), Arihant JH Pillar Team & Other People Also like Jobbers,
Formans, Fitters & Other Workers . Without their support & encouragement JH VolumeI would have not been possible & following the Team Members of JH Pillar.

Mr. Anupam
Ganguly
(Pillar
Head)

Mr. Ramandeep Singh Mr. Parshant Mishra

Mr. Charanjeet Goyal
Mr. Anupam Sharma
Mr. Harsimran Singh
(Deputy Pillar Head)
(Team Member)
(Team Member)
(Team Member) (Team Member)

Mr. Gurtej Singh

(Team Member)

Mr. V.K.SharmaMr. Bikramjeet Singh

Mr. Gurvir Singh Bath
(Team Member) (Team Member)
(TPM Coordinator)

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