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ASHISH GUPTA CN3343 THT2(WEAVING)

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Ashish Gupta
Ashish Gupta

The document discusses efforts to reduce short terry defects in weaving from 1210 PPM to 968 PPM by August 8, 2014. It outlines the TPM project including forming a team, establishing a baseline and target, analyzing causes of defects, and developing an activity plan. Key activities included identifying abnormal conditions through a Fuguai register, analyzing tension variations and gripper issues, and implementing countermeasures like repairs, adjustments and part replacements. The goal was to standardize processes and equipment conditions to sustain the quality improvements.

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TPM is our way of life TPM To Reduce Short Terry In Weaving From 1210 PPM To 968 PPM in THT-2, Till 08th August, 2014 Ashish Kumar Gupta CN 3343 THT-2, Weaving/Production 5 April 2015 1
TPM is our way of life TPM 5 April 2015 2 Crack 10% Cheera 25% Float 13% Lining 3% Short Terry 17% Selvage damage 9% Others 13% C-grade 10% 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%
TPM is our way of life TPM 5 April 2015 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.
TPM is our way of life TPM STEP-0 5 April 2015 4
TPM is our way of life TPM 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 5 April 2015 5
TPM is our way of life TPM 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 process 3) To conduct trials to eliminate abnormalities 3 Mr. Prabhat Kumar To 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 Singh To 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 5 April 2015 6
TPM is our way of life TPM TPM KK Activity Plan Project Name : To reduce short terry in weaving from 1210ppm to 968ppm Owner 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 5 April 2015 7
TPM is our way of life TPM TPM KK Activity Plan Project Name : : To reduce short terry in weaving from 1210ppm to 968ppm Owner 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 5 April 2015 8
TPM is our way of life TPM TPM KK Activity Plan Project Name : : To reduce short terry in weaving from 1210ppm to 968ppm Owner 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 5 April 2015 9
TPM is our way of life TPM STEP-1 5 April 2015 10
TPM is our way of life TPM Flow Chart Process 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 5 April 2015 11 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
TPM is our way of life TPM Step 1.2 Check-Sheet Process Name : Weaving Name of the investigator : Ashish Kumar Gupta Location of Data Collection : R&D Date & time: From 1st week to 13th week Why 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 5 April 2015 12
TPM is our way of life TPM KK Project Target Setting S No. Failure/Defect/Cause Description UOM Baseline Target 1. Short terry ppm 1210 968 Step 1.3 5 April 2015 13
TPM is our way of life TPM STEP-2 5 April 2015 14
TPM is our way of life TPM Step 2.1爐爛. 爐爛. 爐踱. 爐爛 爐爐 爐萎爐逗じ爛爐爐 (TPM Fuguai Register) 1. 爐爐鉦ぎ爛爐迦 爐爐萎ぞ爐爛 2. 爐爐о爐萎 爐爛爐爐逗く爐鉦う爛 爐項ぞ爐迦い 3. 爐爛爐萎爐爐 爐伍爐ムぞ爐 4. 爐伍爐爛爐劇ぃ 爐伍爐萎爐 5. 爐萎爛爐爐朽い爛爐むぞ 爐爛爐 爐伍爐萎爐 6. 爐爐逗ぞ爐朽ざ爛爐爐 爐爐 爐萎爛爐 爐爐萎爐萎 爐朽じ爛爐む 7. 爐爐伍爐萎爛爐劇た爐 爐爐萎爐 1. Minor Flaws 2. Unfulfilled Basic Conditions 3. Inaccessible Places 4. Contamination Source 5. Quality Defect Sources 6. Unnecessary & Non Urgent Item 7. Unsafe Places 爐爛爐萎ぎ爐鉦 爐 爐∇爛爐爐∇た爛 爐爛 爐むぞ爐萎爐 爐∇爛爐爐∇た爛 爐朽ぞ爐迦ぞ 爐爐伍ぞ爐爐鉦え爛爐爐むぞ (Fuguai) 爐朽さ爐朽ぐ爐 爐爐伍ぞ爐爐鉦え爛爐 爐むぞ 爐爛 爐爛爐萎爐鉦ぐ 爐爐伍ぞ爐爐鉦え爛爐爐むぞ 爐爛爐萎 (爐迦ぞ爐/爐伍か爛 爐) 爐朽さ爐爐鉦ぐ爛 爐伍す爛 爐爐萎た爛 爐朽ぞ爐迦ぞ 爐爐朽ぞ爐爛 爐爐爐鉦く / 爐爐鉦ぐ爐爐朽ぞ爐 爐伍爐оぞ爐 爐爛 爐むぞ爐萎爐 (爐迦爛爐劇爐) 爐伍爐оぞ爐 爐爛 爐むぞ爐萎爐 (爐朽ぞ爐伍爐むさ爐朽) 爐迦爐÷ぐ 爐爛爐朽ぞ爐萎ぞ 爐爐爐爛爐爐爛 Sl. No Date of Detectio n Name of Detector Abnormality (Fuguai) description Abnormal ity Type (1/2/3/4/5 /6/7) Abnormality tag (Red / White) Department (Mech./ Elec./ Instr./ Tool/ Process) Executor Name Counter Measure / Action Taken Target Date of Rectifica tion Actual Date of Rectification Remarks 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. 133 5 Red Weaving Dhiran Replaced the load cell and zero setting done 24/06/14 24/06/14 Ok 4. 24/06/14 Virendra Short 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 Dinesh Tension variation in pile warp beam due to faulty load cell at loom no.18 5 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 5 April 2015 15
TPM is our way of life TPM Step 2.2 S 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 Dhiran 25/06/14 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 27/06/14 A. 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 5 April 2015 16
TPM is our way of life TPM STEP-3 5 April 2015 17
TPM is our way of life TPM Step 3.1 Stratification & Analysis of Causes S No. Failure/Defect/Cause Description Stratification Tool Analysis Tool 1. Short terry Flow chart, Fish-bone Check list, Pareto analysis 5 April 2015 18
TPM is our way of life TPM 5 April 2015 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 3.1 Short terry generation in weaving PROCESS FLOW CHART
TPM is our way of life TPM Step 3.1 5 April 2015 20 Problem 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 Prepared By : Ashish Kumar Gupta Approved By : Mr. Ajit Parandekar Improper sub valve timing 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
TPM is our way of life TPM Step 3.1 5 April 2015 21 Process Name : Short terry Name of the investigator : Ashish Kumar Gupta Location of Data Collection : Loom shed Date & time: 27/06/14 to 08/07/14 & 9:00AM to 6:00PM Why 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 16 Negative beam length II I I I II I I I 10 Temple setting I I I I I I I 7 Wrong diameter fed I I I I 4 Weft yarn rupture I I I I 4 Variation in beam hardness I I 2 TOTAL 10 9 9 8 7 9 10 9 9 9 89 Conclusion/ Way Forward : Pile beam tension variation, gripper setting, relay nozzle directed & negative beam length are major problem for generation of short terry defect. Prepared By : Ashish Kumar Gupta Approved By : Mr. Ajit Parandekar
TPM is our way of life TPM Step 3.1 5 April 2015 22 Problem 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. 26 20 16 10 7 4 4 2 29% 52% 70% 81% 89% 93% 98% 100% 100% 100% 100% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 10 20 30 40 50 60 70 80 90 100 Pile beam tension variation Gripper setting Relay nozzle directed Negative beam length Temple setting Wrong diameter fed Weft yarn rupture Variation in beam hardness %CumulativeContribution Frequency/ContributionofCause Causes --> Frequency/ Qty. Frequency/ Qty.
TPM is our way of life TPM Step 3.2 5 April 2015 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&T 1 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 C C Kaizen idea : Upper portion of gripper is tightly cover to reduce vibration effect.
TPM is our way of life TPM Step 3.2 5 April 2015 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&T 1 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 C C Kaizen idea : To change the mild steel pipe line by galvanised irons pipe line to avoid corrosion.
TPM is our way of life TPM Step 3.2 Application of Analytical Techniques S No. Applicable Root Causes/ Vital Few Causes Kaizen 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. 5 April 2015 25
TPM is our way of life TPM Step 3.3 Conduct Experiments/ Develop Prototypes S No. Kaizen Idea Countermeasure/ Action Plan Experiment 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. 5 April 2015 26
TPM is our way of life TPM STEP-4 5 April 2015 27
TPM is our way of life TPM Step 4.1 Make Improvement Proposals S No. Kaizen Idea Countermeasure/ Action Plan Improvement Proposal Approved 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 5 April 2015 28
TPM is our way of life TPM Step 4.2 Compare 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 5 April 2015 29
TPM is our way of life TPM Step 4.3 Check for Possible adverse Effects S No. Kaizen Idea Countermeasure/ Action Plan Approved by HOD? Budget Required Any 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 5 April 2015 30
TPM is our way of life TPM STEP-5 5 April 2015 31
TPM is our way of life TPM Countermeasures implementation plan Project 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 5 April 2015 32
TPM is our way of life TPM 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 5 April 2015 33
TPM is our way of life TPM Step 5.3 TENTATIVE 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: 5 April 2015 34
TPM is our way of life TPM Step 5.3 TENTATIVE STANDARD OPERATING PROCEDUE (SOP) Business : Towel Location/ Unit : FF-2/THT-2 Machine Name/ Process Name : Weaving loom 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) Ashish Kumar Gupta (Approved By) Mr. Ajit Parandekar Format No.:/ Issue Date: Page __ of __Revision No. & Rev. Date: 5 April 2015 35
TPM is our way of life TPM STEP-6 5 April 2015 36
TPM is our way of life TPM 5 April 2015 37 Evaluation of Result of Project (Primary Metric) Target Vs Actual 686 1350 1789 2749 1117 0 500 1000 1500 2000 2500 3000 BSC 1 BSC 2 BSC 3 BSC 4 1st Aug to 6th Aug Actual Base line Target 1210 968 Booking of jail material in between 15th to 31st july
TPM is our way of life TPM Step 6.2 KK Project Results Review S No. Primary Metric UOM Baseline Target Actual (From 1st to 6th Aug) Status (Ok/ Not OK) 1. Short terry ppm 1210 968 1117 OK 5 April 2015 38 *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.
TPM is our way of life TPM STEP-7 5 April 2015 39
TPM is our way of life TPM Step 7.1 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 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) Ashish Kumar Gupta (Approved By) Mr. Ajit Parandekar Format No.:/ Issue Date: Page __ of __Revision No. & Rev. Date: 5 April 2015 40
TPM is our way of life TPM Step 7.1 TENTATIVE STANDARD OPERATING PROCEDUE (SOP) Business : Towel Location/ Unit : FF-2/THT-2 Machine Name/ Process Name : Weaving loom 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.xlsx 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) Ashish Kumar Gupta (Approved By) Mr. Ajit Parandekar Format No.:/ Issue Date: Page __ of __Revision No. & Rev. Date: 5 April 2015 41
TPM is our way of life TPM Step 7.2 5 April 2015 42 Daily 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.
TPM is our way of life TPM Step 7.3 5 April 2015 43 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 11/7/14 Mr. Ajit parandekar Loom shed, THT-2 Subedar Sanjay
TPM is our way of life TPM Step 7.3 5 April 2015 44 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 5/7/14 Mr. Ajit parandekar Sushil Arun Loom shed, THT-2 Sarwan singh Sunil
TPM is our way of life TPM Step 7.3 5 April 2015 45 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 28/6/14 Mr. Ajit parandekar Rakesh Arun Loom shed, THT-2 Jagat negi Ananjay
TPM is our way of life TPM Step 7.3 5 April 2015 46 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 23/6/14 Mr. Ajit parandekar Amandeep Soni kaur Loom shed, THT-2 Ratandeep Rani
TPM is our way of life TPM Step 7.3 KAIZEN 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 Data Benchmark/ 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 NA Problem/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 Ongoing Team 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 singh ok Root Cause : Weak design of gripper 0 1 2 3 4 5 Befor After Shortterryindoff
TPM is our way of life TPM 5 April 2015 48 Consolidating gains Date CSP Prod in MT Actual 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*150 Reduction(Base line-Actual) =0.1% Average production from 1th Aug to 6Th Aug = 40.30MT Saving(1st Aug to 6th Aug) = 3355
TPM is our way of life TPM 5 April 2015 49

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ASHISH GUPTA CN3343 THT2(WEAVING)

  • 1. TPM is our way of life TPM To Reduce Short Terry In Weaving From 1210 PPM To 968 PPM in THT-2, Till 08th August, 2014 Ashish Kumar Gupta CN 3343 THT-2, Weaving/Production 5 April 2015 1
  • 2. TPM is our way of life TPM 5 April 2015 2 Crack 10% Cheera 25% Float 13% Lining 3% Short Terry 17% Selvage damage 9% Others 13% C-grade 10% 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%
  • 3. TPM is our way of life TPM 5 April 2015 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.
  • 4. TPM is our way of life TPM STEP-0 5 April 2015 4
  • 5. TPM is our way of life TPM 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 5 April 2015 5
  • 6. TPM is our way of life TPM 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 process 3) To conduct trials to eliminate abnormalities 3 Mr. Prabhat Kumar To 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 Singh To 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 5 April 2015 6
  • 7. TPM is our way of life TPM TPM KK Activity Plan Project Name : To reduce short terry in weaving from 1210ppm to 968ppm Owner 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 5 April 2015 7
  • 8. TPM is our way of life TPM TPM KK Activity Plan Project Name : : To reduce short terry in weaving from 1210ppm to 968ppm Owner 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 5 April 2015 8
  • 9. TPM is our way of life TPM TPM KK Activity Plan Project Name : : To reduce short terry in weaving from 1210ppm to 968ppm Owner 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 5 April 2015 9
  • 10. TPM is our way of life TPM STEP-1 5 April 2015 10
  • 11. TPM is our way of life TPM Flow Chart Process 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 5 April 2015 11 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
  • 12. TPM is our way of life TPM Step 1.2 Check-Sheet Process Name : Weaving Name of the investigator : Ashish Kumar Gupta Location of Data Collection : R&D Date & time: From 1st week to 13th week Why 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 5 April 2015 12
  • 13. TPM is our way of life TPM KK Project Target Setting S No. Failure/Defect/Cause Description UOM Baseline Target 1. Short terry ppm 1210 968 Step 1.3 5 April 2015 13
  • 14. TPM is our way of life TPM STEP-2 5 April 2015 14
  • 15. TPM is our way of life TPM Step 2.1爐爛. 爐爛. 爐踱. 爐爛 爐爐 爐萎爐逗じ爛爐爐 (TPM Fuguai Register) 1. 爐爐鉦ぎ爛爐迦 爐爐萎ぞ爐爛 2. 爐爐о爐萎 爐爛爐爐逗く爐鉦う爛 爐項ぞ爐迦い 3. 爐爛爐萎爐爐 爐伍爐ムぞ爐 4. 爐伍爐爛爐劇ぃ 爐伍爐萎爐 5. 爐萎爛爐爐朽い爛爐むぞ 爐爛爐 爐伍爐萎爐 6. 爐爐逗ぞ爐朽ざ爛爐爐 爐爐 爐萎爛爐 爐爐萎爐萎 爐朽じ爛爐む 7. 爐爐伍爐萎爛爐劇た爐 爐爐萎爐 1. Minor Flaws 2. Unfulfilled Basic Conditions 3. Inaccessible Places 4. Contamination Source 5. Quality Defect Sources 6. Unnecessary & Non Urgent Item 7. Unsafe Places 爐爛爐萎ぎ爐鉦 爐 爐∇爛爐爐∇た爛 爐爛 爐むぞ爐萎爐 爐∇爛爐爐∇た爛 爐朽ぞ爐迦ぞ 爐爐伍ぞ爐爐鉦え爛爐爐むぞ (Fuguai) 爐朽さ爐朽ぐ爐 爐爐伍ぞ爐爐鉦え爛爐 爐むぞ 爐爛 爐爛爐萎爐鉦ぐ 爐爐伍ぞ爐爐鉦え爛爐爐むぞ 爐爛爐萎 (爐迦ぞ爐/爐伍か爛 爐) 爐朽さ爐爐鉦ぐ爛 爐伍す爛 爐爐萎た爛 爐朽ぞ爐迦ぞ 爐爐朽ぞ爐爛 爐爐爐鉦く / 爐爐鉦ぐ爐爐朽ぞ爐 爐伍爐оぞ爐 爐爛 爐むぞ爐萎爐 (爐迦爛爐劇爐) 爐伍爐оぞ爐 爐爛 爐むぞ爐萎爐 (爐朽ぞ爐伍爐むさ爐朽) 爐迦爐÷ぐ 爐爛爐朽ぞ爐萎ぞ 爐爐爐爛爐爐爛 Sl. No Date of Detectio n Name of Detector Abnormality (Fuguai) description Abnormal ity Type (1/2/3/4/5 /6/7) Abnormality tag (Red / White) Department (Mech./ Elec./ Instr./ Tool/ Process) Executor Name Counter Measure / Action Taken Target Date of Rectifica tion Actual Date of Rectification Remarks 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. 133 5 Red Weaving Dhiran Replaced the load cell and zero setting done 24/06/14 24/06/14 Ok 4. 24/06/14 Virendra Short 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 Dinesh Tension variation in pile warp beam due to faulty load cell at loom no.18 5 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 5 April 2015 15
  • 16. TPM is our way of life TPM Step 2.2 S 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 Dhiran 25/06/14 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 27/06/14 A. 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 5 April 2015 16
  • 17. TPM is our way of life TPM STEP-3 5 April 2015 17
  • 18. TPM is our way of life TPM Step 3.1 Stratification & Analysis of Causes S No. Failure/Defect/Cause Description Stratification Tool Analysis Tool 1. Short terry Flow chart, Fish-bone Check list, Pareto analysis 5 April 2015 18
  • 19. TPM is our way of life TPM 5 April 2015 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 3.1 Short terry generation in weaving PROCESS FLOW CHART
  • 20. TPM is our way of life TPM Step 3.1 5 April 2015 20 Problem 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 Prepared By : Ashish Kumar Gupta Approved By : Mr. Ajit Parandekar Improper sub valve timing 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
  • 21. TPM is our way of life TPM Step 3.1 5 April 2015 21 Process Name : Short terry Name of the investigator : Ashish Kumar Gupta Location of Data Collection : Loom shed Date & time: 27/06/14 to 08/07/14 & 9:00AM to 6:00PM Why 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 16 Negative beam length II I I I II I I I 10 Temple setting I I I I I I I 7 Wrong diameter fed I I I I 4 Weft yarn rupture I I I I 4 Variation in beam hardness I I 2 TOTAL 10 9 9 8 7 9 10 9 9 9 89 Conclusion/ Way Forward : Pile beam tension variation, gripper setting, relay nozzle directed & negative beam length are major problem for generation of short terry defect. Prepared By : Ashish Kumar Gupta Approved By : Mr. Ajit Parandekar
  • 22. TPM is our way of life TPM Step 3.1 5 April 2015 22 Problem 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. 26 20 16 10 7 4 4 2 29% 52% 70% 81% 89% 93% 98% 100% 100% 100% 100% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 10 20 30 40 50 60 70 80 90 100 Pile beam tension variation Gripper setting Relay nozzle directed Negative beam length Temple setting Wrong diameter fed Weft yarn rupture Variation in beam hardness %CumulativeContribution Frequency/ContributionofCause Causes --> Frequency/ Qty. Frequency/ Qty.
  • 23. TPM is our way of life TPM Step 3.2 5 April 2015 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&T 1 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 C C Kaizen idea : Upper portion of gripper is tightly cover to reduce vibration effect.
  • 24. TPM is our way of life TPM Step 3.2 5 April 2015 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&T 1 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 C C Kaizen idea : To change the mild steel pipe line by galvanised irons pipe line to avoid corrosion.
  • 25. TPM is our way of life TPM Step 3.2 Application of Analytical Techniques S No. Applicable Root Causes/ Vital Few Causes Kaizen 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. 5 April 2015 25
  • 26. TPM is our way of life TPM Step 3.3 Conduct Experiments/ Develop Prototypes S No. Kaizen Idea Countermeasure/ Action Plan Experiment 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. 5 April 2015 26
  • 27. TPM is our way of life TPM STEP-4 5 April 2015 27
  • 28. TPM is our way of life TPM Step 4.1 Make Improvement Proposals S No. Kaizen Idea Countermeasure/ Action Plan Improvement Proposal Approved 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 5 April 2015 28
  • 29. TPM is our way of life TPM Step 4.2 Compare 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 5 April 2015 29
  • 30. TPM is our way of life TPM Step 4.3 Check for Possible adverse Effects S No. Kaizen Idea Countermeasure/ Action Plan Approved by HOD? Budget Required Any 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 5 April 2015 30
  • 31. TPM is our way of life TPM STEP-5 5 April 2015 31
  • 32. TPM is our way of life TPM Countermeasures implementation plan Project 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 5 April 2015 32
  • 33. TPM is our way of life TPM 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 5 April 2015 33
  • 34. TPM is our way of life TPM Step 5.3 TENTATIVE 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: 5 April 2015 34
  • 35. TPM is our way of life TPM Step 5.3 TENTATIVE STANDARD OPERATING PROCEDUE (SOP) Business : Towel Location/ Unit : FF-2/THT-2 Machine Name/ Process Name : Weaving loom 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) Ashish Kumar Gupta (Approved By) Mr. Ajit Parandekar Format No.:/ Issue Date: Page __ of __Revision No. & Rev. Date: 5 April 2015 35
  • 36. TPM is our way of life TPM STEP-6 5 April 2015 36
  • 37. TPM is our way of life TPM 5 April 2015 37 Evaluation of Result of Project (Primary Metric) Target Vs Actual 686 1350 1789 2749 1117 0 500 1000 1500 2000 2500 3000 BSC 1 BSC 2 BSC 3 BSC 4 1st Aug to 6th Aug Actual Base line Target 1210 968 Booking of jail material in between 15th to 31st july
  • 38. TPM is our way of life TPM Step 6.2 KK Project Results Review S No. Primary Metric UOM Baseline Target Actual (From 1st to 6th Aug) Status (Ok/ Not OK) 1. Short terry ppm 1210 968 1117 OK 5 April 2015 38 *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.
  • 39. TPM is our way of life TPM STEP-7 5 April 2015 39
  • 40. TPM is our way of life TPM Step 7.1 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 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) Ashish Kumar Gupta (Approved By) Mr. Ajit Parandekar Format No.:/ Issue Date: Page __ of __Revision No. & Rev. Date: 5 April 2015 40
  • 41. TPM is our way of life TPM Step 7.1 TENTATIVE STANDARD OPERATING PROCEDUE (SOP) Business : Towel Location/ Unit : FF-2/THT-2 Machine Name/ Process Name : Weaving loom 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.xlsx 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) Ashish Kumar Gupta (Approved By) Mr. Ajit Parandekar Format No.:/ Issue Date: Page __ of __Revision No. & Rev. Date: 5 April 2015 41
  • 42. TPM is our way of life TPM Step 7.2 5 April 2015 42 Daily 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.
  • 43. TPM is our way of life TPM Step 7.3 5 April 2015 43 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 11/7/14 Mr. Ajit parandekar Loom shed, THT-2 Subedar Sanjay
  • 44. TPM is our way of life TPM Step 7.3 5 April 2015 44 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 5/7/14 Mr. Ajit parandekar Sushil Arun Loom shed, THT-2 Sarwan singh Sunil
  • 45. TPM is our way of life TPM Step 7.3 5 April 2015 45 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 28/6/14 Mr. Ajit parandekar Rakesh Arun Loom shed, THT-2 Jagat negi Ananjay
  • 46. TPM is our way of life TPM Step 7.3 5 April 2015 46 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 23/6/14 Mr. Ajit parandekar Amandeep Soni kaur Loom shed, THT-2 Ratandeep Rani
  • 47. TPM is our way of life TPM Step 7.3 KAIZEN 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 Data Benchmark/ 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 NA Problem/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 Ongoing Team 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 singh ok Root Cause : Weak design of gripper 0 1 2 3 4 5 Befor After Shortterryindoff
  • 48. TPM is our way of life TPM 5 April 2015 48 Consolidating gains Date CSP Prod in MT Actual 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*150 Reduction(Base line-Actual) =0.1% Average production from 1th Aug to 6Th Aug = 40.30MT Saving(1st Aug to 6th Aug) = 3355
  • 49. TPM is our way of life TPM 5 April 2015 49