The document provides information on Total Productive Maintenance (TPM) activities for the Dhampur Distillery department for February 2022. It introduces TPM, outlines its objectives such as zero defects and accidents, and describes the 8 pillars of TPM including autonomous maintenance, planned maintenance, and safety/environmental health. Status updates are provided for various ongoing initiatives within each pillar like number of issues tagged/resolved, kaizen activities, breakdown records, and EHS activities for the past month. Overall the document reports on the department's TPM program aimed at improving productivity, quality and safety.

1. TOPIC OF THE MONTH- FEB 2022
UNIT - DHAMPUR DEPARTMENT – DISTILLERY
TOTAL PRODUCTIVITY MAINTENANCE
TEAM – DISTILLERY
Mr. Jitesh Gupta Sir (G.M chemical)
Mr. Kapildev Sir (Sr. Production Manager)
Mr. Sanjay Chaudhary Sir (Shift Incharge)
Vikas kumar Mishra (G.E.T)
Sudhanshu Bhardwaj (G.E.T)

2. Contents
1. TOPIC INTRODUCTION
2. NEED OF TPM
3. TPM OBJECTIVE
4. TPM Target
5. TPM Pillars
6. TPM Inspection
7. Importance of TPM
2

3. INTRODUCTION TO TPM
T: TOTAL
* Participation of all Employees,
* Include all departments, operation, equipment and process.
P: PRODUCTIVE
* Pursue the maximization of efficiency of the production system
By making all loses zero.
* Zero accident Zero defects Zero breakdowns.
M: MAINTENANCE
* To improve the efficiency of the equipment
* Maintenance means the entire life cycle of the production
systems
3

4. NEED OF TPM
• Avoid wastage in a quickly changing economic
environment.
• Producing goods without reducing product
quality.
• Reducing cost.
• Goods sent to the customer's must be non
defective
4

5. * Increase production while, at the same
time, increase employ moral and job
satisfaction.
* To provide the safe and good working
environment to the worker.
* Achieve zero defect, zero breakdown zero accidents and zero
losses.
* Involve people in all levels of organization.
* from different terms to reduce defects and self maintenance.
* To fulfil regulatory compliance.
TPM OBJECTIVE
DOCUMENT NAME
Document Number 5
ZER
ACCIDENT
QUALITY
DEFECT
BREAKDOWN
WASTE

6. 1 PRODUCTION
* Obtain minimum 80% overall production efficiency
* Obtain minimum 90% overall equipment effectiveness
2 QUALITY
Operate in a manner. So that there are no customer complaint
3 COST
Reduce the manufacturing cost as much as possible
4 DELIVERY
Achieve 100% success in delivering the goods as required by the
customer
5 SAFETY
Maintain an accident free environment
TPM TARGET
DOCUMENT NAME
Document Number 6

7. TPM PILLARS
7
TPM 8 PILLARS
AUTONOMOUS
MAINTENANCE
FOCUSSED
IMPROVEMENT
PLANNED
MAINTENANCE
SAFTEY,
HEALTH
&
ENVIRONMENT
DEVELOPMENT
MANAGEMENT
EDUCATION
&
TRAINING
QUALITY
MAINTENANCE
OFFICE
TPM

8. PILLARS OF TPM
 PILLAR 1 – Autonomous Maintenance
* A collaborative team activity involving production,
maintenance, and engineering
8

9. JH Pillar– Step -01
Weekly Status of Red Tags, White Tags & OPLs
JH Pillar Dashboard
Cost center/ Circle Name Circle Number Circle Leader WT RT
OPL
TOTAL TAG (W)
ATTACHED
TOTAL TAG (W)
REMOVED
PENDING REMOVAL %
A R A R
Cane Handling Devices & Cane
preparation device
C-1 Anand Singh 143 143 148 127 0 4 4 0 100.00%
Mills with TRPF & IRC C-2 Parvender singh 40 40 28 25 0 2 2 0 100.00%
Mill Drives C-3 Guddu Yadav 85 85 7 0 0 85 85 0 100.00%
183 152 0 91 91
Boiling House
Juice Weighment Systems + Juice
Clarification+OC Filter+FCS
C-4 Zulfqar 0 0 33 15 1 0 0 0 #DIV/0!
Pans with Condensors + Crystallisers &
Pugmills
C-5 Vacant/Yogender 0 0 26 24 0 0 0 0 #DIV/0!
All Centrifugal Machines with Air
Compressors+Centrifugal
Pumps+Molasses + Massecuite & Magma
Pumps + High Flow Pumps
C-6 Abhishek Shukla 4 4 18 11 1 4 4 0 100.00%
Evaporator+Juice Heater+Cooling Tower C-7 Sanjeev Chauhan 6 6 41 22 1 6 6 0 100.00%
Dryer house C-8 Saurabh Verma 0 0 24 22 0 0 0 0 #DIV/0!
Water Circulation System- including
tubewells & Sugar ETP
C-9 Arshad Ali 3 3 26 7 2 29 10 19 34.48%
168 101 5 39 20
Co-Gen
170 tph Boiler C-10 Saurabh Singh 2 2 22 11 0 2 2 0 100.00%
2X30 MW Turbines + DG Set & Others C-11 Akshay 0 0 9 6 0 0 0 0 #DIV/0!
Fuel Handling System C-12 Harpreet Singh 8 8 17 15 0 8 8 0 100.00%
Water Treatment plant C-13 Satish Sharma 4 4 5 5 0 4 4 0 100.00%
75 tph Boiler C-14 Sohit Roy 8 8 48 23 0 8 8 0 100.00%
7.47 MW Turbines C-15 Ram Kumar 1 1 5 4 0 1 1 0 100.00%
Fuel Handling System (Out Side Yard) C-16 Mukesh 9 8 28 25 0 9 8 1 88.89%
134 89 0 32 31 1
Distillery
Fermentation and Distillation
C17 Suhail Kumar 0 0 10 0 0 0 0 0 0.00%
C-18 LalJi Pandey 20 20 45 44 0 20 20 0 100.00%
C-19 Rajiv Chauhan 0 0 30 25 1 0 0 0 #DIV/0!
Ethyl Acetate C-20 Sujata Mall 6 6 47 47 0 6 6 0 100.00%
ETP C-21 Rajiv Kaushik 5 5 33 18 2 5 5 0 100.00%
Bottling Plant C-22 JB singh 4 4 2 2 4 4 4 0 100.00%
167 136 7 35 35

10. JH Pillar– Step -02
10
S.O.C., H.T.A. & KAIZEN Status
JH Pillar Dashboard
Cost center/ Circle Name Circle Number Circle Leader SOC HTA
KAIZEN
A R A R
Cane Handling Devices & Cane preparation device C-1 Anand Singh 6 4 0 0 1
Mills with TRPF & IRC C-2 Parvender singh 1 1 5 3 3
Mill Drives C-3 Guddu Yadav 0 0 3 0 0
7 5 8 3 4
Boiling House
Juice Weighment Systems + Juice Clarification+OC
Filter+FCS
C-4 Zulfqar 2 1 0 0 1
Pans with Condensors + Crystallisers & Pugmills C-5 Vacant/Yogender 15 14 1 0 1
All Centrifugal Machines with Air Compressors+Centrifugal
Pumps+Molasses + Massecuite & Magma Pumps + High
Flow Pumps
C-6 Abhishek Shukla 1 1 0 0 1
Evaporator+Juice Heater+Cooling Tower C-7 Sanjeev Chauhan 35 18 0 0 1
Dryer house C-8 Saurabh Verma 4 4 1 0 3
Water Circulation System- including tubewells & Sugar ETP C-9 Arshad Ali 0 0 2 2 2
57 38 4 2 9
Co-Gen
170 tph Boiler C-10 Saurabh Singh 0 0 0 0 0
2X30 MW Turbines + DG Set & Others C-11 Akshay 0 0 0 0 0
Fuel Handling System C-12 Harpreet Singh 0 0 0 0 0
Water Treatment plant C-13 Satish Sharma 0 0 0 0 1
75 tph Boiler C-14 Sohit Roy 0 0 0 0 0
7.47 MW Turbines C-15 Ram Kumar 0 0 0 0 0
Fuel Handling System (Out Side Yard) C-16 Mukesh 1 1 0 0 0
1 1 0 0 1
Distillery
Fermentation and Distillation
C17 Suhail Kumar 0 0 0 0 1
C-18 LalJi Pandey 42 41 1 1 2
C-19 Rajiv Chauhan 0 0 0 0 1
Ethyl Acetate C-20 Sujata Mall 18 18 0 0 0
ETP C-21 Rajiv Kaushik 4 0 1 0 1
Bottling Plant C-22 JB singh 0 0 0 0 5
64 59 2 1 10

11. JH Pillar– Step -03(CLITA Verification)
11
List of CLITA & Few Samples Mentioning Time of CLITA

12. JH Kaizen- Circle 7
DOCUMENT NAME
Document Number 12

13. PILLARS OF TPM
 Pillar 3 – Planned Maintenance
* Logical analysis “Real causes for real counter measure”.
* Focus on prevention.
Example; Preventive maintenance, Breakdown maintenance.
13

14. PM Pillar – Dashboard
14
PM Pillar Dashboard
Section
Zone
Number
Zonal Leader Sub zonal leader RT Equip. stoppages (Hrs) SOC HTA
OPL Kaizen
RCA
A R PM
Shutdow
n
Breakdo
wn
A R A R Open Closed
Mill House Z-1 Ramchandra Sah Harsh Kumar 183 152 1:40 0 25:23:00 7 5 8 3 0 2 3 0
Boiling House Z-2 Harun Khan Raviraj Saxena 168 101 87:45:00 12:00:00 61:15:00 57 38 4 2 1 1 3 1
Cogen- 170 TPH Z-3
Rakesh Kumar
Singh
Vikas Kumar 53 37 1:10:00 0 0:35:00 0 0 0 0 0 0 0 0
Cogen- 75 TPH Z-4 Gursewak Singh 81 52 0 0 0 1 1 0 0 0 0 2 0
Chemical Z-5 K.K Verma Arpan Saini & Ishrat Jamal 167 138 0 0 0 64 59 2 1 0 0 0 0

15. PM Pillar – B/D Record Defect Slip
15
# Month Section Zone leader Sub zone leader No. of defects
Total
rectification
work time (Hrs)
Qty of spares
consumed (No's)
1
Nov-21
Mill House
Ramchandra
Sah
Harsh kumar 34 19:18:00 0
2 Boiling House Harun Khan Raviraj Saxena 63 161:00:00 64
3 Cogen 170 ton Rakesh kumar
Singh Vikas Kumar 34 26
4
Cogen 75 Ton Rakesh Kumar
Singh Gursewak Singh Butter 11 155:30:00 2
5 Chemical Plant
K.K Verma Arpan Saini/Ishrat Jamal 16 45:55:00 15

16. PM Pillar – B/D records
16
Breakdown Record
SECTION EQUIPMENT FREQUENCY IN NOS. DURATION IN HRS. REMARKS
Mill House
CU#1 2 00:16
CU#2 1 00:05
CU#5 1 00:05
102" cane carrier 3 00:16
Cutter#1 1 00:27
IRC#5 1 00:10
Mill#2 11 01:47
Mill#3 1 00:03
Mill#4 7 02:24
Mill#5 6 03:06
Total 34 08:39
Boiling House
Raw Juice pump#1 1 00:02
L-Tyco slate coveyor 1 01:00
A-centrifugal#3 2 02:15
Air compressor#2 1 48:00
A1 mixture 1 03:00
Total 5 54:17
Cogen Both 30MW turbine 1 00:35
Total 1 00:35
Mill Bypass Record
Mill House
Mill1 0 00:00
Mill2 0 00:00
Mill3 0 00:00
Mill4 1 10:39
Mill5 0 00:00
Total 1 10:39

17. PM Pillar – Why- Why Analysis
17

18. PM Pillar – PM Check Sheet
18
Linkage of PM Check Sheet with Abnormality Register

19. • K.K pillar; KOBETSU KAIZEN, It is a japanese term.
• Kobetsu means Focused.
• KAI means change or Improvements.
• ZEN means Good.
• In K.K pillar do SGA.
• Principle behind is that." a very large number of small improvements.
• This pillar is aimed at; Reducing losses in the work place that affect our effenciency.
• Improvements is to eliminate production losses and cost reduction.
K.K pillar
DOCUMENT NAME 19

20. KK Pillar – Lost Cost- SGAs
20
Sr. No. Section Pillar Head SGA List Distillery Section Level Status
1
Distillery Jitesh Gupta
DM water consumption Micro Done
2 Fusel oil Macro Done
3

21.  E.H.S means Environment, Health and Safety.
 Zero accidents and Zero Hazards at works.
 Zero pollution at plant and Environment.
 Target
• ZERO accidents
• ZERO Health damage
• ZERO Fire
• ZERO Losses
• It helps to create a safe work place and surrounding areas that is not affect our process
and procedures.
• It plays an active role in each of other pillars on a regular basis.
E.H.S pillar
Document Number 21

22. EHS Pillar Activities: Dec-21 & Jan-22

23. 1S Drive: Area Vacated & its Effective Utilisation - 2019-20 Vs
2020-21
Area Vacated in year 19-20
S. N Area
Area
(m²)
Effective Utilization
1 Previous cleaned area before Mar.19 12700
2 Near Temple Chemical 494 Vacant
3 New PESO Tank Entry South East Side 936 Vacant
4 PESO Tank North East Side 569 Vacant
5 PESO Tank South East Side 336 Vacant
6 Cooling Tower Road Side 42 Vacant
7 Cooling Tower behind ETP Office, Chemical 45 Vacant
8 Near Multieffect Plant 540 Vacant
9 Bio Scrubber, Chemical 210 New CPU plant
10 Opp. Store/ Cement Store 61 Steel Yard, Material Dept.
11 Road Opp. Store, Sugar 90 Clean Area
12 Opp. Fire Office, Chemical 150 Clean Area
13 Infront of Chemical lab 90 ENA Loading Area
14 Back side of CO2 Plant- Chemical Unit 138 Value yard
15
Molasses Tank Back side of Side of Sugar
Godown- Chemical Unit
225 Clean Area
16 Near RCC gas Holder- Chemical Unit 89 New CPU Unit
17 Near old Multi Effect Plant- Chemical Unit 165 Clean Area
18 Old electrical Store near Work Shop. 1625 Technical Office
19 Drier House Corner 475 Clean Area
Total 18980
Area Vacated in year 20-21
S. N Area
Area
(m²)
Effective Utilization
1 Officer Colony Area 1575 CPU and Green Park
2 40 Ton Boiler Area 611
Heavy Material Storage by
material deptt
3 MPP Building Dismantling Area 549 Used by Material Dept.
4 Mill No. 5 Side Back Side Of Store 195 Clean Area
5 Back Side Of Store Near Chimney & Toilet 208 Clean Area
6 BH Engineer Office near clarifier 40 New Evaporator Body
7 Mill House Near Cane Carrier Side 60 Clean Area
8 BRG Gate Area 249 Clean Area
9 C.O.O Kothi Area 1489 Vacant
10 Cycle Stand Near Switch Yard 289 Clean Area
11 Ehaat Dismantling Area 1134 Cycle and Motor Cycle Stand
12 Old Bio gas Plant scrap Storage, Chemical 331 ENA & Ethyl Filling Station
13 MD House North Side East Side Area 1129 Clean Area
14 MD House Green Area Out Side 903 Green Area
15 MD House Grass Area 443 Green Area
16 Molasses Colony Quarter 1, 2, 3,4,5,6 975 Vacant
17 Temple side colony 1596 Vacant
18 Bio Compost Yard Near Petrol Pump 2610 Lagoon Area
19 Gullu Old Residence 350 New STP Plant Area
Total 11774

24. Identification of High Noise Areas
High Noise area identified at 10 locations and focused to reduce by using engineering,
administrative and PPE’s control.
S.No. Unit Location
Sound Level (Range not
more than 85 Decibel)
Remarks
1 Chemical KBK Distillery, Compressor Room 95 to 105
2 Chemical CO2 plant Compressor Area 90 to 100
3 Chemical Fermentation, Decanter Area 95 to 105
4 Cogen Ground Floor, Turbine 01 95 to 105
5 Cogen Ground Floor, Turbine 02 95 to 105
6 Cogen Feed Water Transfer Pump Area 90 to 100
7 Sugar Drier House, Dust Collector 01 95 to 105
8 Sugar Drier House, Dust Collector 02 95 to 105
9 Sugar Boiling House Area 90 to 100
10 Sugar Mill House, Fibrizer 95 to 105

25. Illumination Level
Illumination Level Zonewise identified
Zone Zone Area/ Location Zone Zone Area/ Location Zone Zone Area/ Location
1
Cane Carrier 01 & 02
7
Sugar – ETP
14
Chemical Unit- Mechanical Workshop
Mill No 01 Cooling Tower Fire Station & Pump House
Mill No 04 QC Lab Sugar Excel Distillery Area-Ground Floor
Mill House Workshop QC Lab Chemical Excel Distillery Area-Top Floor
2
Cane Entry Gate QC Lab MEE Ethyl Acetate Plant
Cane Yard
8
Admin Block KBK Distillery Area-Ground Floor
3
Evaporator Section Guest House KBK Distillery Area-Top Floor
Pan Section Cycle & Scooter Stand
15
Bottling Plant Washing section
Centrifugal Section
9
Residential colony inside plant Bottling Plant Filling section
Boiling section main walkway E D Kothi Bottling Plant Raw Material Store
Clarification Section
10
Residential Main Gate Bottling Plant Finished Goods Store
4
Godown No.11 Molasses Colony
16
Chemical - ETP & MEE
Sulphur yard
11
Chemical Colony CPU Unit
Godown 10 Accounts and Finance Old MEE - Ground Floor
Molasses RCC Tank 4 to 7
12
Baggase Yard Old Old MEE - Top Floor
5
Drier House Baggase Yard New Integrated MEE - Ground Floor
Melting point
13
75 Tonne Boiler Integrated MEE - Top Floor
6
Scrap Yard area 170 Tonne Boiler 01
Spray Pond 170 Tonne Boiler 02
Central Store DG Set Room
Cylinder Store
Lubrication and Oil Store

26. EHS Activities: Green Area Development
130 Plant planted at nearby MD Kothi. 95 flower plants planted in Chemical Unit by using
scrap drums as flower pots, All flower pots painted with tricolor.

27. EHS Pillar - Highlights
27
1S drive carried out in Zone-9 by
EHS team
Before After

28. Thank You…!