jk paper jk paper limitedlimited - iqems india...2018/12/13 · suport to jishu hozen activities...
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JK PAPER JK PAPER LIMITEDLIMITEDUnit: JK Paper Mills, Unit: JK Paper Mills, JaykaypurJaykaypur
J K PAPER …….Creating Lasting Impressions
Smart Safety-Industry Best Practices
Presenter : L M RAO
Date : 03.11.2018
ABOUT THE COMPANY
J K PAPER …….Creating Lasting Impressions Slide No. 1
Role of Leadership in Building &
Sustaining Safety Culture
J K PAPER …….Creating Lasting Impressions Slide No. 2
INDUSTRIAL REVOLUTION 4.0
J K PAPER …….Creating Lasting Impressions
Definition : The full integration of information and communication
technology and automation technology in the "factory of the future” with
traditional manufacturing processes.
Slide No. 3
CostCost ComplexityComplexity� Eliminate waste & losses
� Eliminate hidden cost
� Cost reduction
� Sub-Nano technology
� Cyber Physical System
� Exponential technologies
INDUSTRY 4.0: WHY WE NEED IT?
J K PAPER …….Creating Lasting Impressions
CustomerCustomer CompetitionCompetition
� Personalize
� Fast, Cheap, Quality
� Total Customer Satisfaction
� Digitalization
� Increase competitiveness
� Globalization
Slide No. 4
High Skilled Technical (Engineer)High Skilled Technical (Engineer)
Mid Skilled Mid Skilled
(Technician)(Technician)
CURRENTCURRENT INDUSTRY 4.0INDUSTRY 4.0
LocalLocal
F iF i
High Skilled Innovator (Engineer)High Skilled Innovator (Engineer)
Mid Skilled Mid Skilled
(Specialist)(Specialist)
Local (Existing)Local (Existing)
Local Local
INDUSTRY 4.0: WORKFORCE TRANSFORMATION
J K PAPER …….Creating Lasting Impressions
Low SkilledLow Skilled
(Operator)(Operator)
LocalLocal
ForeignForeign
ForeignForeign
Low SkilledLow Skilled
(Operator)(Operator)
RoboticsRobotics
AutomationAutomation
(Upgrade)(Upgrade)
� Industry 4.0 will eliminate our dependency on Foreign labour workforce
� Industry 4.0 will provide platform for job upgrade on existing local workforce
Slide No. 5
COMPANY POLICY
J K PAPER …….Creating Lasting Impressions Slide No. 6
SHE MANAGEMENT SYSTEM
Unhygienic
working
conditions
Incidents
Poor solid waste
disposal system
Noise Water
Lack of
Safety
Awareness
systems
SAFETY, HEALTH
& ENVIRONMENT
RELATED PROBLEMS Dust
Pollution
Concept & Objective
Back Ground
J K PAPER …….Creating Lasting Impressions
Pollution Pollution
To establish a
full proof safety management system &
its implementation
To establish a
systematic approach to
address Noise, Dust,
Discharge water, solid
waste & create pollution
free environment
To improve the
methodology of health checkup & treatment
ZERO ACCIDENT
IMPROVEMENT IN HEALTH & HYGIENE CONDITION OF
EMPLOYEESZERO POLLUTION
Concept & Objective
Slide No. 7
PROACTIVE
We work on the problems that we still find
GENERATIVE
SHE is how we do business round hereCulture LadderCulture Ladder
Successful Safety Management
REACTIVE
Safety is important, we do a lot every time we have an
J K PAPER …….Creating Lasting Impressions
CALCULATIVE
We have systems in place to manage all hazards
PATHOLOGICAL
Who cares as long as we’re not caught
accident
Slide No. 8
Technology
and standards
SHE
Management
Systems• Engineering improvements
• Behaviour
• Visible leadership / personal
accountability
• Shared purpose & belief
• Aligned performance commitment &
external view
• SHE delivers business value
Successful Successful Safety ManagementSafety Management
SHE SHE Performance over timePerformance over time
J K PAPER …….Creating Lasting Impressions
Time
Incid
ent r
ate
Improved
culture
g g p
• Hardware improvements
• Safety emphasis
• E&H Compliance
• Integrated SHE-MS
• Reporting
• Assurance
• Competence
• Risk Management
Slide No. 9
Establishing Safety System
Suport to Jishu
Hozen Activities
Safety Patrolling
Analysis of
Accidents
Training on importance of Safety during Initial
cleaning with Safety Checklist
- Preparation of Route Map
- Identification & Elimination of Hazards
- Human action related accidents
- Equipment related accidents
- Preventive Measures
- Implementation of various permit systems
- Evaluation of Safety performance through
Safety
ittINTEGRATED
Sample of Safety Checklist
Support to Jishu Hozen
SHE MANAGEMENT SYSTEM
J K PAPER …….Creating Lasting Impressions
Near Miss
Accidents
Safety Audit &
Supervision
Safety Awareness &
Training
Emergency
Preparedness &
Response
- Recording all Near Miss cases
- Analysis & Prevention
- Internal Audit & External Audit
- Supervision by Deptl.heads & Safety
stewards
- On the job Practical Training
- Shop floor Training
- Site safety instruction with OPL
- Display of Safe Operating Procedures.
- Celebrations & Competetions
- Mock Drills for Toxic release & Fire
INTEGRATED
SAFETY
ACTIVITY
Elimination Process Of the Identified Hazard
Slide No. 10
Analysis of AccidentsSafety Pyramid
INVESTIGATION
ELIMINATED
ROOT CAUSE
ANALYSIS
IMPLEMENTATION OF
COUNTER MEASURES
EVALUATION OF
INCIDENTSREOCCURRENCE
REVIEW
ACCIDENT
Accident Investigation Flow Chart
SHE MANAGEMENT SYSTEM
Reportable Accidents (Absenting
> 48 hrs)
Non-Reportable Accidents
(Absenting < 48 hrs)
First Aid Cases (Absenting < 3
hrs)
Near Miss
Cases
U/A
Kn
ow
led
ge
Ab
ility
Mo
tiva
tio
n
De
sig
n
Ma
inte
na
nce
Actio
n o
f
oth
ers
Re
active
ap
pro
ach
Pro
-a
ctive
ap
pro
ach
La
gg
ing
Ind
ica
tors
Le
ad
ing
Ind
ica
tors
U/C
J K PAPER …….Creating Lasting Impressions
Accident Status – (2017-18)
GOOD
Slide No. 11
0 0 0 0 0 0 0 0 0 0 0 00
1
2
3
4
5
APR MAY JUN JULY AUG SEP OCT NOV DEC JAN FEB MAR
No
s
MONTH
REPORTABLE ACCIDENT-2017-18
GOOD
Total-0
143 151168 167
147
197174 180 184 182
162 162
0
50
100
150
200
250
APR MAY JUN JULY AUG SEP OCT NOV DEC JAN FEB MAR
NEAR MISS CASES-2017-18GOOD
Total-2017
25 6
3 34
3 47 6 5
23
2
1 23
2 20 3
01
0
5
10
15
20
25
30
APR MAY JUN JULY AUG SEP OCT NOV DEC JAN FEB MAR
CONTRACTOR COMPANY
FIRST AID CASES-2017-18
58 8
4 57
5 67
95
3
GOOD
Total-72
K M
305
480
305
480
0
100
200
300
400
500
600
Unsafe Act Unsafe Condition
Chart Title
Identified Rectified
Capturing of Unsafe Act & Conditions-2017-18
46
551
896
401
54 72
347
46
551
896
401
54 72
347
0100200300400500600700800900
1000
Ext
.Sa
fety
Au
dit
Int.
Sa
fety
Au
dit
Se
lf S
afe
ty A
ud
it
Sp
eci
fic
Sa
fety
Au
dit
Sr.
Off
icia
l S
urp
rise
Au
dit
Sr.
Mg
mt.
Nig
htA
ud
it
Da
ily
Ob
s. B
y
Sa
fety
Off
ice
rs
No.of Observations
SAFETY AUDIT COMPLIANCE STATUS 2017-18
SAFETY PERFORMANCE FOR THE YEAR 2017-18
J K PAPER …….Creating Lasting Impressions
33 35 37 47 42 42 39 41 40 43 46 49
582
776846
952
606 596 597539
617
867948
1025
0
200
400
600
800
1000
1200
Ap
r.1
7
Ma
y.1
7
Jun
.17
Jul.
17
Au
g.1
7
Se
pt.
17
Oc
t.1
7
No
v.1
7
De
c.1
7
Jan
.18
Fe
b.1
8
Ma
r.1
8
Tr. Conducted Participants
SAFETY TRAINING (CLASS ROOM)-2017-18
Tr. Prog-494
Participants -8964
22 23 28 16 26 9 29 7 18 18 16 9 21 23 9220283 329 403 292 416
263452
184 263472
251 173385
571256
3971
0
500
1000
1500
2000
2500
3000
3500
4000
Safe
ty M
anag
em
en
t Sy
ste
m
Use
of
PP
Es
Wo
rk P
erm
it S
yste
m
Inci
de
nt R
ep
ort
ing
Syst
em
Ne
ar M
iss
Cap
turi
ng
Be
hav
iou
r B
ase
d S
afe
ty
Eme
rge
ncy
Pre
par
ed
en
ess
Pla
n
Co
nfi
ne
d S
pac
e S
afe
ty
Ch
em
ical
Saf
ety
Traf
fic
Safe
ty M
anag
em
en
t
He
igh
t W
ork
Saf
ety
Ho
t W
ork
Saf
ety
Lift
ing
Too
ls &
Tac
kle
s
Mat
eri
al H
and
ling
HIR
A
SOP
s /
SMP
s
Tr.Programme Participants
SAFETY CLASS ROOM TRAINING FOR THE YEAR 2017-18
No.of Trainings-494
No.of Particpants-8964
Slide No. 12
SAFETY PERFORMANCE FOR THE YEAR 2018-19
0 0 0 0 0 00
1
2
3
4
5
APR MAY JUN JULY AUG SEP OCT NOV DEC
No
s
Month
MONTH WISE TREND OF REPORTABLE ACCIDENT-2018-19
GOOD
0 0 0 0 0 00
1
2
3
4
5
APR MAY JUN JULY AUG SEP OCT NOV DEC
No
s
Month
MONTH WISE TREND OF NONREPORTABLE ACCIDENT-2018-19
GOOD
J K PAPER …….Creating Lasting Impressions
Company-03
Contractor-11
Total-14
GOOD Total-261Total-458
52 3 3 3
33
2 2 1 00
5
10
15
20
25
30
APR MAY JUN JULY AUG SEP OCT NOV DEC
Contractor Company
MONTH WISE TREND OF FIRST AID ACCIDENT-2018-19
8
3 5 5 4 3
GOOD
207228 234 222
177
249
0
50
100
150
200
250
300
APR MAY JUN JULY AUG SEP OCT NOV DEC
NEAR MISS CASES-2018-19
GOODTotal-1317Company-9
Contractor-19
Total-28
Slide No. 13
SHE MANAGEMENT SYSTEM
Unsafe
Condition, 22
Unsafe Act, 50
CAUSE WISE ANALYSIS OF FA-2017-18
J K PAPER …….Creating Lasting Impressions Slide No. 14
Head, 9
Trunk, 4
Upper
Limb, 32
Lower
Limb, 23
Both
(UL&LL), 2Misc, 2
Injury Wise Analysis of FA-2017-18
EMERGENCY PREPAREDNESS
EMERGENCY
ON-SITE
EMERGENCYOFF-SITE
EMERGENCY
NATURAL
HAZARDS
J K PAPER …….Creating Lasting Impressions
TOXIC
HAZARD
FIRE
HAZARD
EARTHQUAKE,
etc.
CYCLONE FLOOD
Slide No. 15
IDENTIFICATION OF MOST CREDIBLE HAZARD SCENARIO
� Identification of Hazardous Chemicals:
1. Chlorine :Toxic & Threshold Quantity
� Analysis Of Hazard:
1. Spread of Chlorine
2. Concentration
3. Distance to travel
� Mitigation Plan
1. Emergency Preparedness Plan
2. PPE
Geographical Analysis by
DGFASLI, Mumbai
The following chemicals have been
identified as hazardous chemicals used
in our mills.
Chlorine ( Cl2 )
Chlorine Dioxide ( ClO2 )
Sulphur Dioxide ( SO2 )
Caustic Soda lye ( NaOH )
Hydrogen Peroxide ( H2O2 )
Hydrochloric Acid. ( HCl )
Sulphuric Acid (H2SO4)
Out of these Chlorine (Cl2) is the most
hazardous chemical used in our mill.
EMERGENCY PREPAREDNESS
M/s Sun
Consultancy, Bhubanes
war
J K PAPER …….Creating Lasting Impressions
Activation & Closing Procedure for Toxic & Fire
Fire Training Fire Mock Drill
Emergency Training On-Site Chlorine Mock Drill
Mock Drill during the year 2017-18
Ext Int
Fire 1 123
Toxic 2 12
Hydrant Motor Pump Tr. on use of SCBA
Slide No. 16
Off-Site Chlorine Mock Drill Presentation of Emergency Plan in DCG Meeting Off-Site Emergency Plan
Steps taken to reduce the potential hazard
EMERGENCY PREPAREDNESS
J K PAPER …….Creating Lasting Impressions
A. Initially when plant started, chlorine was stored in 2 storage tanks of capacity 40 MT each.
B. After the Bhopal gas tragedy , one of the above storage tank has been isolated.
C. The storage quantity in the second tank has been reduced from 40 MT to 25 MT.
D. And later on, the potential has been further reduced by isolating both the storage tank 1&2.
E. We have again modified the unloading system by connecting 900 Kg tonners directly and being
consumed in the process.
F. We have provided 4 nos. of chlorine sensors in the Chlorine Storage Shed. If leakage occurs, it
is indicated on the control panel which is located in Incident control room / Operator room.
H. One sensor has been installed at our unloading bank to sense the chlorine leakage during
unloading.
I. One more sensor has been provided in the gasifier room to sense the leakage of chlorine.
J. 4 nos. of Chlorine sensors have been provided at Chlorine Dioxide Plant.
Slide No. 17
TABLE OF CONTENTS
SL. NO. DESCRIPTION PAGE NO.
1.0 General Information about the factory 03-07
1.1 About Organization 01-01
1.2 Company & Unit Profile 01-02
1.3 Manufacturing Process & Mill Design 02-07
1.4 Paper Making Process Flow 07-07
2.0 Product / Bi-product 08-08
2.1 Product Profile 08-08
2.2 Bi Product Profile 08-08
3.0 Identification of Hazard 09-16
3.1 Possible Causative Factor 09-09
3.2 Consequence Analysis for Hazard Scenario 09-15
4.0 Emergency Command Structure 16-16
5.0 Role of key persons 17-18
5.1 Role of Works Main Controller (WMC) 17-17
5.2 Role of Site Incident Controller (SIC) 17-17
5.3 Role of Chief Safety Co-ordinator(CSC) 17-18
5.4 Role of Combat Team 18-18
Unit: JKPM, Jaykaypur, Dist: Rayagada, Odisha -765017 EMERGENCY PLAN FOR NATURAL HAZARD- 2014- -
EMERGENCY PLAN
EMERGENCY PREPAREDNESS
J K PAPER …….Creating Lasting Impressions
5.5 Role of Rescue Team 18-18
5.6 Role of Auxiliary Team 18-18
6.0 Action plan for On-Site Emergency Plan 19-20
7.0 Silent Hour Command Structure 21-21
8.0 Activation & Closing procedure 22-22
ANNEXURE
SL. NO. DESCRIPTION PAGE NO.
1.0 Emergency Contact Numbers 24-25
1.1 Important Local Admn. Telephone Nos. 24-24
1.2 Telephone nos of Key Persons of the factory 24-25
1.3 Others Persons Telephone Nos. 25-25
2.0 Instruction Sheet 26-27
FOR NATURAL HAZARDS
JK PAPER LTD (UNIT – JKPM)
At/PO-JAYKAYPUR, DIST- RAYAGADA ODISHA – 765017
Do’s & Don’ts
Before the Cyclone season:
� Check the building; secure loose tiles and carry out repairs of doors and windows
� Remove dead branches or dying trees close to the building; anchor removable objects such as
lumber piles, loose tin sheets, loose bricks, garbage cans, sign-boards etc. which can fly in
strong winds
� Keep some wooden boards ready so that glass windows can be boarded if needed
� Demolish condemned buildings
When the Cyclone starts
� Listen to the radio (All India Radio stations give weather warnings).
� Keep monitoring the warnings. This will help you prepare for a cyclone emergency.
� Pass the information to others.
� Ignore rumours and do not spread them; this will help to avoid panic situations.
� Believe in the official information
� When a cyclone alert is on for your area continue normal working but stay alert to the radio
warnings.
� Stay alert for the next 24 hours as a cyclone alert means that the danger is within 24 hours. � Do not delay and run the risk of being marooned
� Provide strong suitable support for outside doors.
� If you do not have wooden boards handy, paste paper strips on glasses to prevent splinters.
However, this may not avoid breaking windows.
� Get extra food, which can be eaten without cooking. Store extra drinking water in suitably
covered vessels.
� Small and loose things, which can fly in strong winds, should be stored safely in a room.
� Be sure that a window and door can be opened only on the side opposite to the one facing the
wind.
� If the centre of the cyclone is passing directly over plant, there will be a lull in the wind and rain
lasting for half an hour or so. During this time do not go out; because immediately after that,
very strong winds will blow from the opposite direction.
� Switch off the electrical supply.
� Remain calm.
When Evacuation is instructed
� Head for the proper shelter or evacuation points indicated by the plant authority.
� At the shelter follow instructions of the person in charge.
� Remain in the shelter until you are informed to leave
Post-cyclone measures
� Strictly avoid any loose and dangling wires from lamp posts.
� If you have to drive, do drive carefully.
� Clear debris from the area immediately.
Do’s & Don’ts:
What to Do Before an Earthquake
� Repair deep plaster cracks in ceilings and foundations.
� Anchor overhead lighting fixtures to the ceiling.
� Follow BIS codes relevant to your area for building standards
� Fasten shelves securely to walls.
� Place large or heavy objects on lower shelves.
� Brace overhead light and fan fixtures.
� Repair defective electrical wiring and leaky gas connections. These are potential fire risks.
� Secure water heaters, LPG cylinders etc., by strapping them to the walls or bolting to the floor.
� Identify safe places indoors and outdoors.
� Know emergency telephone numbers (such as those of doctors, hospitals, the police, etc)
� Educate all
Help your community get ready
� Publish a special section in your local newspaper with emergency information on earthquakes.
Localize the information by printing the phone numbers of local emergency services offices
and hospitals.
� Conduct week-long series on locating hazards in the home.
� Work with local emergency services and officials to prepare special reports for people with
mobility impairment on what to do during an earthquake.
� Provide tips on conducting earthquake drills
� Interview representatives of the gas, electric, and water companies about shutting off utilities.
What to Do During an Earthquake
Stay as safe as possible during an earthquake. Be aware that some earthquakes are actually foreshocks and a larger earthquake might occur. Minimize your movements to a few steps that reach a nearby safe place and stay indoors until the shaking has stopped and you are sure exiting is safe.
If indoors
� DROP to the ground; take COVER by getting under a sturdy table or other piece of furniture;
and HOLD ON until the shaking stops. If there is no a table or desk near you, cover your face
and head with your arms and crouch in an inside corner of the building.
� Protect yourself by staying under the lintel of an inner door, in the corner of a room, under a
table or even under a bed.
� Stay away from glass, windows, outside doors and walls, and anything that could fall, (such as
lighting fixtures or furniture).
� Stay in bed if you are there when the earthquake strikes. Hold on and protect your head with a
pillow, unless you are under a heavy light fixture that could fall. In that case, move to the nearest
safe place.
� Use a doorway for shelter only if it is in close proximity to you and if you know it is a strongly
supported, load bearing doorway.
DO’s & DON’Ts of Cyclone DO’s & DON’Ts of Earthquake
Slide No. 18
Cl2 STORAGE SHED FRP FUNNEL SAFETY VALVE Cl2 SENSORS
INFRASTRUCTURE AVAILABLE
LIME BAG STORE
J K PAPER …….Creating Lasting Impressions
FRP HOOD
SNIFFER SYSTEM
CAUSTIC PIT
TAPPING POINT UNIVERSAL RING SYSTEMCHAIN & YOKE SYSTEM
CAUSTIC TANKWARNING SYSTEM SAFETY TIPS
PPE ROOM
Slide No. 19
Internal :
• Specific Safety Audit by Safety Officer
• Bimonthly Self Safety Audit by Department
• ISO internal Audit once in a quarter
• Six months Cross Functional Safety Audit
• Sr. Executive Plant Visit
• Sr. Executive Night Surprise Visit
External :
• Once in two years by accredited External Agency
• ISO Audit in every six month
• Annual Inspection by Asst. Director, Factories &
Boilers, Rayagada Zone
Safety Audit Safety Audit
AUDITS
J K PAPER …….Creating Lasting Impressions Slide No. 20
TRAININGS & AWARENESS
J K PAPER …….Creating Lasting Impressions Slide No. 21
SAFETY PROMOTIONAL ACTIVITIES
Road Safety Week
Observance of National Safety Day / Week
J K PAPER …….Creating Lasting Impressions
Obse a ce o at o a Sa ety ay / ee
Observance of National Disaster Prevention Day
Observance of Fire Safety Week
Observance of World Environment Day
Slide No. 22
LEVEL 7
LEVEL 6
LEVEL 5
EVE 4 TPM OE/CI ERP
TPM-CONSISTENCY AWARD
TPM COMMITMENT AWARD
OHSAS: 18001
TPM SPECIAL AWARD
GROWTH PLAN
J K PAPER …….Creating Lasting Impressions
LEVEL 4
LEVEL 3
LEVEL 2
LEVEL 1
1980-1985 1986-1990 1991-1995 1996-2000 2001-2005 2006-2010 2011-2020
QUALITY CIRCLE
ISO 14001 ENVIRONMENT SYSTEM
TPM, OE/CI, ERP
SUGGESTION SCHEMES
ISO 9001 QUALITY SYSTEM
Slide No. 23
TPM ORGANISATION
Mr.Biswajeet DwivediMr. Biswajit Deb
Chairman : Mr. PK Suri
Labour Union
Mr. L.M. RaoMr. A. Tripathy
Mr. G.V. Joga RaoMr Ch. V. Ramana
TPM APEX COMMITTEE
TPM Secretariat
1 Kobetsu KaizenP
SUB COMMITTEES
J K PAPER …….Creating Lasting Impressions
Pulp Mill, Paper
Machines, Recovery
ElectricalMechanica
lInstrumentation
Boilers, Turbines,
Water Supply
Purchase, Sales,
Stores, Accounts
28 4 11 56
Personnel, HRD,
Welfare
Total TPM Circles (54)
HeadManufacturing
HeadMaintenance
HeadCommercial
HeadUtilities
HeadPersonnel &
Admn. 2 Jishu HozenMr. CSR Appa Rao
3 Planned MaintenanceMr. MRKM Rao
4 Quality MaintenanceMr. GS patnaik
5 Initial Flow ControlMr. P. Suryanarayana
6 Education & TrainingMr. Dibyendu Basu.
7 Office ImprovementMr. Biswajit Dwivedi
8 Safety, Health & EnvironmentMr. S. Mohanty
9 LogisticsMr. S Gaikwad
1 Kobetsu KaizenMr. AK Mishra
PR
OCESS
INNO
VATION
Total TPM Circles consists of 1481 Members 10 New Product DevelopmentMr. Susants Nayak
Slide No. 24
Relationship between KMI, Policies, KPI & KAIKMI BACKGROUND & CHALLENGES POLICY PILLAR POLICY KPI KAI IMPROVEMENT GRAPHS
1. SPEED LOSS
2. PLANNED SHUT LOSS
3. MANAGEMENT LOSS
4. EQUIPMENT FAILURE LOSS
5. DEFECT FILURE LOSS
6. YIELD LOSS
7. CHEMICAL CONSUMPTION LOSS
8. ENERGY LOSS
9. INVENTORY LOSS
1. WHY-WHY ANALYSIS
2. PM ANALYSIS
3. BOTTLENECK ANALYSIS
4. COUNTER MEASURES
5. KAIZEN REGISTRATION
6. KAIZEN IMPLEMENTATION
1. REDUCTION IN C,L,I & T TIME
2. KAIZENS RELATED TO SOURCES OF CONTAMINATION
3. KAIZENS RELATED TO INACCESSIBLE AREA
4. MINOR STOPPAGES
5. BREAKDOWN DUE TO BAD OPERATION
6. BREAKDOWN DUE TO DETERIORATION OF BASIC CONDITION
7. BREAKDOWN ATTENDED BY JISHU HOZEN
8. OME POINT LESSONS
1. WHITE TAGS
2. RED TAGS
3. KAIZEN SHEETS
4. OPL SHEETS
5. WHY-WHY
6. TRAINING
1. A RANK EQUIPMENTS MAJOR FAILURE
2. A RANK EQUIPMENTS MEDIUM FAILURE
3. A RANK EQUIPMENTS MINOR FAILURE
4. A RANK EQUIPMENTS TOTAL FAILURE
5. TOTAL FAILURE HOURS( A RANK)
6. MTBF
7. MTTR
8. MAINTENANCE COST
9. LUBRICATION COST
1. WHY/ WHY
2. COUNTER MEASURES
3. TBM COMPLIANCE
4. CBM COMPLIANCE
5. CORRECTIVE MAINTENANCE
6. MP SHEETS
7. KAIZENS
8. OPL's
9. TRAINING
1. CUSTOMER COMPLAINT
2. IN-PROCESS REJECTION
3. RE-WORK LOSS
1. 4M CONDITION COMPLAINCE
2. WHY-WHY ANALYSIS
3. COUNTER MEASURE
4. OPLS
4. TRAININGS
5. KAIZENS
6. 4M CONDITION REVISED
7. VISUAL CONTROL
8. POKE-YOKE
RELATIONSHIP BETWEEN KMI POLICIES,KPI AND KAI
MACHINE
STRENGTH:
1.QUALITY & TECHNOLOGY
2.GOOD CONFIGURTION
3.SUITABLE TO CERTAIN QUALITY OF PAPER
WEAKNESS:
1.SPACE OCCUPANCY OF MACHINE
2.MANPOWER OPERATIG IS NOT SKILLED
3.SLOW SPEED & AGED MACHINE
OPPORTUNITY:
1.LOW COST LABOR
2.GSM VARIATION IS HIGH
3.WIDE RANGE OF PAPER
THREATS:
1.ENVIRONMENT REGULATION
2.HUMAN INJURIES
3 WATER AVAILABILITY IS LOW
MAN
STRENGTH:
1.OPERATIONAL EFFICIENCY
2.DISTRIBUTION NETWORK
WEAKNESS:
1.RAW MATERIAL
OPPORTUNITY:
1.AVAILABILITY OF TRAINED MANPOWER
THREATS:
1.RAW MATERIAL & COST
VISION
(KMI)
TO BE
DYNAMIC
BENCHMAR
K LEADER IN
INDIAN
PAPER
INDUSTRY
TPM POLICY
In our continuous pursuit for organizational excellence we are
committed to:
1. Customer delight by providing world class product &
services
2.Be a dynamic benchmark and leader in pulp & paper
industry through process innovation in the entire business
chain.
3.Develop pride for all stake holders including society around.
4.Build a culture of intellectual honesty and professional
integrity
TPM POLICY
In our continuous pursuit for organizational excellence we are
committed to:
1. Customer delight by providing world class product & services
2.Be a dynamic benchmark and leader in pulp & paper industry
through process innovation in the entire business chain.
3.Develop pride for all stake holders including society around.
4.Build a culture of intellectual honesty and professional
integrity
TPM POLICY
In our continuous pursuit for organizational excellence we are
committed to:
1. Customer delight by providing world class product &
services
2.Be a dynamic benchmark and leader in pulp & paper
industry through process innovation in the entire business
chain.
3.Develop pride for all stake holders including society around.
4.Build a culture of intellectual honesty and professional
integrity
TPM POLICY
In our continuous pursuit for organizational excellence we are
committed to:
1. Customer delight by providing world class product &
services
2.Be a dynamic benchmark and leader in pulp & paper
industry through process innovation in the entire business
chain.
3.Develop pride for all stake holders including society around.
4.Build a culture of intellectual honesty and professional
integrity
TPM POLICY
In our continuous
pursuit for
organizational
excellence we are
committed to:
1. Customer delight
by providing world
class product &
services
2.Be a dynamic
benchmark and
leader in pulp &
paper industry
through process
innovation in the
entire business chain.
3.Develop pride for
all stake holders
including society
around.
4.Build a culture of
intellectual honesty
and professional
integrity
QUALITY POLICY
"To provide customer
delight- both internal
land external through
our products and
services at lowest
cost by continuous
improvement in
processes,
productivity, quality
and management
systems"
QEHS POLICY
We manufacture and
supply Pulp Paper
KK POLICY
AIMING TO MAXIMIZE THE OVERALL
EFECTIVENESS OF EQUIPMENT & PROCESS
THROUGH LOSS & COST MINIMIZATION
THROUGH KAIZENS & IMPROVING OEE
JH POLICY
TO PREVENT EQUIPMENT DETERIORATION BY
MAINTAINING SET OPERATING CONDITION
PM POLICY
TO FOCUS ON MTBF & MTTR AND THEREBY
IMPROVING EFFICIENCY OF MAINTENANCE
SYSYTEM AND REDUCTION OF MAINTENANCE
COST
QM POLICY
TO ACHIEVE REDUCTION IN CUSTOMER
COMPLAINT BY ENSURING QUALITY AT THE
VERYBEGINNING OF PRODUCTION PROCESS
KMI, POLICIES, KPI & KAI
J K PAPER …….Creating Lasting Impressions
1. NEW EQUIPMENT
2. NEW PROCESS
3. NEW PROCEDURE
4. INNOVATION
5. NEW PROJECT DEVELOPMENT
6. NO. OF INITIAL FLOW DEVELOPMENT
7. NO. OF TRAINING TO OPERATOR OF NEW PLANT
8. LOW COST AUTOMATON
1. MP SHEETS
1. TRAINING MANDAYS
2. SKILL UPGRADATION
3. SUGGESTIONS / KAIZENS
4. MULTISKILLING
5. COMPETENCY DEVELOPMENT OF EXECUTIVES
1. NO. OF TRAINING
2. SKILL ENHANCEMENT
3. SAFETY & HEALTH TRAINING
4. NO. OF KAIZENS / SUGGESTIONS
5. REWRD & RECOGNITION
1. ADMINISTRATION COST REDUCTION
2. INVENTORY CARRYING COST
3. INTERNAL LEAD TIME (PR TO PO CONVERSION COST)
4. ON-TIME DELIVERY
5. SAVING IN BOUGHT OUT
6. LABOUR PRODUCTIVITY (PER TON OF PAPER)
1. WHY-WHY ANALYSIS
2. COUNTER MEASURES
3. KAIZENS
4. JOB STANDARDIZATION
5. SYSTEM IMPROVEMENT
6. VENDOR DEVELOPMENT
7. ALTERNATE RESOURCE
1.REPORTABLE INCIDENTS
2.NON-REPORTABLE INCIENTS
3.FIRST AID INCIDENTS
4.NEAR MISS INCIDENTS
5.OCCUPATIONAL HEALTHCHECKUPS FOR EMPLOYEES
6.REDUCTION IN USAGE FOR OF EAR-PLUG IN NOISE PRONE AREA
7.REDUCTION IN USAGE FOR OF NOSE-MASK IN NOISE PRONE AREA
8.REDUCTION OF BIOCHEMICAL OXYGEN DEMAND (BOD) IN DISCHARGED EFFLUENT
9.REUCTION OF SUSPENDED SOLIDS
10.USE OF TREATED DOMESTIC EFFLUENT
11.USE OF TREATED EFFLUENT
1. WHY-WHY ANALYSIS
2. COUNTER MEASURES
3. KAIZENS & OPLs
4. STANDARDIZATION
5. LOW COST AUTOMATION
6. IMPROVEMENTS
7. RESOURCE CONSERVATION
1. PROCUREMENT LOGISTIC COST
2. INTERNAL LOGISTIC COST
3. SALES INTERNAL LOGISTIC COST
4. SALES OUTBOUND LOGISTIC COST
1. WHY-WHY ANALYSIS
2. COUNTER MEASURES
3. KAIZENS & OPLs
4. LOW COST AUTOMATION
5. IMPROVEMENTS
COMPETITION
STRENGTH:
1.BRAND
2.PRICE LEADERSHIP
WEAKNESS:
1.GROWTH
OPPORTUNITY:
1.HIGH GROWTH OF MARKET SEGMENT
2.LIMITED PRESENCE OF ORGANISED PLAYER IN
HIGH PAPER VALUE
THREATS:
1.POSSIBLE ENTRY OF MNCs
2.INCREASING COMPETITION FROM NON-
INTEGRATED PRODUCTS
SUPPLIER
STRENGTH:
1.LOCATION OF SUPPLIER
2.MARKET SHARE IN BRANDED PAPER
WEAKNESS:
1.FIXED COST
2.JKPM LOCATION
OPPORTUNITY:
1.LARGE MARKET IN WESTERN MARKET
2.HIGH DEMAND OF PACKAGING BRAND(ITC
DOMINANT)
THREATS
1.FALLING IMPORT TARRIF
3.WATER AVAILABILITY IS LOW
TO BE
DYNAMIC
BENCHMARK
LEADER
IN INDIAN
PAPER
INDUSTRY
TPM POLICY
In our continuous pursuit for organizational excellence we are
committed to:
1. Customer delight by providing world class product & services
2.Be a dynamic benchmark and leader in pulp & paper industry
through process innovation in the entire business chain.
3.Develop pride for all stake holders including society around.
4.Build a culture of intellectual honesty and professional integrity
TPM POLICY
In our continuous pursuit for organizational excellence we are
committed to:
1. Customer delight by providing world class product & services
2.Be a dynamic benchmark and leader in pulp & paper industry
through process innovation in the entire business chain.
3.Develop pride for all stake holders including society around.
4.Build a culture of intellectual honesty and professional integrity
TPM POLICY
In our continuous pursuit for organizational excellence we are
committed to:
1. Customer delight by providing world class product &
services
2.Be a dynamic benchmark and leader in pulp & paper
industry through process innovation in the entire business
chain.
3.Develop pride for all stake holders including society around.
4.Build a culture of intellectual honesty and professional
integrity
TPM POLICY
In our continuous pursuit for organizational excellence we are
committed to:
1. Customer delight by providing world class product &
services
2.Be a dynamic benchmark and leader in pulp & paper
industry through process innovation in the entire business
chain.
3.Develop pride for all stake holders including society around.
4.Build a culture of intellectual honesty and professional
integrity
TPM POLICY
In our continuous pursuit for organizational excellence we are
committed to:
1. Customer delight by providing world class product &
services
2.Be a dynamic benchmark and leader in pulp & paper
industry through process innovation in the entire business
chain.
3.Develop pride for all stake holders including society around.
4.Build a culture of intellectual honesty and professional
integrity
supply Pulp, Paper
and Paper Board for
Photocopying,
Printing and Writing
applications.
At JK Paper Limited,
Unit : JK Paper Mills,
we are committed to
adding value for our
stake holders and
achieve sustainable
growth through :
1.Manufacture and
supply of consistent
quality products
complying with
customer’s
requirements,
2.Protection of the
environment
including prevention
of pollution,
3.Prevention of
human injury and ill
health,
4.Ensuring fulfillment
of compliance
obligations
5.Complying with the
requirements of
applicable
management system
standards and
integrating them with
our Business
Strategies,
6.Continual
improvement of
Quality,
Environmental and
Occupational Health
& Safety
Management systems
and their
performance,
7.Adoption of
cleaner technologies,
processes and
resource conservation
8.Afforestation
through social and
farm forestry by
clonal technology,
This Policy is
communicated within
our organization and
is made available to
the relevant
interested parties, as
appropriate.
IFC POLICY
AIMIMG DEVELOPMENT AND MAINTAINING
OF HIGH EFFICIENT EQUIPMENT AND
FOCUSSING ON RELIABILITY OF EXISTING
EQUIPMENT
E&T POLICY
TO DEVELOP INDIVIDUAL SKILL THROUGH
FOCUSSED TRAINING PROGRAMS TO IMPROVE
COMPANY'S BUSINESS RESULT AND MORALE
OF THE WORKFORCE
OTPM POLICY
AIM TO ELIMINATE LOSSES IN OFFICE BY
IMPROVING OFFICE FUNCTIONAL EFFICIENCY &
SUPPORTING PRODUCTION DEPT.
SHE POLICY
TO WORK IN A SAFE, POLLUTION FREE &
CLEAN ENVIRONMENT WITH ZERO ACCIDENT
LOGISTIC POLICY
TO REDUCE THE COST ASSOCIATED WITH
PROCUREMENT BOTH INTERNAL LOGISTIC
COST & SALES LOGISTIC COST
Slide No. 25
KMI / KPI / KAI Improvement Sheet
KMI, KPI & KAI
J K PAPER …….Creating Lasting Impressions Slide No. 26
JK
PM
NE
W P
RO
DU
CT
ION
SY
ST
EM
(NP
S)
Co
ntin
uo
us
Op
era
ting
Pla
nt
Custo
me
r
De
light P
lant
No
Sto
ck
Pla
nt
Fix
ed
Co
st
Pla
nned
Shutd
ow
n
Varia
ble
Co
st
Ze
ro In
terru
-
ptio
n P
lant
Cu
sto
me
r
Sa
tisfa
ctio
n
Em
plo
ye
e
Sa
tisfa
ctio
n
Lo
we
st C
ost
Pla
nt
Lea
d
Tim
e
Raw
mate
rial
Cost
Pow
er &
Fuel
Cost
Chem
ical
Cost
Logis
tic
Cost
No
Sto
ppage
No
Tro
uble
Sm
all L
ot
Pro
ductio
n
Inte
gra
ted
Lin
eIn
vento
ry
JK
PM
NE
W P
RO
DU
CT
ION
SY
ST
EM
IMA
GE
TR
EE
Man
Pow
er
Cost
Over-
heads
Cost
No. o
f
Shutd
ow
n
Dura
tion
Per
Shutd
ow
n
Cost P
er
Shutd
ow
n
mprovement
Raw Material
ntation
e Chemical
iciency
nate Fuel
n of linkage coal
te purchase
t feeding
mode of despatch
abour productivity
sourcing
und Management
g of S/D jobs
fe enhancement
ce planning
in tools & tackles
cal path method
ous Spares
sourcing
breakdown
adjustment
ess stoppage
nor stoppage
Speed loss
ect rate
Adjustment
t piece
ocess in tandem
lenecking
Crew Multiskilling
Material
WIP
ed Goods
ew Products
roved Products
Customer
me delivery
Maintenance
New
Pro
duct
Serv
ices
So
cia
l
Sa
tisfa
ctio
n
Glo
ba
l
Sa
tisfa
ctio
n
& Development
e Infrastructure
er Consumption
Discharge to River
Sequestration
er Harvesting
J K P
APER
…….C
reating L
asting Im
pression
s
LO
WC
OS
TP
LA
NT
CO
NT
INU
OU
S
OP
ER
AT
ING
PLA
NT
NO
ST
OC
K P
LA
NT
CU
ST
OM
ER
DE
LIG
HT
PLA
NT
•L
ow
co
st a
uto
ma
tion
•R
eso
urc
es c
on
se
rva
tion
•W
aste
utiliz
atio
n
•E
limin
atio
n o
f Mu
ltiple
ha
nd
ling a
ctiv
ities
•L
oss e
limin
atio
n
•Z
ero
de
fect
•E
limin
atio
n o
f Bre
ak
do
wn
•R
ed
uce
d p
lan
t sh
ut
do
wn
s
•M
ain
tain
ed e
quip
ment
ba
sic
co
nd
ition
•E
ffectiv
e p
lan
ne
d
ma
inte
nan
ce
•R
ed
uctio
n in
inve
nto
ry
leve
l
•E
nh
ancin
g O
PE
to
red
uce
WIP
•F
IFO
an
d ju
st in
time
follo
we
d
•W
ork
ing o
n firs
t pie
ce
righ
t pie
ce
.
•Z
ero
incid
en
t
•S
afe
ty b
ud
die
s
Slid
e N
o. 2
7
Yield Im
Alternate R
Plan
Alternate
Effic
Alterna
Maximization
Proximat
Direct
Alternative mo
Increase in lab
Outso
Innovative Fu
Clubbing
Equipment lif
Advance
Improvement i
Use of critica
Indigeno
Outso
Zero br
Setup & a
Zero proce
Zero mino
Zero Sp
Defe
Setup & A
First
Bring the proc
Debottl
Operational Cr
Raw M
W
Finishe
No. of Ne
No. of Impro
Visit to
On Tim
Chance M
Training &
Work Place
Fresh Water
Treated Effluent D
Carbon Se
Rain Wate
JK PAPER MILLS :: RAYAGADA
SAFETY IMPROVEMENT DEPARTMENTWISE For the Year 2017-18
Sl No. Department No. of ImprovementsHierarchy of Control hazard
Elimination Substitution Engineering Administrative PPE
1 PM1-5 11 5 0 6 0 0
2 PM#6 11 2 1 8 0 0
3 Pulp Mill 36 8 7 18 0 3
4 Power Block 15 0 0 15 0 0
5 R 18 8 0 7 1 2
IMPROVEMENTS
J K PAPER …….Creating Lasting Impressions
5 Recovery 18 8 0 7 1 2
6 FH Old 8 0 0 6 2 0
7 FH#6 20 6 10 4 0 0
8 Quality 9 2 1 4 1 1
9 Sales 8 1 0 1 6 0
10 Stores 10 1 0 6 2 1
11 Environment 38 0 0 38 0 0
12 Instrument 11 0 3 8 0 0
13 Civil 4 0 1 1 0 2
14 Electrical 37 20 3 12 1 1
15 Mech.Workshop 4 0 0 4 0 0
240 53 26 138 13 10
Slide No. 28
IMPROVEMENTS
Auto ignition system for HCl
synthesis
Installed a bag filter at limekiln to
localize lime dust Dust collecting through vacuum
unit at pet coke storage area
J K PAPER …….Creating Lasting Impressions
Provided sprinkler system at
coal yardInstallation of heat exchanger to
prevent emission HCl fumes
Pneumatic break provided to stop
free rotation of roller
Slide No. 29
Activity KK JH QM PM SHE OTPM IC ET
*
Result Area P Q C D S M
1
(illustration with sketch) (illustration with sketch) 2
3
4
Benefits:
KAIZEN IDEA - SHEET
S
Plant : FINISHING HOUSE PM 6 Machine: SHEETER
Theme:- LIFTING TABLE AREA FOUND MORE GAP
ACCIDENT MAY HAPPENED Idea: SUPPORTING PLATE MAKE AT LIFTING TABLE AREA
Problem / Present status Countermeasure: Benchmark ZERO BREAK DOWN
(in words) Target 30.04.2017
LIFTING TABLE HAVE MORE GAP GAP SHOULD BE COVERED OR SUPPORTED
BY PLATE
Kaizen start 15.04.2017
Kaizen finish 15.05.2017
Team members
BINOD PATTNAIK
DILLIP KUMAR
SANTOSH PRADHAN
TAPAN KU DAS
AFTER PROVIDING THE SUPPORT THE PLATE AT LIFTING
TABLE ACCIDENT NOT HAPPING & MACHINE WILL BE
SAFE
JKPM-TPM
Activity KK JH QM PM SHE OTPM IC ET
Result Area P Q C D S M
1
2
3
4
5
KAIZEN IDEA - SHEET
Plant : FINISHING HOUSE PM 6 Machine: KICKER MACHINE
Theme:- KICKER HUTTER NOT AVAILABLE Idea: - HUTTER TO BE PROVIDED
Problem / Present statusCountermeasure:
Benchmark ZERO BREAK DOWN
(in words) Target 25.03.2017
REEL ASRS KICKER HUTTER NOT
AVAILABLE
HUTTER TO BE PROVIDED AT REEL ASRS
KICKER
Kaizen start 18.02.2017
Kaizen finish 25.03.2017
Team members
TAPAN KUMAR DAS
(illustration with sketch) (illustration with sketch) BISWAJIT DAS
SANTOSH PRADHAN
BINOD PATTNAIK
BISWAJIT PRADHAN
Benefits:
JKPM-TPM
Activity KK JH QM PM SHE OTPM IC ET
Result Area P Q C D S M
1
(illustration with sketch) 2
3
4
KAIZEN IDEA - SHEET
Plant : FINISHING HOUSE PM 6 Machine: PALLETIZER SECTION
Theme:- PROFILE CHECK ERROR BY THE MAZDOOR AT
PALLETIZER SECTION .Idea: COMPACTER TYPE MACHINE TO BE INSTAL AT CONVEYOR NO 5102 & 5103
Problem / Present statusCountermeasure:
Benchmark
(in words) Target 01.11.2017
MAN POWER USING FOR CORRECT THE
PROFILE CHECK ERROR .
MAN POWER REDUCE BY USING
COMPACTOR .
Kaizen start 10.09.2017
Kaizen finish 01.11.2017
Team members
SATISH BELE
(illustration with sketch) DILIP BEHERA
KEDAR NATH MAHARANA
SANTOSH PRADHAN
JKPM-TPM
SAFETY IMPROVEMENT KAIZENS
Activity KK JH QM PM SHE OTPM IC ET
Result Area P Q C D S M
Problem / Present status: Countermeasure:
Abhishek Tiwari, Sourav Banerjee, Manoranjan Sahu
Team members:
(lllustration with sketch)
it becomes difficult to control the HCl fume arranged Kaizen start 23.08.2017
emissions Kaizen finish 25.08.2017
Kaizen Theme:
Provision of water spraying arrangement at the top of HCl filters
for safety during any leakage at HCl filter area.
Idea:
Provide a spray shower with DM water supply
Benchmark
During sudden leakages of HCl filter Emergency spray shower system to be Target
KAIZEN IDEA - SHEETJH
S
Plant : ClO2 Plant Machine: HCl filter
JKPM-TPM
Activity KK JH QM PM SHE OTPM IC ET
Result Area P Q C D S MKAIZEN IDEA - SHEET
SAFETY
Plant : FINISHING HOUSE PM 6 Machine: SHEETER
Theme: -SHEETER IDLER ROLLER MOVING FREELY Idea: BRAKE ARRANGEMENT FOR THE IDLER ROLLER FOR STOPPING WHENEVER
THE PAPER BREAKS AT SHEETER.
Problem / Present status Countermeasure: Benchmark ZERO ACCIDENT
(in words) Target 25.05.2018
WHILE PAPER THREADING IN
BETWEEN THE WEB GUIDE ROLLER
Kaizen start 17.05.2018
Kaizen finish 25.05.2018
JKPM-TPM
J K PAPER …….Creating Lasting Impressions
Analysis: Results:
(Why-why analysis) (illustration with sketch)
Sl
No
M/c
NoStatus
SAFE
LIFTING TABLE HAVE MORE GAP AFTER PROVIDING THE SUPPORT THE
PLATE AT LIFTING TABLE ACCIDENT NOT
HAPPING & MACHINE WILL BE SAFE
1 WHY - ACCIDENT WILL BE
HAPPENED
2 WHY - THERE IS MORE GAP IN
LIFTING TABLE
3 WHY - THERE IS NO SUPPORTING
PLATE
Scope & Plan for Horizontal Deployment
Target
dateResponsibility
0
0.5
1
APR-17 MAY-17 JUNE-17 JULY-17 AUG-17
ACCIDENT
Sl
No
M/c
NoStatus
THERE IS NO CHANCE TO ACCIDENT AT REEL ASRS
KICKER .
Analysis: Results:
WHILE THE REEL KICK FROM KICKER AT
THAT TIEM THERE IS NO ALERT . IT CAN
BE AN ACCIDENT .
THERE IS NO CHANCE TO ACCIDENT AT
REEL ASRS KICKER .
(Why-why analysis) (illustration with sketch)
1 WHY - KICKER HUTTER NOT AVAILABLE
2 WHY - HUTTER TO BE PROVIDED .
3 WHY -
Scope & Plan for Horizontal Deployment
Target
dateResponsibility
0
0.5
1
1.5
APR-17 MAY-17 JUNE-17 JULY-17 AUG-17
NEAR MISS
5
Analysis: Results:
(Why-why analysis) (illustration with sketch)
Sl
No
M/c
NoStatus
AJIT JAIN
Benefits:
AFTER INSTALATION OF COMPACTOR ONE MAN POWER
REDUCE FROM PALLETIZER SECTION .WHEN THE PALLET ERROR AT
PALLETIZER SECTION AT THE TIME ONE
MAZDOOR USING FOR CLEAR THE ERRO
R.
Complete
ONE MAN POWER REDUCE FROM
PALLETIZER SECTION AFTER INSTALATION
OF COMPACTOR .
1 WHY - THE PROFILE CHECK ERROR IN
PALLETIZER SECTION
2 WHY - COMPACTOR NOT AVAILABLE
3 WHY -
Scope & Plan for Horizontal Deployment
Target
dateResponsibility
12.11.17
1. SATISH BELE
2. AJIT JAIN
3. KEDAR NATH MAHARANA
4. SANTOSH PRADAN
5. DILLIP BEHERA
Slide No. 30
Benefits:
Analysis: Results:
Sl
No
M/c
NoStatus
31.08.17 Abhishek Tiwari
Scope & Plan for Horizontal Deployment
Target
dateResponsibility
( )
1) Hazardous free environement
2) No leakage of HCl.
1 1
Emission effect towards surrounding reduced, So
number of safety incidents reduced.
3) No production stoppage
3
00
0.5
1
1.5
2
2.5
3
3.5
Before After
No. Of Near miss incidents
More emmision of Hazardous
HCl fumes
Leakage from Hcl filter
Damage from filter body and
cover due to excess heat as it is
exposed to sun.
Why
Why
1
2
3
4
5
Sl
No
M/c
NoStatus
AT SHEETER SECTION,ACCIDENT MAY
HAPPENED (HAND MAY CONTACT
WITH THE IDLER ROLLER.
BRAKE SYSTEM TO BE PROVIDED Kaizen finish 25.05.2018
Team members
SANTOSH RAO
(illustration with sketch) (illustration with sketch) ANAND RIWARI
Benefits:
AFTER PROVIDE THE BRAKING SYSTEM AT IDLLER
ROLLER THE ROLLER STOPS DURING PAPER BREAK AT
SHEETER.ACCIDENT ELEMINATED.
Analysis: Results:
THERE IS NO BRAKING SYSTEM TO
STOP THE IDLLER ROLLER.
AFTER PAPER BREAK THE BRAKE ACTIVED
& STOP THE ROLLER & THE OPERATOR
CAN PASS THE PAPER EASYLY.
(Why-why analysis) (illustration with sketch)
ANKIT KUMAR
BINOD PATTNAIK
SANTOSH PRADHAN
1 WHY - SHEETER IDLLER ROLLER
MOVING FREELY.
2 WHY - IDLLER ROLLER MOVEMENT
IS FREE
3 WHY - THERE IS NO SAFETY COVER
& STOPPER .
4 WHY - BRAKING SYSTEM NOT
Scope & Plan for Horizontal Deployment
Target
dateResponsibility
2
SHE
ETE
R
LINE
1
25.07.2018
1. SARIF (MECH)
2. ANKIT (MECH)
3. ANAND TOWARI (MECH)
4. BINOD PATTNAIK(PROCES)
PENDING
1
0 0 00
0.5
1
1.5
MAY-18 JUNE-18 JULY-18 AUG-18
ACCIDENT
Focus Area-Yard Department
SAFETY IMPROVEMENTS AT YARD
MECHANIZATION OF WOOD HANDLING STACKING AREA
4
5
REPORTABLE ACCIDENT
GOOD
4
5
NON REPORTABLE ACCIDENT
GOOD
J K PAPER …….Creating Lasting Impressions Slide No. 31
0 0 00
1
2
3
2016-17 2017-18 2018-19(Up to Sept.)
No
s
Year
0 0 00
1
2
3
2016-17 2017-18 2018-19(Up to Sept.)
No
s
Year
241
298
156
0
50
100
150
200
250
300
350
2016-17 2017-18 2018-19(Up to Sept.)
No
s
Year
NEAR MISS CASES
GOOD26
9
00
5
10
15
20
25
30
2016-17 2017-18 2018-19(Up to Sept.)
No
s
Year
FIRTST AID CASES
GOOD
Speed LimitSeparate Entry & Exit Road for vehicles
ROAD SAFETY
Convex mirrors at blind
corners
J K PAPER …….Creating Lasting Impressions
Designated Truck Parking Area Separate safe path provided for pedestrianTemporary gate provided at rly crossing
area
Slide No. 32
• We have prepared on-site emergency plan for toxic release and fire & explosions.Periodically as per scheduled mock drills (dry & wet) are conducted. Gaps & lapsesobserved during the drills are noted and rectified.
• All Near miss incidents are captured; analyzed and suitable corrective & preventivemeasures are taken.
• Daily Safety pledge by all employees is carried out in all the departments at the beginningof all shifts (A,B,C,& General)
• At J K Paper Mills, National Safety Day/Week, Fire Safety Week, Environment Day,
Odisha Disaster Preparedness Day and National Day for Disaster reduction &Chemical Disaster Prevention Day are celebrated in the mills by good gathering .Safetypromotional activity like Quiz, Essay, Slogan, Posters, Skit & etc. competitions wereconducted and suitably recognized & rewarded.
• Inside the mills safety slogans, cautions boards, signs boards, assembly points andambulance points are identified and displayed.
• All lifting tools, lifting machines, and pressure vessels are tested and inspected as perFactories Act and Orissa Rules.
• Continuous training on different best safety practices (List of various training programmesenclosed in the Annexure-II)
• Noise levels and Dust emission levels are measured in all the areas of the mills. Suitablekaizen themes are generated and implemented on continual basis to reduce minimumpossible.
• All best possible measures are taken to eliminate heat, humidity, fumes, etc in ordercreate a safe work environment.
• We have 10 nos. of training centers to educate all the employees in order to improve skill,knowledge, and positive attitude towards improvement of safety.
• We are generating operational related standards to eliminate minor injuries in materialhandling areas.
• Health check up for all the employees are conducted and treated if any abnormality foundwith the employees health.
• Occupational health check ups were conducted by external specialist and suitablemeasures are taken.
• We also carry out best safety practices in Fire safety, Electrical safety, Chemical safety,and etc.
• In addition to all above activities we have started implementation of focused safetymanagement in all the departments, in order to involve all the employees in the safetyactivities to eliminate incidents.
Environment, Occupational Safety & Health Profile
JK PAPER MILLS with its dedicated efforts and strong commitment has been continuously improving its performance in the areas of Safety, Health and Environment. The systems and practices introduced by the Mill have led to its being the first In Indian paper mill to receive ISO 14001 Environment Management Certification in 1998 and the „Greenest Paper Mill‟ Award of CSE in 1999 and Top 2 Paper Mills for getting 3-leaves award from CSE, New Delhi in 2004. 2nd Best Pollution Control Excellence Award for implementing effective Pollution Control Measures and adopting good environmental management practices during 2004 by Orissa Pollution Control Board, Bhubaneswar. JK Paper Mills has won numerous National and International Awards for Safety and Occupational Health
J K PAPER MILLS JAYKAYPUR
“BEST SAFETY PRACTICES AT OPERATING PLANT”
J K Paper Mills is an ISO-9001(2008); ISO-14001(2004) and OHSAS-18001(2007) certifiedcompany and all the system procedures were implemented as an integrated management systemto improve the performance in the areas of Safety, Health and Environment & Quality. JKPM hasestablished a Best Safety Management System and followed strictly.
Best Safety Management System at JKPM: • All Statutory and legal requirements are complied.
• All accidents / incidents are investigated, analyzed and suitable corrective & preventivemeasures taken.
• Preparation of Incident analysis for every first aid cases in power point mode consisting ofthe following slides and organizing sharing sessions to employees of the other areas toincrease the awareness :
� Incident details � What happened? � What went wrong? � Prevention of reoccurrence.
• Job safety analysis is carried out for each critical activity.
• Hazard Identification and Risk Assessment is carried out and reviewed periodically.
• Work permit system (Height work, Hot work, Confined space, Excavation, EquipmentIsolation, etc.) is strictly followed.
• We have four safety committees as following : � Central safety co-ordination committee(monthly), � Departmental safety committees(monthly), � Safety Steward Committee(Six month) and � Contractors Safety Committee (six months).
All the observations made during the period are reviewed in the above committeemeetings and action plan are made by the concern for implementation.
• All the safety related matters are reviewed in our daily morning departmental meetings.
• Audits both (internal and external) are carried out and observations made are rectified.
• We carry out theme based patrolling with the help of a route map by different levels: - Shop floor supervisor and workmen daily during Jishu Hozen activity - Safety officer daily - Safety steward weekly - Cross functional teams monthly - Head of the departments monthly All the observation made during the patrolling are analyzed and eliminated bygenerating suitable kaizens and one point lessons.
• JKPM has enforced without helmet and shoes employees are not allowed into the Factory.
• JKPM has identified all relevant PPE’s required by employees were identified, distributedand ensured by monitoring frequently and also periodically, safety officer checks the PPE’sregister and its use.
• Standard operating procedures and safe maintenance procedures are generated andfollowed. And all the SOP’s are displayed near the equipments.
B t S f t P ti F d S f t M t S t
Day Time Programme Venue Resource Person
03-06-2017 8:00 AM Inagural ceremoney Store Office Department In-charge
03-06-2017 4.00 PM Safety Awareness Training Mecha.(Work Shop) SafetyDept.
06-06-2017 4.00PM Material Handling Mecha.(Work Shop) Mr.T.R. Rathor
10-06-2017 4.00 PM
Work Instruction/SOP trng.for loading unloding of CL2
cylinders. Mecha.(Work Shop) Mr.N.Panda
10-06-2017 4.00 PM training on hazarious chemical Mecha.(Work Shop) SafetyDept.
13-06-2017 4.00 PM
Work Instruction/SOP trng.for loading unloding of Sulphate
bags. Mecha.(Work Shop) Mr.Ramesh Kumar.
17-06-2017 4:00 PM Eargonomics Mecha.(Work Shop) Safety Dept.
17-06-2017 4.00 PM Work Instruction/SOP trng.for issue of materials. Mecha.(Work Shop) Mr. D.P.Baidya
19-06-2017 4.00 PM Use Of PPEs Mecha.(Work Shop) Safety Dept.
22-06-2017 4.00 PM HIRA Review Mecha.(Work Shop) Mr.KK. Tripathy
24-06-2017 10.00 AM Audit Chemical Area by Cross Functional Team Mecha.(Work Shop) Safety Dept./ Stores Dept.
24-06-2017 4.00 PM Work Instruction/SOP trng. On packing material handling Mecha.(Work Shop) Mr. KK Tripathy
27-06-2017 4.00PM Accident Investigation & Reporting Training Mecha.(Work Shop) Safety dept.
03-07-2017 4.00PM Work Instruction / SOP Training.for chemical issue. Mecha.(Work Shop) Mr. Ramesh
05-07-2017 4.00PM Behavioral Safety Mecha.(Work Shop) Mr.L.M.Rao, DGM (Safety)
08-07-2017 4.00PM First aid Mecha.(Work Shop) Dr. M.C. Lenka
08-07-2017 10.00 AM Audit Packing Area by Cross Functional Team Mecha.(Work Shop) Safety Dept.
11-07-2017 4.00PM Fire fighting Mecha.(Work Shop) Mr.D.K.Samal, MGR (Security)
14-07-2017 10.00 AM Audit of material yard by cross functional team. Store Office Safety Dept. & Stores Officer
14-07-2017 4.00 PM Work Instruction/SOP trng. On stores equipement handling Mecha.(Work Shop) Mr.P.R. Barik
17-07-2017 4.00PM Last quarter accident analysis. Safety Dept.
20-07-2017 10.00 AM Equipment Safe to Run certification audit. Store Office Safety Dept & Store Officers
20-07-2017 4.00PM Safe handling of compressed cylinder. Mecha.(Work Shop) Mr. Sameer Behera
23-07-2017 4.00PM Safety in Mechanical & Manual Handling. Mecha.(Work Shop) Safety Dept
26-06-2017 4.00PM Review of Statutory Requirement Mecha.(Work Shop) Safety dept.
28-07-2017 4:00 PM
Work Instruction/SOP trng.for heavy material, O2 & DA
cylinders. Mecha.(Work Shop) Mr. Sameer Behera
29-07-2017 4.00PM Closing Ceremoney Store Office Department In-charge
FOCUSED SAFETY MANAGEMENT SYSTEM
STORE MONTH OF JUNE & JULY
BEST SAFETY PRACTICES
J.K.PAPER MILLS : JAKAYPUR
FOCUSED SAFETY MANAGEMENT SYSTEM
Department: Stores Month – June- 2017
1) Identification :- a) Unsafe act. b) Unsafe condition. c) Near miss capturing. d) Dos & Don’ts generation e) Rectification of the above.
2) Safety Suggestions. 3) Training :-
i) General Safety. a) Use of PPE’s. b) Work permit system. c) Incident reporting /Investigation with root cause analysis. d) Behavioral Safety. e) Ergonomics. f) First Aid g) Fire Fighting
ii) Work Instruction & SOP Trainings. a) Loading, Unloading of CL2 cylinders . b) Loading, Unloading of Sulphate bags. c) Heavy materials O2 & DA Cylinders. d) Issue of Materials.
iii) Work Instruction / Safe operating procedure.
4) Revisiting of system procedure review of HIRA. 5) Good House Keeping.
6) On the job training (Pep talk). 7) Cross Functional Audit.
8) Safe to Run. 9) Statutory compliance.
10) Job Safety Analysis.
J K PAPER …….Creating Lasting Impressions
CENTRI-
CLEANER
DRIER
WIRE
PART
MG
CYLINDER
PRE
DRIER
CUTTER
ROPE
REEL
ROPE
REEL
SIZE
PRESS
POST
DRIERCALENDER
POPE
REEL
PRESSAPPROACH
FLOW
PD
PLANT
PAPER M/C.
I, III, IV & V
PAPER M/C.
II
Best Safety Practices Focused Safety Management System
Rout Map for Safety Patrolling Rout Map & Patrolling Checklist HAZOP Study
Slide No. 33
Hazard Identification &
Risk AssessmentWork Permit System Scaffolding Tag Vehicle Inspection
BEST SAFETY PRACTICES
J K PAPER …….Creating Lasting Impressions
Award / Reward Violation Memo Training Passport Emergency Card
Slide No. 34
Caution board and Hooter to alert during movement of trainProhibited area
BEST SAFETY PRACTICES
J K PAPER …….Creating Lasting Impressions
Restriction on usage of mobile phone Instruction for Drivers displayed at entry gate, truck parking area and drivers rest shed
Slide No. 35
Pneumatic & Battery operated Reel Pusher to prevent occupational hazards eliminating
manual shifting
Instead of inserting hand, Paper puller is
used to remove loose broke.
BEST SAFETY PRACTICES
J K PAPER …….Creating Lasting Impressions
Paper Cartons palletized by Robots
Slide No. 36
Before After
Customized Guard Fabricated and installed in the chain saw
Lifeline arranged to untie rope on truck & Collecting sample from Tanker
BEST SAFETY PRACTICES
J K PAPER …….Creating Lasting Impressions Slide No. 37
Safety Skit by Employees CCTV Camera and Monitoring Display at Strategic Locations in the plant
BEST SAFETY PRACTICES
Safety Trainings on various topics
J K PAPER …….Creating Lasting Impressions
Various Safety Competitions involving school students to increase awareness
Awarding Safety conscious employees, Members of Mahila Mandal & School children on different occasions
Slide No. 38
Skill Development Programme
BEST SAFETY PRACTICES
J K PAPER …….Creating Lasting Impressions Slide No. 39
BEST SAFETY PRACTICES
Safety Pledge at workplaceTool Box Talk Caution Displayed at Chemical zone
J K PAPER …….Creating Lasting Impressions Slide No. 40
Safety & Health Policy displayed in Odia &
English near biometric punching machine
Caution at Robot working zone Safety Instructions for Reel ASRS
BEST SAFETY PRACTICES
J K PAPER …….Creating Lasting Impressions Slide No. 41
PICTORIAL AWARENESS ON SAFETY
Lay out of Fire Fighting
Equipment's in Departments
Display of Exit Route Usage of PPE & Tips for Winder
Operation
Emergency Contact Numbers at
workplaces
J K PAPER …….Creating Lasting Impressions
5 “S” Status Boards at every
Department
Display on Good Housekeeping Display on walls Caution at work
Display on speed limit Display of Ambulance PointsDisplay on containers
Slide No. 42
SAFETY WITHOUT WORDS
J K PAPER …….Creating Lasting Impressions Slide No. 43
HEALTH CARE CENTRE
Chlorine Inhalation & Burn Treatment JK Medical Centre CC Unit
J K PAPER …….Creating Lasting Impressions
Vertigo Test arrangementBeds for Treatment Audiometry Chamber
Different Lab Instruments
Slide No. 44
Health Awareness Training Awareness on Occupational Health
HEALTH & HYGIENE
Awareness on Hygiene at Shop floor
J K PAPER …….Creating Lasting Impressions
Hygiene Committee Meeting
Internal Health Check Up External Health Check Up Blood Donation Camp
Free Health Camp at 3 Villages Free camp for Cataract Treatment
Slide No. 45
Noise Level Reduction Dust Level Reduction
ENVIRONMENT
J K PAPER …….Creating Lasting Impressions Slide No. 46
Counter Measures Counter Measures
1 Coal Yard Tolerable L2Spriklers for Dust
suppression providedSatisfactory L3
2 Chipper House Tolerable L2Spriklers for Dust
suppression providedSatisfactory L3
3 Lime Handling Tolerable L2 Back filters provided Satisfactory L3
4 Guest House Satisfactory L3 Satisfactory L3
sl no Identified areas Previous level Counter Measures Present level
Sewage Treatment PlantEffluent Treatment Plant
After
(mg/l)
Before (mg/l)CT
Facility for Treatment / Disposal of Effluents / Wastes
BOD – 150 - 200
COD – 250 - 300
TSS - 300 - 500 BOD – 06 - 08
COD – 20 - 22
TSS - 04 - 06
J K PAPER …….Creating Lasting Impressions
Scientific Land Fill for disposal of HW Front View of Scientific Land Fill
Sewage Treatment PlantEffluent Treatment Plant
Slide No. 47
RAIN WATER HARVESTING PROVISION AT DIFFERENT PLACES
J K PAPER …….Creating Lasting Impressions Slide No. 48
SOLID WASTE MANAGEMENT
Particulars Utilisation / Disposal
Chipper Dust/PithUsed in our Coal Fired Boilers
along with Coal.
Fly Ash 100% generated fly ash is being
used for making fly ash brick by
brick manufacturer.
Bottom Ash Land filling
ETP Primary SludgeUsed by outside Agency for
manufacturing of Cartons & Egg
Tray.
ETP Secondary SludgeDisposed in landfill.
Fly Ash
Brick Mfg.
JKPur Market
Building in Fly Ash
Brick
J K PAPER …….Creating Lasting Impressions
Lime Sludge Lime Sludge - Out of total
generation 98% is being re-burnt
in Lime Kiln Plant and generate
lime is used in our process & 2%
use for filling up low laying areas.
Ash and inert from lime
kiln
Land filling
Dregs and Grits from recovery
Repairing of Road & Road
Making.
Plastics - HDPE Bags Selling to Authorized Recyclers
Pvt. Building in
Reclaimed Land
A nearby village on
Reclaimed Land
Slide No. 49
• Installed Methanol Plant for distillation of foul condensate from evaporator and used as fuel in Lime Kiln
Plant as a result the emission of SOG eliminated and Odour reduced drastically.
• Installed & commissioned a new Sewage Treatment Plant.
• Treated Sewage water is being again used in our process since three year
• Introduced On-line sprinklers at Coal Yard & Chip Conveyors.
• 100% fly ash is being utilized for manufacturing bricks.
• Use of bio-mass in Coal Fired Boiler for resource conservation.
• Adopted latest environment friendly processes and technologies in Pulp Mill, Recovery, Power Plant &
Lime Kiln in 2013.
ENVIRONMENT INITATIVES
J K PAPER …….Creating Lasting Impressions
• Water consumption per ton of paper reduced from 72m³ to 36.15m³.
• AOx level in treated effluent reduced from 0.6 to 0.14 kg/t.
• Augmented the existing ET Plant with latest technology to increase the treated effluent quality. As a result,
the quality parameters are far below the prescribed norms.
• Pet coke is being used as fuel in place of Producer Gas since 2015.
• On-line emission monitoring of Air & Water for better control of Pollution.
• Promoting social and farm forestry using clonal technology with a target of planting 12000 hectares every
year.
Slide No. 50
SPECIFIC POWER CONSUMPTION, KWH/T SPECIFIC STEAM CONSUMPTION,T/T
SPECIFIC WATER CONSUMPTION M³/T % OF UTILIZATION OF RENEWABLE ENERGY
1403
12721211
1140 1130
1000
1100
1200
1300
1400
1500
20
13
-14
20
14
-15
20
15
-16
20
16
-17
20
17
-18
SE
C K
wH
/T
Year
8.37.4
6.1 5.8 5.75
0
2
4
6
8
10
20
13
-14
20
14
-15
20
15
-16
20
16
-17
20
17
-18
Sp
eci
fic
ste
am
con
sum
pti
on
t/m
t
Year DISPLAY OF AIR PARAMETERS
NEAR THE MAIN GATE
SPECIFIC CONSUMPTION (ENVIRONMENT)
GOOD GOOD
J K PAPER …….Creating Lasting Impressions
SPECIFIC WATER CONSUMPTION, M³/T % OF UTILIZATION OF RENEWABLE ENERGY
61.91
40.31 37.47 38.61 36.10
0
10
20
30
40
50
60
70
20
13
-14
20
14
-15
20
15
-16
20
16
-17
20
17
-18
Sp
.Wa
ter
Co
nsu
mp
tio
n
Year
40.46
52.8 53.8162.6 60.89
0
10
20
30
40
50
60
70
20
13
-14
20
14
-15
20
15
-16
20
16
-17
20
17
-18%
of
ren
ew
ab
le e
ne
rgy
YearAMBIENT AIR QUALITY
MONITORING STATION
GOODGOOD
Slide No. 51
METHANOL PLANT IN PLACE OF SOG
Methanol Plant
J K PAPER …….Creating Lasting Impressions
SOG System
� 20% Conc. of Methanol in SOG
� Requires support fuel to fire
� Due to High volume in gas, can’t be
stored
� Water vapours not utilized
� Any interruption in LK operation, results
in odour in nearby area
Methanol System
� 80% Conc of Methanol
� Need support fuel but energy conserved.
� Saves on fuel demand for LK
� Liquid Methanol can easily be stored
� Condensate can be recovered
� During LK shut, Methanol can be stored,
hence no odour.
Slide No. 52
NEW INITIATIVES
J K PAPER …….Creating Lasting Impressions
A Mobile Safety APP has been lunched for
instant capture and communication of Unsafe
Acts, Unsafe Conditions & Nearmiss cases for
quick action
Slide No. 53
Our ClO2 plant has become the model plant in the
mills and considered as Safety Aaina where all the
Safety measures has been taken care with priority.
NEW INITIATIVES
Safety Buddies of 10 nearby Industries CGM (Mfg) addressing Safety Buddies Awareness Training to Safety Buddies
SAFETY BUDDIES
J K PAPER …….Creating Lasting Impressions Slide No. 54
Visit to nearby Safety Buddies Industry to improve Safety Culture
National Level :
� National Safety Awards 2016 (Winner) for Accident Free Year
� Prime Minister Shram Award-2015
State Level :
� Best Performance in Safety, Health & Environment-2016 (1st Prize)
Lowest Weighted Frequency Rate of Accidents 2017 (1St Prize)
Reward & Recognitions
Achieved
27.26
Million Safe
J K PAPER …….Creating Lasting Impressions
� Lowest Weighted Frequency Rate of Accidents-2017 (1St Prize)
� State Shrama Awards-2014, 2015, 2016 & 2017
� CII SHE Excellence Awards 2016-2017 (Certificate of Appreciation)
� CII SHE Excellence Awards 2017-2018 (Certificate of Appreciation)
� Greentech Gold Safety Award for the year 2016
� Best Factory Medical Officer for Occupational Health-2015
Slide No. 55
Million Safe
Man Hours
(since 21st
July 2015 to
till date)
SHE Excellence Appreciation Award 2017-18 from CII (ER)
SAFETY AWARDS
National Safety Award for Accident Free Year 2016
J K PAPER …….Creating Lasting Impressions
First Prize in “Lowest weighted
Frequency Rate of Accidents” in the
State for the year 2017
Best Performance in
Safety, Health and
Environment in the State for
the year 2016
Best Occupational Doctor 2017SHE Excellence Appreciation
Award 2016-17 from CII (Easter
Region)
Shrama Award 2014Shrama Award 2014Shrama Award 2014Greentech Gold in 2016
Slide No. 56
Greentech Silver in 2011Greentech Silver 2012Greentech Silver 2013 National Safety Award 2012
SAFETY AWARDS
J K PAPER …….Creating Lasting Impressions
Sword of Honour from BSC
Slide No. 57
J K PAPER …….Creating Lasting Impressions