By combining TPM, Autonomous Maintenance and basic environment engineering, the textile mill stabilised packing operations, improved moisture regain and achieved significant yield and cost benefits.
Context and Challenges
A leading home-textile manufacturer running high-speed towel weaving, processing and packing was facing low, inconsistent moisture regain at dispatch, frequent minor stoppages and breakdowns on packing and handling equipment, poor conditions in the packing area and safety issues. Management wanted to improve moisture regain and yield, cut breakdowns and defects, and create a clean, safe, well-managed packing area using TPM.
Our Approach
The improvement was run as a TPM-based Lean Kaizen project in the towel packing section:
Diagnostic & Baseline Creation: Mapped the flow from drying/finishing to cutting, folding and packing, identifying where moisture was lost and where stoppages occurred. Measured baseline moisture levels, breakdowns, minor stoppages, defects and safety incidents.
Root Cause Analysis: Analysed the impact of open doors, cross-drafts and low humidity on towel moisture and dust build-up. Used cause–effect and Gemba observations to understand chronic equipment problems and micro-stops.
TPM & Environment-Control Measures: Designed and implemented environment controls and Autonomous Maintenance routines on key machines.
Standardisation & Daily Work Management: Introduced 5S, visual boards, daily huddles and simple TPM governance to sustain and build on the improvements.
Key Strategies Implemented
Environment Control in Packing Area
- Installed PVC curtains at open sides to isolate the packing area from the rest of the shop floor.
- Created poly chambers with controlled conditions in both sections to protect towels after drying.
- Installed humidifiers and Akimist nozzles with fans to maintain required humidity, reduce dust and minimise moisture loss.
TPM & Autonomous Maintenance on Packing Equipment
- Launched AM Step 1–3 on focus machines: Deep cleaning to expose hidden defects and abnormal conditions, Red/green tagging and prioritised closure of abnormalities and defined daily/weekly checks (cleaning, lubrication, tightening, safety) for operators.
- Linked AM with planned maintenance to stabilise basic conditions and reduce unplanned breakdowns.
5S, Visual Management & Workplace Organisation
- Implemented 5S in packing and sub-stores – marked locations for tools, trolleys and consumables; defined clear material lanes; removed junk and unnecessary items.
- Improved housekeeping and visibility so problems (oil leaks, misaligned guards, unsafe conditions) became obvious and could be addressed early.
Daily Work Management & Capability Building
- Set up visual performance boards in the area tracking breakdowns, defects, moisture levels and plan vs actual.
- Introduced short daily huddles at the line to review previous day’s performance, highlight abnormalities and agree 2–3 key actions.
- Trained operators, fitters and supervisors in TPM basics, AM routines and focused problem solving, and established a simple weekly TPM review rhythm.
Results Achieved
Within a few months of implementing TPM and environment controls in the packing section, the mill achieved:
- Breakdowns on pilot equipment reduced to near-zero, with breakdown PPM brought down to 0 in the treated area.
- Accidents and critical safety incidents eliminated, with accident count reduced to 0 during the review period.
- Packing-related defects and rework reduced to 0, as stabilised conditions and AM routines removed recurring causes of damage and contamination.
- Significant moisture and yield gain on finished towels, with moisture-regain benefits quantified at more than INR 1 crore equivalent over six months, validated by costing.
- A noticeably cleaner, more organised and controlled work environment, with operators independently sustaining 5S, daily checks and problem-tagging.