machine refurbishing, operator training - Nov & Dec 2025
First would like to thank Amma & Dharmendra garu for giving me an opportunity to be part of this project. Also, happy getting a chance to associate with old friends.
After the preliminary discussions with all concerned members on 31st Aug in Jangaon unit and 8th Oct in Malkha office, Hyderabad, we made plans and budget estimates to revive the unit. The preparatory works planned included: works related to the existing shed floor and fibre sheets repairs, discussing and finalizing the vendors on schedule, scope of work and payments, listing spare parts required, getting quotes and planning procurement, organizing the equipment, parts and accessories in the shed, and identifying and selecting local women for unit operators.
The work in the unit commenced from 9th November, 2025. The shed repair works involved fixing new fibre sheets. Installation work of mill card, draw frame, simplex and ring frame was done from 12th till 26th Nov. Some fine tuning is pending, planned to be done later. Malkha card work is pending. The installation team was informed to train the new operators on all machines with respect to regular cleaning, maintenance to be done, usage of tools, etc., especially the do's & don'ts. The 6 new operators assisted the installation team in cleaning the machines, which is a part of their training to understand the functional parts, maintenance, settings, etc., doing hands-on. A few training sessions were conducted on the machine functioning, importance of following good practices, discipline, safety and hygiene aspects. Training in operating all machines with required input material and recording data was also started.
The efforts of the team, new operators and installation team during this period are very much appreciated. Regular follow-up and guiding Manikanta in planning works and training the operators was done, along with discussing the next steps and updating Dharmendra garu on the action plan for his inputs and feedback.
December 2025 - Operator Training
The December month plan was mostly on training the new set of unit operators: making them aware of the machine, parts functioning, settings, etc.; correct operating procedure of all machines to achieve the desirable quality and output (though output might be less than the target); demonstrating the operating process with operators from Pulugurtha team for few days; taking the operators to Pulugurtha unit on an exposure visit to observe entire unit operations; and training them in maintaining the log books and other records.
Manikanta gave training on the functional parts in each machine -- name, function, etc. Further explanation on each machine function and the impact if not operated properly on quality and wastage was provided during visits to Jangaon unit on 11th and Pulugurtha unit on 28th. Training in operating all machines and recording data such as machine run time, input/output/waste material, and operator at each machine was also carried out.
To give them more confidence and one-to-one attention, 3 operators from Pulugurtha unit came to Jangaon unit for 3 days from 11th to 13th. This actually helped them to understand correct practices which can help them to increase productivity and freely discuss their doubts. A visit was made on 11th and they were told to use this opportunity and learn from the seniors. Operators' attendance and timings in the register were also checked, and a lot of gaps were noted. A graph was plotted to explain to them the need for improvement as it can affect the unit's overall productivity.
They were given a 2-week duration to practice based on the training and tips given by Pulugurtha operators and improve their performance on the machines. They were then taken on a 2-day orientation visit to Pulugurtha to see all the unit operations from the moment the shutter is opened in the morning till the time the unit is closed in the evening. The purpose was to make them understand the various tasks (machine related and other works), coordination between the team in managing these tasks timely, actual machine productivity and quality they are able to achieve -- which will be the benchmark for them to target in Jangaon.
Thanks to Pulugurtha management and operators for this Jangaon visit to train the new operators.
January Month Plan:
The plan for January is to make all operators able to run all machines, maintain log books, and complete the Malkha card assembly.
Jagan
14 january 2026