Introduction: Why CLITA, Why Now
Jagdamba Polymers Limited has embarked on a structured CLITA journey to strengthen machine care, reduce downtime, and build operator ownership on the shopfloor. CLITA—Cleaning, Lubrication, Inspection, Tightening and Adjustment—is a key Autonomous Maintenance tool under TPM. By adopting this model, the company is shifting daily equipment care from being a maintenance-led task to a shared operator–maintenance responsibility. This approach marks the beginning of the company’s broader move toward TPM-level excellence and world-class maintenance standards.
The Starting Point: Objectives and Scope
The CLITA program began with well-defined goals aimed at creating daily discipline, strengthening awareness, and improving equipment health across the plant. In the first phase (June 2024), 23 machines from the Injection, Blow Moulding, PU and Sweep sections were brought under the CLITA scope, allowing the company to pilot the method deeply before expanding.
Key objectives included:
- Developing everyday machine-upkeep habits among operators
- Enhancing basic condition monitoring awareness
- Reducing minor stops, leaks and avoidable breakdowns
- Upgrading operator and supervisor skills in routine maintenance
Program Design: Roadmap and Ownership
To convert CLITA from a concept into a behavioural routine, Jagdamba Polymers followed a clear five-phase roadmap covering awareness training, ownership allocation, tagging, improvements and audits. This step-by-step approach mirrors global Autonomous Maintenance practices where operators gradually build knowledge through cleaning, inspection and exposure to abnormalities.
Machine ownership was central to the design. For each of the 23 machines, a supervisor was designated as the CLITA owner and supported by an operating-staff team. Detailed “Machine Ownership Distribution” lists ensured every machine had a clearly responsible team, making ownership visible and systematic on the shopfloor.
Standard Work: Checklists, Tagging and Audits
Daily CLITA checklists, weekly reviews by area champions and monthly audits by the Plant Head helped make routine machine care consistent. A simple visual tagging system further strengthened abnormality management—with Red Tags for defects and White Tags for OK conditions.
Teams tracked seven key abnormality categories such as leaks, loose parts, abnormal noise, vibration, overheating, wear and potential quality/safety issues. Match-marking, CLITA boards and visible indicators helped operators inspect machines quickly and accurately.
Before–After Improvements: Accessibility, Leaks, Visual Management
One of the most visible outcomes was the significant improvement in machine appearance and accessibility. Photographic evidence from the CLITA journey shows leakages eliminated, inspection points cleared, hard-to-reach areas cleaned, and visual management systems added. Over time, machines that earlier had stains, clutter or restricted access began appearing almost “like new,” reflecting TPM’s global guidance that initial cleaning and improved access form the foundation of Autonomous Maintenance.
Operator Involvement and Culture Change
A notable change emerged in the mindset of operators. Through daily CLITA checks, awareness sessions and hands-on involvement, operators began viewing machines as “their” responsibility.
This shift led to:
- More abnormalities being spotted and tagged early
- Smoother coordination between production and maintenance
- Operators planning CLITA activities around production schedules
- Better teamwork in tackling recurring issues
Such cross-functional collaboration strengthens long-term Autonomous Maintenance and contributes directly to improved OEE.
Quantitative Achievements: Reliability Gains and Reduced Losses
The CLITA program delivered strong, measurable improvements.
Breakdowns reduced from 122 in 2023–24 to 69 in 2024–25—a 43% reduction. Abnormalities dropped from 112 to 69, marking an improvement of 38.3%. Additionally, MTBF showed continuous improvement while MTTR reduced due to quicker, more structured responses. These results highlighted how routine CLITA discipline directly enhances machine reliability.
Governance, Recognition and Sustainability
To ensure CLITA remained a continuous practice and not a one-time exercise, Jagdamba Polymers established a robust review rhythm with daily checks, weekly area-champion reviews and monthly audits. The CLITA committee played a key role in standardising checklists, tracking audit outcomes and sharing best practices across departments.
Recognition events further strengthened commitment. Teams showcased before–after improvements, graphs and tags to management, while operators and owners were formally appreciated. The message “Healthy Machines, Proud Operators!” became the spirit driving the initiative.
The Way Forward: Digitalisation and Full Autonomous Maintenance
The company considers CLITA as the foundation of its long-term Autonomous Maintenance ladder. Future plans include expanding CLITA to all machines, digitalising CLITA tracking, and integrating operator checks into maintenance planning and TPM reviews. A structured Kaizen and suggestion system will support operators in converting CLITA findings into small, meaningful improvements that reduce losses and improve safety and quality.
By combining disciplined CLITA routines, strong governance, operator involvement and future-focused digitalisation, Jagdamba Polymers is building a sustainable culture of machine ownership that supports higher productivity and long-term competitiveness.