Discipline, Devotion, and Driving Change: That's about 22nd March 2025
A Strange Gap in Facebook Birthdays
Something unusual happened today—for the second day in a row, none of my Facebook friends had a birthday. Considering that I have almost 3,000 friends and usually wish 5-7 people daily, this was quite surprising. A small thing, but it made me pause. Patterns break sometimes, reminding us that even in the most regular things, there can be unexpected gaps.
A Fresh Start After the Rains
Last night, from 9 PM to 10 PM, a heavy shower poured down, washing away the dust and heat. The morning that followed was cool, fresh, and crisp. The air smelled different—like a new beginning. It is amazing how nature cleans itself and resets everything, while we, in our workplaces, struggle so much just to keep things organized.
A Song, A Prayer, and A Truth
In our morning gathering, a team member sang a prayer—one of my favorites. As I listened, I felt its rhythm matched closely with ‘Itni Shakti Hamen Dena Daata.’
Everyone needs a prayer. Because everyone carries something—a pain, a struggle, a moment of weakness. Prayer gives us faith to push forward. No matter how tough the journey, it reminds us that we are not alone.
I took the opportunity to appreciate the excellent work done by the Mechanical team in the ESP chain conveyor area. The area, once a dust-laden mess, is now clean. A small change, but a huge improvement in working conditions.
I also reminded everyone about:
✔ The Five Cardinal Rules of Safety
✔ CLTI (Cleaning - Lubrication - Tightening - Inspection)
✔ 5S for workplace efficiency
And once again, I repeated my standing request: Report near-misses! They are warnings of something bigger that could go wrong.
Night Vigilance: No Room for Lapses
Yesterday’s night vigilance report was alarming. Too many people were caught sleeping on duty.
Since Night Vigilance has now become a regular practice, any negligence must be dealt with immediately. By the next working day, action must be taken. I instructed the Admin department to issue warning letters where required. Discipline must be enforced. Without it, every system fails.
More is Not Always Better
I strongly believe in a simple principle:
The more inventory you have, the harder it is to find what you need.
This applies not just to materials but also to manpower. The more people you have, the harder it is to get work done efficiently. Too many people dilute responsibility. A lean, efficient, and accountable team is always better than a crowded, directionless workforce.
A Smarter Approach to Cleaning Clinker Silo Top
Regarding the use of UT pumps for Clinker Silo top cleaning, I advised my team:
➡ First, conduct a trial at ground level.
➡ Design customized nozzles to generate a stronger water-jet.
We have done this in past plants. It works. But execution must be smart, not random. Planning makes all the difference.
ISO Audit: Finding the Gaps
At 3:30 PM, we had the ISO Audit Closing Meeting. The findings were expected—but disappointing. Internal audits are the best tools for self-improvement, and they should never be compromised.
Some major gaps identified:
⚠ Management of Change is missing.
⚠ Breakdown analysis is not being done.
⚠ New supplier registration does not involve EHS criteria.
⚠ No evidence of hydrostatic testing.
⚠ PM checks lack proper acceptance criteria and documentation.
⚠ Lux level measurement and illumination issues.
⚠ Oil drums are left open with oil inside.
⚠ Calibration records (Instrumentation) are missing or poorly maintained.
⚠ Legal requirements need to be translated into English and reviewed for validity.
The Real Challenge: Making ISO Work for Us
The biggest task now is not just to fix these gaps but to make ISO a living process—something that works every day, not just during audits.
ISO should not be a formality. It should be a mindset.
➡ People will keep changing, but systems should remain strong.
➡ Checklists must be meaningful, not just a ‘tick-the-box’ exercise.
➡ Preventive maintenance and documentation must be real, not just for records.
➡ Continuous improvement must be the culture, not an occasional project.
My task now: How to make the ISO process run effectively? This is not just about compliance—it’s about creating a plant that runs better, cleaner, and safer every single day.
As always, there is work to do. And we will get it done. 🚀
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