16 Losses

 

The 16 Losses In Total Productive Maintenance

To pinpoint and remove all inefficiencies within a process system involving humans, machines, and materials, we've categorized the losses into 16 distinct groups, which will be outlined one by one below.

Equipment Losses:

1. Breakdown Loss: 

The equipment malfunctions, leading to a halt in the operation of the line or process. This is often regarded as a sporadic failure, usually resulting from a failure of an equipment component.

Examples: Motorbike stopped suddenly due to chain sprocket broken.

2. Setup and Adjustment Loss:

This loss takes place during the transition between different products. Setup time refers to the duration required to switch a process from the final part of one production run to the initial good, consistent part of the subsequent production run.

Examples: Model changing, setting changing

3. Cutting Blade Replacement Loss:

The time wasted in replacing any consumable tooling item that has become worn, ineffective, or damaged.

Examples: CNC machine tools replacement due to damaged or worn out.

4. Start-up Loss:

The losses experienced during the startup of equipment, as it transitions to stable operating conditions following either scheduled or unscheduled shutdowns.

Examples: The extruder machine needs to get certain temperature to operate in tyre industry.

5. Minor stoppage and Idling Loss:

These are generally minor interruptions that are not documented as breakdowns, leading to the machine pausing or idling for brief intervals. These occurrences are frequently chronic losses, occurring repeatedly, often unrecorded, and typically lasting less than one minute.

Examples: Sensor not working due to dust particles accumulated or sensor position adjustment.

6. Speed Reduction Loss:

This loss is caused by operation at a lower speed than the design speed.

Examples: Single manpower used to operate 2 machines.

7. Defect and Rework Loss:

This refers to the loss associated with defective products, specifically those that are not produced correctly on the first attempt, necessitating rework, repair, or disposal.

Examples: Weld fillet under size and need to reweld again.

8. Shutdown Loss:

The loss caused by intentionally turning off the equipment in the production plan.

Examples: Preventive maintenance as planned.

Manpower Losses:

9. Management Loss:

Management issues are responsible for these losses in waiting time.

Examples: Bus late, canteen delay, shortage of manpower.

10. Motion Loss:

Inefficiencies arise from unnecessary or excessive movement and transportation by operators, stemming from inadequate layout and work organization.

Examples: Material searching here and there for assembling the product.

11. Line Organisation Loss:

This loss is attributed to a lack of operators on the line, as well as operators being required to manage more equipment than initially anticipated.

Examples: Manpower Shortage, Process not defined properly.

12. Distribution Loss:

This loss represents the time squandered due to the improper or ineffective transportation of raw materials, packaging, or products to and from the factory or production line.

Example: BOP delay.

13. Measurement And Adjustment Loss:

This loss results from the regular monitoring and modifications implemented to avert the reemergence of issues.

Example: Fixture correction to meet the component dimension within the tolerance level.

Yield, Energy And Tooling Loss:

14. Yield Loss:

The overall loss is calculated by comparing the input of raw materials with the output of finished products.

Examples: Material Fly loss, Material cutting loss.

15. Energy Loss:

Energy loss refers to the portion of input energy that cannot be utilized efficiently for processing purposes.

Examples: Minor stoppage losses.

16. Tool Losses:

This represents the expense associated with the physical usage of spare parts or the refurbishment and maintenance of items utilized on the production line.

Examples: Die replacement or correction.