Sunday, March 17, 2019

16 Major Losses in TPM



16  MAJOR  LOSSES

The 16 major losses that are identified and worked upon while implementing Total Productive Maintenance in a manufacturing plant are as detailed below : 


Category A.   Seven major losses that impede overall equipment efficiency: 

(1) Failure losses (Breakdown) : Losses due to failures/ break downs . Types of failures include sporadic function-stopping failures(complete break-downs), and function-reduction failures in which the function of the equipment drops below normal levels (partial break downs or slowing down of machine).
(2) Set up and adjustment losses: Stoppage losses that accompany set-up changeovers.
(3) Cutting blade change losses  : Stoppage losses caused by changing the cutting blade due to breakage, or caused by changing the cutting blade when the service life of the grinding stone, cutter or bite has been reached.
(4) Start-up losses : When starting production, the losses that arise until equipment start-up, running-in and production processing conditions stabilize.
(5) Minor stoppage and idling losses : Losses that occur when the equipment temporarily stops or idles due to sensor actuation or jamming of the work. The equipment will operate normally through simple measures (removal of the work and resetting).
(6) Speed losses : Losses due to actual operating speed falling below the designed speed of the equipment.
(7) Defect & rework loss : Losses due to defects & reworking  

CATEGORY B.   Losses that impede equipment loading time
(8) Shutdown (SD) losses : Losses that arise from planned equipment stoppages at the production planning level in order to perform periodic inspection and statutory inspection
CATEGORY    C.   Five   Major   losses   that    i mpede   workers   efficiency
(9) Management losses : Waiting losses that are caused by management, such as waiting for materials, waiting for a dolly, waiting for tools, waiting for instructions etc.
(10) Motion losses : Man-hour losses arising from differences in skills involved in etc.
(11) Line organization losses : Idle time losses when waiting for multiple processes or multiple platforms.
(12) Distribution losses : Distribution man-hour losses due to transport of materials, products (processed products) and dollies
(13) Measurement and adjustment losses : Work losses from frequent measurement and adjustment in order to prevent the occurrence and outflow of quality defects

CATEGORY D.  Three major losses that impede efficient use of production subsidiary resources
(14) Energy losses : Losses due to ineffective utilization of input energy (electric, gas, fuel oil, etc.) in processing. 
(15) Die, jig and tool losses : Financial losses (expenses incurred in production, regarding renitriding, etc.) which occur with production or repairs of dies, jigs and tolls due to aging byond services life or breakage.
(16) Yield losses : Material losses due to differences in the weight of the input

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