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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