Described shortly 16 major losses in Industry with Practical Example

1. Major Losses in HIP Shine
Bathroom Fittings
Khondoker Shafiqul Islam Ullash
Assistant Manager (Operation)
RFL-RPL (Shine-Bathware)
Email: rfl936@prangroup.com
Mobile: 01924-601330

2. What are Losses?
“Losses in the production environment are
those areas where the greatest amounts of
Materials and Time is wasted.”
- kunio shirose, 1989

3. 3
16Major Losses Which Obstruct Production Efficiency
 5 Major Losses Obstructing
Manpower Efficiency
 3 Major Losses Obstructing
Material & Energy Utilization
 8 Major Losses Obstructing
Equipment Efficiency

4. 4
5 Major Losses Obstructing Manpower Efficiency:
1. Management Loss
16 Major Losses - continued
• Canteen
• Punch
• Id Card
• Salary Line
• Frequently Decision Change
Now Punch Active Machine is in HIP-B15 & Others Improvement Work is on Going

5. 5
5 Major Losses Obstructing Manpower Efficiency:
1. Management Loss
2. Operating Motion Loss
16 Major Losses - continued
Developed & Maintain Some SOP to minimize Material Handling Time
Previous Present

6. 6
5 Major Losses Obstructing Manpower Efficiency:
1. Management Loss
2. Operating Motion Loss 3. Line Organization Loss
16 Major Losses - continued
Developed & follow some Guide Line to Solve this loss
*** New appointed Operator Will work easy work First the Day by Day We will
provide Critical Work

7. 7
5 Major Losses Obstructing Manpower Efficiency:
1. Management Loss
2. Operating Motion Loss
3. Line Organization Loss
4. Logistics Loss
16 Major Losses - continued
OIL

8. 8
5 Major Losses Obstructing Manpower Efficiency:
1. Management Loss
2. Operating Motion Loss
3. Line Organization Loss
4. Logistics Loss
5. Measurement & Adjustment Loss
16 Major Losses - continued

9. Another Initiative to Reduce Measurement &
Adjustment Loss Material Losses
1. Huge dust contain in Tap Body
2. Rejection Percentage High
1. Very Efficient
2. No Dust or other particle in Tap Body
3. Rejection percentage reduce
Previous Present

10. 10
3 Major Losses Obstructing Material & Energy Utilization:
1. Energy Loss
16 Major Losses - continued
Save Huge time For Mold
Load Unloading

11. 11
3 Major Losses Obstructing Material & Energy Utilization:
1. Energy Loss
2. Die, Tool, & Fixture Loss
16 Major Losses - continued
Material Lick in Mold
Limit Switch Check
Ejector Pin Check
Product Eject Accurately from Mold
Skilled Operator
Careful During working
Creating Awareness Our Production
People:
Next Time We will Take a Training on
This Bellow Point

12. 12
3 Major Losses Obstructing Material & Energy Utilization:
1. Energy Loss
2. Die, Tool, & Fixture Loss
3. Material Loss
16 Major Losses - continued
Wrong ! Mixing of Raw
Materials
Maintain Mixture Log Book
And Always Checked by QC

13. 13
8 Major Losses Obstructing Equipment Efficiency:
16 Major Losses - continued
1. Machine Failure / Breakdown
 Tooling Failures
 Unplanned Maintenance
 General Breakdowns
 Equipment Failure

14. 2. Set-Up & Adjustment Loss
Set-Up : Losses due to changeover
Adjustment : Minor process adjustments
8 Major Losses Obstructing Equipment Efficiency:
16 Major Losses - continued
 Setup/Changeover
 Material Shortages
 Operator Shortages
 Major Adjustments
 Warm-Up Time

15. 3. Startup Loss/startup Reject:
8 Major Losses Obstructing Equipment Efficiency:
16 Major Losses - continued
Incorrect AssemblyAdjustment loss
Created Awareness Our Production People :

16. Sl. No Accessories Name Name Of Mold/Product
Length
(mm)
width
(mm)
Standard
Machine
Cavity
Loading
Time
Unloading
Time
Total
Standard
Loding
Unloading
Time
Standard
Rejection Pcs
1 Royel dreanag net body Royel dreanag net body 300 250 250 1 45 35 80 8
2 Royel dreanag net Royel dreanag net 300 230 250 2 44 32 76 8
- - - - - - - - - - -
- - - - - - - - - - -
- - - - - - - - - - -
130
Elegant Tissue
Holder (TH3-1)
Elegant Tissue holder
cover
420 380 160 2 40 25 65 13
236
Elegant Tissue
Holder (TH3-2)
Elegant Tissue holder
body
330 280 1 35 25 60 10
Standard Time for Shine 132 Mold’s
Load, Unload & Rejection
It Saves Huge Time & Rejection & Increase Production

17. 4. Consumable Parts Change Loss :
8 Major Losses Obstructing Equipment Efficiency:
16 Major Losses - continued
 Running maintenance
 Electrical
 fuse problem
 Heater problem etc.
 Mechanical
 Valve Problem
 Hydraulic Oil problem etc.
We Can’t Overcome 100% But we are more e
Careful on This area and Improving

18. 5. Minor Stoppage & Idling Loss:
Losses we have a tendency to “put up with”
8 Major Losses Obstructing Equipment Efficiency:
16 Major Losses - continued
 Obstructed Product Flow
 Component Jams
 Miss feeds
 Sensor Blocked
 Delivery Blocked
 Cleaning/Checking
We Can’t Overcome 100% But we are more e
Careful on This area and Improving

19. 8 Major Losses Obstructing Equipment Efficiency:
16 Major Losses - continued
6. Speed Loss:
P-1
Capacity
90 PCS
P-3 C30 pcs
P-4
Capacity
90pcs
P-2
C. 45pcs
P-2
C. 45pcs
P-3 C30pcs
P-3 C30 pcs
P-1
Capacity
90 PCS
P-4
Capacity
90pcs
P-2
C. 45pcs
P-3 C30pcs Final Product
30Pcs
Final Product
90Pcs

20. Effect of Time Study & Line Balancing on
Slot Handle Tap S1
Jan-16 Feb-16
Date A-Shift B-Shift Date A-Shift B-Shift
01.01.16 1920 2120 01.02.16 2416 2580
02.01.16 1760 1360 02.02.16 2720 2840
03.01.16 1920 1560 03.02.16 2972 3180
4.01.16
Inventory
1960 04.02.16 3342 2480
05.01.16 0 05.02.16 2532
Off day
06.01.16 1920 06.02.16 1210
07.01.16 1920 07.02.16 2216 2646
08.01.06 1950 1440 08.02.16 2310 2440
09.01.16 2080
Factory Day
09.02.16 0 2500
10.1.16 2140 10.02.16 2680 2450
11.01.16 2140 2200 11.02.16 2440 2730
12.01.16 1720 12.02.16
Off day
2668
13.01.16 1572 13.02.16 2372
14.01.16 1680 1840 14.02.16 2630 2400
Total 35,202.00 Total 58,754.00
Production Increasing 23,552 PCS which Market Value 9,42,080.00 Taka!

21. 7. Defect & Rework Loss:
8 Major Losses Obstructing Equipment Efficiency:
16 Major Losses - continued
Accurate product
Never Need to
Rework
Created Awareness Our Production People :

22. 8. Planed Stoppage
8 Major Losses Obstructing Equipment Efficiency:
16 Major Losses - continued

24. SAFELY work on Going
 It helps to Identify
where we need to Take
Action Very Visually

25. Please Work Safely & Return Home
SAFELY