Loss in manufacturing

1. Loss Structure
Concept and Overview

2. OEE calculation
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3. Why Use Six Big Losses?
The Six Big Losses are very well-aligned to discrete manufacturing
and provide a more detailed perspective on equipment loss than
OEE. Since the Six Big Losses are derived from TPM, each loss maps
very well to a specific set of countermeasures. Not only do you get
more information – you get a foundation for more effective actions
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5. Six Big Losses
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7. Six Big Losses
Availability Losses
Breakdowns •Machine Failure
•Unexpected Breakdown of Equipment
•General Maintenance
Set-Up and Adjustment •Changeover
•Material Shortages
•Machine Warm-up
Performance Losses
Speed Losses •Operator Efficiency
•Machine Wear down
•Operating Under Capacity
Small Stops and Idling •Jams, Blocks, and Obstructions
•Cleaning
•Output Checking
•Misfeeds
Quality Losses
Production Defects (During
Production)
•Product Damages and Expiration
•Scraps
Startup Rejects (Before Steady
Production)
•Improper Assembly
•Scrap
•Product Damages
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20. Equipment Losses
The 7 main equipment losses :
• Planned Losses / Shutdowns
• Equipment failures
• Start-ups
• Minor stoppages and Unloaded operation
• Lower speed
• Defective and Reprocessed Production
• Set-ups and Adjustments
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Losses that have interference in the
equipment performance”.

21. Six Big Losses
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22. How to Reduce Losses
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