What are 16 Major Losses in TPM?
→ Losses in the production process mean the greatest amounts of materials, money, energy, and time are wasted.
→ In Total Productive Maintenance (TPM), there are 16 defined set of criteria related to various losses, which is known as 16 Major Losses.
→ The names of these losses might be different in different organizations, but the categories and concepts are the same.
→ These 16 Major Losses in Total Productive Maintenance (TPM) impact on Product Quality, productivity, and profitability of the organization.
→ So we need to identify and eliminate these losses from the organization.
→ Some of the reasons for the losses can be summarized as below:
⇢ We are running production for excess timing.
⇢ Production is interrupted or stopped
⇢ Non -value-adding activity is performed
⇢ The machine is idle or we can say not planning
⇢ When a machine is not running as per the design-rated speed
⇢ The machine is consuming additional time, money, and energy than the specified requirement.
The 16 Major Losses in Production
→ The 16 Major losses in Total Productive Maintenance (TPM) are further divided into different categories as mentioned below
- Losses Impacting on Availability - 8 Losses (Refer 1 to 8 Losses in the below list)
- Losses Impacting on Performance - 5 Losses (Refer 9 to 13 Losses in the below list)
- Losses Impacting on Resources Consumption - 3 Losses (Refer 14 to 16 Losses in the below list)
→ The 16 Major losses in TPM are mention below
- Equipment Failure (Breakdown) Loss
- Set up & Adjustment Loss
- Cutting Tool/Blade Change Loss
- Start-up Loss
- Minor Stoppage & Idling Loss
- Speed Loss
- Defect & Rework Loss
- Shutdown Loss (Planned Maintenance Loss)
- Management Loss
- Motion Loss or Operating Motion Loss
- Line Organization Loss
- Distribution/Logistic Loss
- Measurement & Adjustment Loss
- Energy Loss
- Consumable Loss
- Yield Loss
8 Types of Losses - Impacting on Availability
01. Equipment Failure (Breakdown) Loss
→ Equipment Failure means the machine is under any kind of breakdown and not able to operate.
→ We can also include the failure - if the machine is not able to operate at rated capacity due to a technical problem.
→ Our target is zero breakdowns.
→ For this kind of failure generally, we are doing Breakdown Maintenance.
→ We can eliminate Equipment failure by implementing a Preventive Maintenance Plan.
02. Set up & Adjustment Loss
→ While we have any changeover on the machine at that time we have a loss that is called setup and adjustment loss.
→ The changeover includes product changeover, jig/fixture changeover, tool/die changeover, etc.
→ We can use the Single Minute Exchange of Die (SMED) technique for minimizing Setup & Adjustment Loss.
03. Cutting Tool/Blade change Loss
→ While we are changing or replacing the cutting tool/blade at that time the loss is created that is known as a Cutting Tool/Blade change loss.
→ We are changing various tools like a drill bit, grinding wheel, tap, rammer, cutter, etc.
→ We can use the Single Minute Exchange of Die (SMED) technique for minimizing Setup & Adjustment Loss.
→ Also, alternatively, we can develop a more durable cutting tool or Implement various Kaizens for reducing this loss.
04. Start-up Loss
→ A Startup loss occurs while we are starting the machine.
→ It includes stabilize the production and need to take approval from QA before continuing the production.
→ So this loss considers as a startup loss until the machine runs at rated speed.
→ As per the manufacturing product, the startup process may include the production process, cleaning, conditioning, stabilization.
→ We can reduce this loss by standardizing the processes and parameters.
05. Minor Stoppage & Idling Loss
→ While machine stops frequently for a very small time period and this activity occurs multiple times in a shift that is considered the minor stoppages and Idling Loss.
→ Minor stoppages might be possible due to malfunction of sensors, jamming of product, resetting parameters, etc.
→ Sometimes we stop machines for a job removing or resetting that is also an example of Minor Stoppage.
06. Speed Loss
→ If the machine is running less than the design speed then it is considered as the speed loss.
→ If the machine's rated design speed is 60 products per minute and we are getting the actual output is products per minute then there is a speed loss of 5 products per minute.
→ So our target should be the machine must be running at the design speed for minimizing the speed loss.
07. Defect & Rework Loss
→ If the machine is producing a defective product and we are spending time to rework the defective product that is called the Defect and Rework Loss.
→ For eliminating this loss we need to standardize processes and parameters.
→ For better understanding, you can refer to the 5S Methodology.
08. Shut down Loss (Planned Maintenance Loss)
→ When Equipment is shut down for the Planned Maintenance, the loss is considered a Shutdown Loss or Planned Maintenance Loss.
→ Sometimes the equipment should be shut down due to periodic inspection, statutory or regulatory compliance.
5 Types of Losses - Impacting on Performance
09. Management Loss
→ The waiting losses that are caused by management are called Management Loss.
→ Some examples of management losses are waiting for materials, waiting for machine spares, waiting for tools, waiting for instructions, waiting for manpower, etc.
10. Motion Loss or Operating Motion Loss
→ If we take excess motion/steps for any process so that is known as a Motion Loss or Operating Motion Loss.
→ This happens mostly due to inefficient process layout.
→ To minimize or eliminate this loss we need to implement automation or optimize the process layout and steps.
11. Line organization Loss
→ Line balancing loss is the waiting loss at the process level.
→ Line balancing means if any product is manufactured in four steps then the speed of all steps or all stations should be the same.
→ The product should not be ideal at any stage of the process.
→ To eliminate this loss we need to use the Line Balancing or Bottleneck Analysis Concept.
12. Distribution Loss
→ Distribution Loss is related to man-hour losses due to transport of materials, semi-finished products, or finished products from one location to another.
→ To eliminate this kind of loss we can implement automation for material/product transportation at different levels.
13. Measurement & Adjustment Loss
→ The man-hour loss is due to frequent measurement & adjustment of machine settings to prevent the quality defects is called a Measurement & Adjustment Loss.
→ That is happening during continuous production.
→ So we can minimize this kind of loss by implementing various Poka Yoke and Process Standardization.
3 Types of Losses - Impacting on Resources Consumption
14. Energy Loss
→ The losses due to ineffective utilization of input energy like electric, gas, fuel oil, steam, air, and water, etc in processing is called Energy Loss.
→ Examples of Energy Loss are losses due to heat radiation, leakage of fuel, leakage of air, Leakage of oil, etc.
→ Energy loss has a high impact on total cost so we need to minimize this kind of loss.
15. Consumable Loss
→ The losses due to repair and replacement of any spare, die, tool, etc is called Consumable loss.
→ Spare get damaged after the service life so we need to change it - this is coming under the consumable loss.
16. Yield Loss
→ Sometimes the weight of the finished product is higher than the design specification that is due to maintaining the good quality of the product but it's a loss of the manufacturer that is called Yield Loss.
→ Sometimes instead of excess material, excess processing is required for a good quality product that is also a Yield Loss.
→ For better understanding we take one example - Increase casting wall thickness to avoid blow-hole defect leading to more machining time and loss of material.
INTERSTING
ردحذفThanks!!!
حذفReally informative and helpful
ردحذفThank you very much for your kind comment!!!
حذفVery Good knowledge
ردحذفThank you
حذفWhat measures can we take to enhance the OEE?
ردحذفYou can go with our article thanks
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