16 Big Losses In Manufacturing - Total Productive Maintenance(TPM)

16 Losses  In Manufacturing - Total Productive Maintenance(TPM):

To help identify all losses in a process system (man/machine/material), and thus,eliminate them, they have been divided into 16 categories, and can be grouped accordingly, as shown in Figure 1, with orange representing the equipment related losses, blue representing the losses relating to manpower and yellow representing the losses relating to resource consumption.

Figure 1: 16 Losses  In Manufacturing - Total Productive Maintenance(TPM)

 Equipment Losses                Manpower Losses                   Yield, Energy & Tooling Loss

1.     1. Breakdown loss                                9. Management Loss                             14. Yield Losses

2. Set up & adjustment loss               10. Motion Loss                                       15. Energy
3. Cutting blade replacement loss    11. Line Organization Loss                     16. Die, Tool and Jig Losses
4. Start-up loss                                     12. Distribution Loss
5. Minor stoppage & idling loss         13. Measurement and Adjustment Loss
6. Speed reduction loss
7. Defect & rework loss
8. Shutdown loss

Equipment Losses :

1. Breakdown loss: 

The equipment breaks down causing the function of the line or process to stop.Often this is considered as a sporadic failure, typically caused by equipment component failure.

2. Set up & adjustment loss: 

This loss occurs during a changeover between products. Set up time is defined as the amount of time taken to change a process over from the last part of a production run to the first good, repeatable part of the next production run. Adjustment within the set up time is often hidden, and involves tweaking settings until optimal run conditions are achieved.

3. Cutting blade replacement loss: 

The time loss incurred swapping any consumable tooling item when it has become worn/ineffective or damaged.

4. Start-up loss: 

The loss incurred whilst starting up equipment, to get to steady state operating conditions, after planned or unplanned shutdown.

5. Minor stoppage & idling loss:

These are typically small stoppages not logged as breakdowns and issues causing the machine to pause or idle for short periods. They are often chronic losses, regularly repeated, often not recorded and usually less than 1 minute duration.

6. Speed reduction loss:

This loss occurs from operating at a speed less than the design speed.

7. Defect & rework loss: 

This is the loss of defective product i.e. Not Right First Time which requires rework, repair or scrap.

8. Shutdown loss: 

The loss incurred by deliberately shutting down the equipment within the production plan.

Manpower Losses:

9. Management Loss:

These are waiting time losses generated by management problems..

10. Motion Loss: 

Losses are created due to unnecessary/excessive operator movement and transportation, as a result of poor layout and work organisation.

11. Line Organisation Loss: 

This loss results from a shortage of operators on the line and operators having to work on more equipment than was originally planned.

12. Distribution Loss: 

This loss is the wasted time that is experienced in the incorrect or inefficient delivery of raw materials, packaging or products to and from the factory or the production line.

13. Measurement and Adjustment Loss: 

This loss is caused by the frequent measurement and adjustment to prevent the recurrence of problems.

Yield, Energy & Tooling Loss:

14. Yield Losses:

This is the total loss between the input of raw material and the output of finished goods.

15. Energy: 

Energy loss is the input energy which cannot be used effectively for processing

16. Die, Tool and Jig Losses: 

This is the cost of the physical consumption of the spare parts or the refurbishment/maintenance of items that are used on the line.

SEE ANOTHER POST : 

What is Total productive maintenance (TPM)? The five goals of TPM?