Six Big losses in the workplace

The objective of TPM is maximization of equipment effectiveness. TPM aims at maximization of machine utilization and not merely machine availability maximization. As one of the pillars of TPM activities, Kaizen pursues efficient equipment, operator and material and energy utilization that is extremes of productivity and aims at achieving substantial effects. Kaizen activities try to thoroughly eliminate losses.

Six major losses that were identifying. Details of which is given below.

1. Equipment failure causes production downtime. Equipment failure requires maintenance assistance and can be prevent with the use of appropriate preventive maintenance actions, develop and apply operating procedures, and design changes. Most importantly, equipment failure requires an improvement effort that should be the result of a successful partnership between production and maintenance. Predictive maintenance techniques such as vibration, oil, and thermo graphic analysis can be use to anticipate equipment failure. If the failure occurs, it is important to use Root Cause Failure Analysis (RCFA) techniques to identify the root cause of the problem and effective and applicable solutions that will eliminate or mitigate the failure occurrence and impact.


2. Set-up and adjustments: This refers to loss of productive time between product types, and includes the warm-up after the actual changeover. Changeover time should be include in this loss opportunity and it should not be part of the plan downtime.


3. Small stops are typically less than 5-10 minutes and they are typically minor adjustments or simple tasks such as cleaning. They should not be cause by logistics.


4. Speed losses are cause when the equipment runs slower than its optimal or design maximum speed. Examples include machine wear, substandard materials, operator inefficiency, equipment design not appropriate to the application, etc.


5. Losses during production include all losses cause by less-than-acceptable quality after the warm-up period.


6. Losses during warm-up include all losses cause by less-than-acceptable quality during the warm-up period.

Analyze the cycle

By comparing all complete cycles to the Ideal Cycle Time and filtering the data through a Small Stop Threshold. Reduce Speed the errant cycles can be automatically categorize for analysis. The reason for analyzing Small Stops separately from Reduce Speed is that the root causes are typically very different.

Often a Six Sigma program, where a common metric is achieving a defect rate of less than 3.4 defects per million "opportunities". It is use to focus attention on a goal of achieving "near perfect" quality.