16 Major Losses identified by TPM 1.
Breakdown Loss :
Loss of time wherein machine has stopped on it's own, machine has been stopped e.g. due to quality issue, speed loss, etc. For calculation of OEE, a part of breakdown, which has resulted in loss of opportunity of production, shall be considered. e.g. e.g. If machine is repaired on a holiday, repair time shall be included in breakdown time, howeer such time shall not be considered for OEE calculation. !ll repairs that are not part of planned maintenance "based on annual plan# are part of breakdown loss. loss. e.g. If e.g. If a bearing has failed prematurely, its replacement shall be breakdown loss.
•
•
2.
Plan Planne ned d Main Mainte tena nanc nce e Loss Loss::
$he actiity that is pre%decided "annual calendar# with a realistic estimate. e.g. in the the year ear F&, F&, spar spare e part parts s of the the mach machin ines es will will be repl replac aced ed with with a spec specif ific ic predetermined periodicity, periodicity, irrespectie of the life left ( failure occurred occurred due to the the spare part in question "$ime bound maintenance#. It will also include specific predetermined oerhaul program. 3.
Set ! Loss:
$he loss attributed to change of setup from one component to other component. "ote) "ote) It shall include time for remoal, fi*ing, ad+ustment(repair. etting is complete when - st +ob is as per specifications. e.g. e.g. hange of /igs 0 fi*ture "as applicable in machining area#, hange of die "as applicable in stamping area 0 foundry#. #.
Tool c$ c$ange Loss:
$ool change loss is defined as a loss occurred while changing tools 0 tooling in running production till -st ok part is produced. "ote) "ote) $ime lost in changing drills, bushes, dressing wheels, etc. %.
Start ! ! Loss:
$he time required for the equipment to attain optimal operating condition. e.g. e.g. Paint s$o! & oen & oen temperature is e*pected to reach ' o( before baking can start. )eat Treat*ent & Furnace & Furnace should attain + attain + o( before charge is put inside. ,ondry P- & 1ie is heated to o( before start of production. 6.
Minor Sto!s:
It is a performance%related loss "usually less than a minute# that results in stoppage of material moement. e.g. e.g. Limit switch is manually operated to restore operating condition, omponent has stuck to die while stamping % it is re*o/ed by one toc$. 0.
S!eed Loss :
Loss due to increase in on line and(or auto cycle time due to reduction in speed, feed. e.g. e.g. ycle time of 2idma 3orer has gone up from 4.5 min to 6.5 min due to feed ariation.
.
efects :
7umber of parts that are not confirming to specification. e.g. e.g. 8ework, 8e+ection. .
Manage*ent Loss :
Loss due to wrong planning. e.g. $ools, 9aterial, Instructions are not aailable. 14. 14. 5!er 5!erat atin ing g Motio Motion n Loss Loss : Loss that reduces human efficiency. e.g. e.g. 2alking of operator is more because of inefficient layout, Operator's motion economy is iolated due to skill difference, operator is wasting some time in searching tools(tooling etc., operator's morale is low, and it affects his performance. 11. 11. djs djst* t*en entt Loss Loss : $ime required to ad+ust tool and(or equipment in order to restore component accuracy. e.g. $ool is ad+usted after eery 7'7 cycles 7'7 cycles to ad+ust si:e. 12. 12. Line Line 5rg 5rgan anis isat atio ion n Loss Loss : Loss inoling line balancing, multi machine operations. e.g. Line '!' is not balanced properly 13. 13. Logi Logist stic ics s Los Loss s: Loss due to non%aailability of material. e.g. Finished 0 !ccepted rank ases are ready but not sent to assembly line due to some reason which results in loss of Engine !ssembly. 1#. 1#. +ield ield Loss : Loss of raw material in any form. e.g. 3lanks e.g. 3lanks generated in stamping operation, hips generated in machining operation, lurry of paint, runners(risers in foundry application. 1%. 1%. 8ner 8nergy gy Loss Loss : Loss of energy in the form of heat, power, air, water, fuel due to leakage and or oerload. It is to be measured by consumption. 16. 16. ie ie 9 Tool Tool Loss Loss : Loss resulting from manufacturing and repair of tools 0 tooling. It also includes consumption of FO items and sand.
