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.
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