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    16 Losses

    Uploaded by

    Muthu Vellayappan
    The document lists 16 major losses that can impede production efficiency. It then provides loss matrices for different production groups (rolling mills, tube mills, draw benches, etc.) that indicate which losses affect each machine or process. The matrices track the 16 losses across various equipment to help identify optimization opportunities.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as XLS, PDF, TXT or read online from Scribd

    16 Losses

    Uploaded by

    Muthu Vellayappan
    4K views9 pages
    The document lists 16 major losses that can impede production efficiency. It then provides loss matrices for different production groups (rolling mills, tube mills, draw benches, etc.) that indicate which losses affect each machine or process. The matrices track the 16 losses across various equipment to help identify optimization opportunities.

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    © Attribution Non-Commercial (BY-NC)

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    XLS, PDF, TXT or read online from Scribd

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    The document lists 16 major losses that can impede production efficiency. It then provides loss matrices for different production groups (rolling mills, tube mills, draw benches, etc.) that indicate which losses affect each machine or process. The matrices track the 16 losses across various equipment to help identify optimization opportunities.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    4K views9 pages

    16 Losses

    Uploaded by

    Muthu Vellayappan
    The document lists 16 major losses that can impede production efficiency. It then provides loss matrices for different production groups (rolling mills, tube mills, draw benches, etc.) that indicate which losses affect each machine or process. The matrices track the 16 losses across various equipment to help identify optimization opportunities.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    of 9
    At a glance
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    The document discusses various types of losses that can occur across different production processes in a steel plant. It provides loss matrices to track losses for different equipment and identifies factors that can lead to losses.

    The document mentions 16 major types of losses including equipment failure, setup/adjustment, tool change, start up, minor stoppages, speed, defect and rework, scheduled downtime, management, operating motion, line organization, logistics, measurement and adjustment, energy, die/jig/tool, and yield losses.

    Factors like equipment failure, setup/adjustment times, tool changes, start up processes, line organization, logistics, and measurement can all contribute to losses depending on the specific production process or equipment being used.

    16 Major Losses

    Category Loss No Loss Name

    1 Equipment Failure Loss

    2 Setup / Adjustment Loss


    7 Major
    Losses 3 Tool Change Loss
    that
    impede 4 Start Up Loss
    Overall
    Equipment 5 Minor Stoppages
    Efficiency
    6 Speed Loss

    7 Defect & Rework Loss

    Losses
    that
    impede
    8 Scheduled Downtime Loss
    Equipment
    Loading
    Time

    9 Management Loss

    5 Major 10 Operating Motion Loss


    losses that
    impede 11 Line Organization Loss
    Worker
    Efficiency 12 Logistics Loss

    13 Measurement & Adjustment Loss

    3 Major 14 Yield Loss


    losses that
    impede
    efficient 15 Energy Loss
    use of
    Production
    subsidiary 16 Die,Jig & Tool Loss
    resources
    LOSS MATRIX
    GROUP : ROLLING MILLS

    Loss No Loss Name 4H1 4H2 4H3 6H 2H1 2H2

    1 Equipment Failure Loss

    2 Setup / Adjustment Loss X X X

    3 Tool Change Loss

    4 Start Up Loss X X X X X

    5 Minor Stoppages

    6 Speed Loss

    7 Defect & Rework Loss

    8 Schdeuled Downtime Loss

    9 Management Loss

    10 Operating Motion Loss

    11 Line Organization Loss X X X X X X

    12 Logistics Loss X X X X X

    13 Measurement & Adjustment Loss

    14 Energy Loss

    15 Die,Jig & Tool Loss

    16 Yield Loss
    LOSS MATRIX
    GROUP : TUBE MILLS

    Loss No Loss Name TM 1 TM 2 TM 3 TM 4 TM 5

    1 Equipment Failure Loss

    2 Setup / Adjustment Loss

    3 Tool Change Loss

    4 Start Up Loss X X X X X

    5 Minor Stoppages

    6 Speed Loss

    7 Defect & Rework Loss

    8 Schdeuled Downtime Loss

    9 Management Loss

    10 Operating Motion Loss

    11 Line Organization Loss X X X X X

    12 Logistics Loss

    13 Measurement & Adjustment Loss

    14 Energy Loss

    15 Die,Jig & Tool Loss

    16 Yield Loss
    LOSS MATRIX
    GROUP : DRAW BENCHES

    Loss No Loss Name E1E2E3C1C2D1D2D3D420T30T40T

    1 Equipment Failure Loss X

    2 Setup / Adjustment Loss

    3 Tool Change Loss

    4 Start Up Loss X X X X X X X X X X X X

    5 Minor Stoppages

    6 Speed Loss X X

    7 Defect & Rework Loss X

    8 Schdeuled Downtime Loss

    9 Management Loss

    10 Operating Motion LossX X X X X X X X X X X X

    11 Line Organization Loss

    12 Logistics Loss

    13 Measurement & Adjustment Loss X

    14 Energy Loss

    15 Die,Jig & Tool Loss

    16 Yield Loss
    LOSS MATRIX
    GROUP : SLITTERS
    18 15 10 35 45
    00 00 00 0 0
    Loss No Loss Name 35" 10"12 1/2"15"
    M M M M M
    M M M M M
    1 Equipment Failure Loss

    2 Setup / Adjustment Loss

    3 Tool Change Loss

    4 Start Up Loss X X X X X X X X X

    5 Minor Stoppages

    6 Speed Loss

    7 Defect & Rework Loss

    8 Schdeuled Downtime Loss

    9 Management Loss

    10 Operating Motion Loss

    11 Line Organization LossX X X X X X X X X

    12 Logistics Loss X X X X X X X

    13 Measurement & Adjustment Loss

    14 Energy Loss

    15 Die,Jig & Tool Loss

    16 Yield Loss
    LOSS MATRIX
    GROUP : RHF FURNACES

    600
    600 3
    KW 575
    Loss No Loss Name RHF 1 RHF 2 KW T/H
    Ne KW
    Old r
    w

    1 Equipment Failure Loss

    2 Setup / Adjustment Loss X X

    3 Tool Change Loss X X X X X X

    4 Start Up Loss

    5 Minor Stoppages

    6 Speed Loss

    7 Defect & Rework Loss

    8 Schdeuled Downtime Loss

    9 Management Loss

    10 Operating Motion Loss

    11 Line Organization Loss X X X X X X

    12 Logistics Loss

    13 Measurement & Adjustment Loss X X X X X X

    14 Energy Loss

    15 Die,Jig & Tool Loss X X X X X X

    16 Yield Loss
    LOSS MATRIX
    GROUP : BELL FURNACES
    Narrow Wide
    Loss No Loss Name
    Width Width
    1 Equipment Failure Loss

    2 Setup / Adjustment Loss X X

    3 Tool Change Loss X X

    4 Start Up Loss

    5 Minor Stoppages

    6 Speed Loss

    7 Defect & Rework Loss

    8 Schdeuled Downtime Loss

    9 Management Loss

    10 Operating Motion Loss

    11 Line Organization Loss X X

    12 Logistics Loss

    13 Measurement & Adjustment Loss X X

    14 Energy Loss

    15 Die,Jig & Tool Loss X X

    16 Yield Loss
    LOSS MATRIX
    GROUP : PICKLING

    Push
    Wet
    Loss No Loss Name Pull
    Process
    Pickling

    1 Equipment Failure Loss

    2 Setup / Adjustment Loss X

    3 Tool Change Loss X

    4 Start Up Loss

    5 Minor Stoppages

    6 Speed Loss

    7 Defect & Rework Loss

    8 Schdeuled Downtime Loss

    9 Management Loss

    10 Operating Motion Loss X X

    11 Line Organization Loss X X

    12 Logistics Loss

    13 Measurement & Adjustment Loss X

    14 Energy Loss

    15 Die,Jig & Tool Loss X

    16 Yield Loss
    LOSS MATRIX
    GROUP : CENTRALISED MECH. MAINT. CONTROL

    Floor
    DG Compr-
    Loss No Loss Name Crane Move.
    Sets essor
    Equip.

    1 Equipment Failure Loss

    2 Setup / Adjustment Loss X X X X

    3 Tool Change Loss X X X X

    4 Start Up Loss X

    5 Minor Stoppages

    6 Speed Loss

    7 Defect & Rework Loss X X X X

    8 Schdeuled Downtime Loss

    9 Management Loss

    10 Operating Motion Loss X X X X

    11 Line Organization Loss X X X X

    12 Logistics Loss X X

    13 Measurement & Adjustment Loss X X X X

    14 Energy Loss

    15 Die,Jig & Tool Loss X X X X

    16 Yield Loss X X

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