Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
Scribd Logo
Upload

Welcome to Scribd!

  • 233 views

    6 Big Losses Presentation

    Uploaded by

    Muthuswamy
    The document discusses the 6 big losses that can impact equipment efficiency: 1) failure/breakdown losses, 2) set-up and adjustment losses, 3) cutting blade losses, 4) start-up losses, 5) minor stoppage/idling losses, and 6) speed losses. It defines each loss type and provides examples. The document also discusses how to measure the 6 big losses and presents various approaches to eliminating each type of loss, such as using root cause analysis, SMED exercises, cycle time analysis, and Six Sigma's DMAIC process. The overall goal is to identify and address the sources of downtime and defects in order to improve production efficiency.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    6 Big Losses Presentation

    Uploaded by

    Muthuswamy
    233 views21 pages
    The document discusses the 6 big losses that can impact equipment efficiency: 1) failure/breakdown losses, 2) set-up and adjustment losses, 3) cutting blade losses, 4) start-up losses, 5) minor stoppage/idling losses, and 6) speed losses. It defines each loss type and provides examples. The document also discusses how to measure the 6 big losses and presents various approaches to eliminating each type of loss, such as using root cause analysis, SMED exercises, cycle time analysis, and Six Sigma's DMAIC process. The overall goal is to identify and address the sources of downtime and defects in order to improve production efficiency.

    Original Description:

    6 big

    Original Title

    6-Big-Losses-Presentation

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document discusses the 6 big losses that can impact equipment efficiency: 1) failure/breakdown losses, 2) set-up and adjustment losses, 3) cutting blade losses, 4) start-up losses, 5) minor stoppage/idling losses, and 6) speed losses. It defines each loss type and provides examples. The document also discusses how to measure the 6 big losses and presents various approaches to eliminating each type of loss, such as using root cause analysis, SMED exercises, cycle time analysis, and Six Sigma's DMAIC process. The overall goal is to identify and address the sources of downtime and defects in order to improve production efficiency.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    233 views21 pages

    6 Big Losses Presentation

    Uploaded by

    Muthuswamy
    The document discusses the 6 big losses that can impact equipment efficiency: 1) failure/breakdown losses, 2) set-up and adjustment losses, 3) cutting blade losses, 4) start-up losses, 5) minor stoppage/idling losses, and 6) speed losses. It defines each loss type and provides examples. The document also discusses how to measure the 6 big losses and presents various approaches to eliminating each type of loss, such as using root cause analysis, SMED exercises, cycle time analysis, and Six Sigma's DMAIC process. The overall goal is to identify and address the sources of downtime and defects in order to improve production efficiency.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 21
    At a glance
    Powered by AI
    The key takeaways are about OEE (Overall Equipment Effectiveness) and the 6 big losses that impact production efficiency.

    The 6 big losses discussed are: 1) Failure/Breakdown Losses, 2) Set-up and Adjustment losses, 3) Cutting Blade Losses, 4) Start-up Losses, 5) Minor Stoppage/Idling Losses, 6) Speed losses.

    The 6 big losses are defined as: losses due to equipment failures, changeover/setup times, blade replacement/damage, start-up after repairs/downtime, temporary machine malfunctions, and differences between actual and standard cycle times.

    OEE VS 6 BIG

    LOSSES

    OEE Workshop
    Siyambulela Bozo: Junior Project Manager
    AIDC - TPM
    Presentation Overview

    1. What are Losses


    2. Defining the 6 Big Losses
    3. Measuring 6 Big Losses
    4. How to Eliminate the 6 Big
    Losses?
    • Conclusion
    1. What Are Losses?
    “ Losses in the production environment are those
    areas where the greatest amounts of materials and
    time is wasted” -
    Kunio Shirose, 1989
    There are 16 Major Losses that can impede Improvement of
    Production Efficiency

    A) 7 Major Losses that can impede equipment efficiency


    B) 1 Major Loss that can impede machine loading time
    C) 5 Major Losses that can impede improvement of work
    D) 3 Major Losses that can impede effective use of production resources
    2.Defining 6 Big Losses
    2. Defining 6 Big Losses
    1. Failure/Breakdown Losses
     Losses due to sporadic / chronic failures result in time
    losses (declining output) and volume losses (defects)
     Losses requiring replacement or repair of machine
    parts for machine to function
     Losses requiring 5-10 minute or more for repairs
    Sporadic Failures
     Attract major attention and countermeasures are
    immediately developed and implemented e.g. Tool
    Breakdown
    Chronic Failures
     Frequent failures which remain unresolved due to
    ineffective countermeasures
    2. Defining 6 Big Losses
    2. Set-up and Adjustment losses
     Time losses from end of the production of a previous item,
    through changeover and setup of new product tools
     Time losses after set-up by doing trial and error adjustments
    to buy-off good part after many parts try out
    3. Cutting Blade Losses
     Losses due to regular blade exchanges and other
    blade replacement by blade damages and volume
    losses
     Losses due to breakage and chipping of blade, blade tip
    rework
     Losses due to material and yield losses
    2. Defining 6 Big Losses
    4. Start-up Losses
     Time losses from start-up after
    periodic repair
     Time losses from start-up after
    suspension (long-time
    stoppage)
     Time losses after lunch breaks

    5. Minor Stoppage / Idling Losses


     Losses due to temporary malfunction of machine
     Losses requiring removal of abnormal work pieces and
    resetting
    2. Defining 6 Big Losses
    6. Speed losses
     Losses occurring due to
    slow equipment speed
     Losses due to difference
    between the design speed
    and the actual machine
    speed
     Losses caused when the
    design speed is slower
    than present technological
    standards or the desirable
    condition

    E.g. If standard cycle time is set at


    60seconds, and actual operation time is
    65seconds, speed loss is 5 seconds
    3. Measuring 6 Big Losses
    OEE in China
    4. Eliminating 6 Big Losses
    4. Eliminating 6 Big Losses
    4. Eliminating 6 Big Losses
    4. Eliminating 6 Big Losses
    4. Eliminating 6 Big Losses
    4. Eliminating 6 Big Losses
    4. Eliminating 6 Big Losses
    Conclusion
    Down Time

    1. Breakdowns due to equipment failure


    - Apply Ishikawa Root Cause Analysis as a Team and solve root cause of equipment
    2. Setup and adjustment (e.g. exchange of dies in injection molding machines)
    - Perform SMED Exercise

    Speed Losses

    3. Idling and minor stoppages (abnormal operation of sensor, etc.)


    - Cycle time analysis to see the process that frequently causes the stoppage
    4. Reduced speed (discrepancies between designed and actual speed of equipment)
    - Compare all cycle times to ideal cycle time and focus on eliminating errant times
    Defects

    5. Defects in process and rework (scrap and quality defects requiring repair)
    - Six Sigma (DMAIC Process Improvement Approach)
    6. Reduced yield between machine startup and stable production
    - Six Sigma (DMAIC Process Improvement Approach)

    You might also like