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Industrial Losses

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78kbalaji

The document outlines 16 types of losses that can occur during manufacturing training material. It describes losses from equipment failures, job and tool changes, start-up times, minor stoppages, reduced speeds, defects and reworks, scheduled downtime, management issues, operating motions, line organization, logistics, measurements and adjustments, energy use, tool wear, and material yield losses. Examples are provided for each type of loss to illustrate how it can impact key performance metrics like overall equipment effectiveness, output, and costs. The goal of the training material is to help identify and classify different sources of inefficiency in manufacturing processes.

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Download as PPT, PDF, TXT or read online from Scribd
Download as ppt, pdf, or txt

Industrial Losses

Uploaded by

78kbalaji
121 views22 pages
The document outlines 16 types of losses that can occur during manufacturing training material. It describes losses from equipment failures, job and tool changes, start-up times, minor stoppages, reduced speeds, defects and reworks, scheduled downtime, management issues, operating motions, line organization, logistics, measurements and adjustments, energy use, tool wear, and material yield losses. Examples are provided for each type of loss to illustrate how it can impact key performance metrics like overall equipment effectiveness, output, and costs. The goal of the training material is to help identify and classify different sources of inefficiency in manufacturing processes.

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Training material for TPM 16 looses

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The document outlines 16 types of losses that can occur during manufacturing training material. It describes losses from equipment failures, job and tool changes, start-up times, minor stoppages, reduced speeds, defects and reworks, scheduled downtime, management issues, operating motions, line organization, logistics, measurements and adjustments, energy use, tool wear, and material yield losses. Examples are provided for each type of loss to illustrate how it can impact key performance metrics like overall equipment effectiveness, output, and costs. The goal of the training material is to help identify and classify different sources of inefficiency in manufacturing processes.

Copyright:

Attribution Non-Commercial (BY-NC)
Download as PPT, PDF, TXT or read online from Scribd
Download as ppt, pdf, or txt
121 views22 pages

Industrial Losses

Uploaded by

78kbalaji
The document outlines 16 types of losses that can occur during manufacturing training material. It describes losses from equipment failures, job and tool changes, start-up times, minor stoppages, reduced speeds, defects and reworks, scheduled downtime, management issues, operating motions, line organization, logistics, measurements and adjustments, energy use, tool wear, and material yield losses. Examples are provided for each type of loss to illustrate how it can impact key performance metrics like overall equipment effectiveness, output, and costs. The goal of the training material is to help identify and classify different sources of inefficiency in manufacturing processes.

Copyright:

Attribution Non-Commercial (BY-NC)
Download as PPT, PDF, TXT or read online from Scribd
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16 LOSSES Training Material

1. EQUIPMENT FAILURE / BREAKDOWN LOSS


Losses Description: 1A - Equipment Failure: TIME Lost due to a Breakdown involving replacement of spares Example: Seal replacement due to Hydraulic cylinder oil leakage in Press Losses Description: 1B Breakdown: TIME Lost due to a Breakdown without replacement of spares Example: Correcting pressure regulating valve settings due to Hydraulic pressure is low Losses related to: Equipment

Losses Affecting: OPE/OEE/Availability

2. JOB CHANGE LOSS


Losses Description: 2A - Job Change - Auto: TIME Lost due to Change over from one product to another Example: Job change from Regulating Sleeve 0350 to 0507 in 50/4 Compaction Press. Losses Description: 2B - Job Change Manual: TIME Lost due to Change over from one product to another Example: Job change from Regulating Sleeve 0350 to 0507 in 40 T Sizing press Losses related to: Equipment

Losses Affecting: OPE/OEE/Availability

3. TOOL CHANGE LOSS


Losses Description: 3A - Tool Change: TIME Lost due to Change over of any tool of the running product.

Example: Top Punch change in 0350 compacting press.


Losses Description: 3B Coil Change: TIME Lost due to Change over of RM coil of the running product

Example: Raw Material bundle change in sawing Machine.


Losses Description: 3C Tool service: TIME Lost due to service / service delays of running / new tools Example: Top Punch Polishing in 0350 compacting press for flaking Losses related to: Equipment

Losses Affecting: OPE/OEE/Availability

4. START-UP LOSS
Losses Description: Start - up: TIME Lost initially after switching on an equipment till it is ready for production. Example: Time required for the Sintering Furnace to reach the Set Temperature for Heat Treatment Process.

Losses related to: Equipment

Losses Affecting: OPE/OEE/Availability

5. MINOR STOPPAGE & IDLING LOSS


Losses Description: Minor Stoppage: OUTPUT Lost due to equipment stopping for minor problems Example: Vibrator bowl feeder setting in Press.

Losses related to: Equipment

Losses Affecting: OPE/OEE/Performance Rate

6. REDUCEED SPEED LOSS


Losses Description: Reduced Speed: OUTPUT Lost due to operating the machine below the rated / designed speed Example: 1. Reducing the Strokes per minute from 18 to 16 to prevent weight variation in 0350 Compaction Press. 2. Reducing the speed due to finish problem in CNC Machine.

Losses related to: Equipment

Losses Affecting: OPE/OEE/Performance Rate

7. DEFECTS & REWORK LOSS


Losses Description: Defect / Rework: TOTAL QUANTITY rejected and sorted out as OK/Rework/Scrap Example: 1. Quantity rejected for under fill problem in CV inner upsetting 2. Crack in PM Parts

Losses related to: Equipment

Losses Affecting: OPE/OEE/Performance Rate

8. SCHEDULED DOWN LOSS


Losses Description: 8A - JH Activity: TIME Lost due to JH activities done by stopping the machine Example: JH Activities like Cleaning, Lubrication, Inspection etc

Losses Description: 8B PM Activity: TIME Lost due to PM activities done as per PM calendar
Example: Preventive Maintenance carried out in a Machine Losses Description: 8C Meetings: TIME Lost due to meetings held by stopping the machine

Example: Daily Meetings / Circle Meetings / Medical Centre Visit

8. SCHEDULED DOWN LOSS


Losses Description: 8D - Development: TIME Lost due to Booking of machine for Development activities Example: Development trail by PED

Losses Description: 8E Not Scheduled: If machine is not scheduled to run in a shift


Example: No Market Order / No Production Planning

Losses related to: Equipment

9. MANAGEMENT LOSS
Losses Description: 9A - Want of Tools: TIME Lost due to Non-availability of Tools. Example: Press Waiting for CV Inner Die from Tool Room.

Losses Description: 9B Awaiting Instruction: TIME Lost due to delay in giving Work order/Schedule/Instruction
Example: Wire Cut M/c waiting for CNC Programme / Work order Losses Description: 9C Want of RM: TIME Lost due to delay in giving RM to the machine

Example: Press Waiting for Slug from Coating Plant.

9. MANAGEMENT LOSS
Losses Description: 9D - Want of Men: TIME Lost due to Nonavailability of Men on a schedule machine Example: Operator Leave / Permission

Losses Description: 9E Want of Gas/Air/Oil: TIME Lost due to Non-availability of GAS (Air) supply to the machine
Example: Compressed Air not available for the press. Losses Description: 9F Want of Power: TIME Lost due to Non-availability of Electrical Power supply to the machine

Example: Electrical Power supply not available for the CNC M/c

9. MANAGEMENT LOSS
Losses Description: 9G - Awaiting Inspection: TIME Lost in waiting for first-off sample approving authority Example: Waiting for first product approval from Quality

Losses Description: 9H Want of Order: If machine cannot run due to Non-availability of orders
Example: No Market Order Losses Description: 9T Want of Containers :TIME Lost due to delay in giving tote box/trolley/half-drum/tray.

Example: Want of Trolley / Tray / Pallets

9. MANAGEMENT LOSS
Losses related to: Man

Losses Affecting: OPE

10. OPERATING MOTIONS LOSS


Losses Description: Operating Motion: OUTPUT Lost due to Unnecessary movement of Materials, operators etc (operator skills & Efficiency) Example: Input Material / Tray kept at a long distance from the machine.

Losses related to: Man Power

Losses Affecting: OPE/OEE/Performance Rate

11. LINE ORGANISATION LOSS


Losses Description: Line Organization: OUTPUT Lost due to idling of line/multi-machine operations Example: Machine waiting due to delay in previous process / machine.

Losses related to: Man Power

Losses Affecting: OPE/OEE/Performance Rate

12. LOGISTICS LOSS


Losses Description: Logistics: TIME Lost due to operator stopping the Machine to get load. Example: Operators performing material movement instead of running the machine.

Losses related to: Man Power

Losses Affecting: OPE

13. MEASUREMENT & ADJUSTMENT LOSS


Losses Description: 13A - Measurement: OUTPUT Lost due to Inspection Example: Machine stopped for inspecting the products while running Losses Description: 13B Adjustment: OUTPUT Lost due to Adjustments to correct quality problems

Example: Die Position adjustment to correct concentricity problem


Losses related to: Man Power

Losses Affecting: OPE/OEE/Performance Rate

14. ENERGY LOSS


Losses Description: Energy: Cost control for effective use of Energy Example: Energy loss due to leakage from the Furnace door

Losses related to: Energy

Losses Affecting: Cost

15. DIE & TOOL LOSS


Losses Description: Die/Jig/Tool/Spare: Cost control for effective use of indirect materials Example: Repair losses for the broken tools

Losses related to: Material

Losses Affecting: Cost

16. MATERIAL YIELD LOSS


Losses Description: Yield: Cost control for effective use of direct materials Example: Wastage of Material due to excess machining stock given

Losses related to: Material

Losses Affecting: Cost

THANK YOU FOR THE PARTICIPATION

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