16 major losses
Loss Tree
16 major losses during production activities
Why required to control this 16 major losses during production activities?
- to reduce material loss, energy loss, effort loss
- manufacturing cost it is also a part of the quality plus competition
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Loss Tree
16 major losses during production activities
(A) machine related losses that reduce overall equipment efficiency
1. Failure losses (also known as breakdown loss)
Machine is schedule for production but not running due to some failure (breakdown) or some sort
down time longer than two minute should have a reason associated with it and it shall be considered equipment failure
Examples: unplanned stop /downtime, tooling failure, breakdown, unplanned maintenance, no operator or materials, problem with upstream equipments, downstream is blocked, bearing failure due to wear, mechanical / electrical fault
2. Setup and adjustment losses (also known as changeover losses )
This losses occurs during changeover between products /size
It defined as the amount of time taken to change a process over from the last part of a production run to the first good
Examples: changing the product / size
Adjustment loss is tooling adjustment, equipment adjustment, example quality inspection
3. Cutting blade and jig changing losses
Time loss occurs during replacing any consumable tooling when it has became worn, ineffective or damage
Examples: cutting / grinding tools changing
4. Startup losses
Losses occurs while starting up equipment until production process stabilize after breakdown or stop
5. Minor stoppages in idling losses
Losses occurs when equipment temporally stops or idle due to sensor actuation or jams of the work
Usually less than 1 minute duration, regular repeated problem
Examples: Misfeeds, material jams, obstructed product flow, incorrect setting, miss aligned, blocked sensors, equipment design issues, periodic quick cleaning
6. Speed reduction losses
This loss occurs due to operating at a speed less than design speed
Examples: line speed reduced due to quality shoes for mechanical problems
Common reasons for reduced speed include dirty or worn out equipment, poor environmental condition, operator inexperience, startup and shutdown
7. Defect and Rework losses
Losses due to defect and reworking
Examples: out of spec product, poor surface finish, incorrect labelling
8 shutdown losses
Losses due to planned equipment stoppages at the production planning level
Examples: routine maintenance, periodic inspection, statutory inspection
(B) worker efficiency related losses
9. Management losses
This is waiting losses generated by management problems
Examples: failure to provide materials, spare parts, tools, dollies/ trolleys, manpower resources, utilities, work instructions
10. Motion losses
Motion losses occurs due to unnecessary movement and transportation, as a result of poor layout and work organisation
Examples: walking loss, wasted motion, unnecessary reaching andl Lifting
11. Line organisation losses
This loss occurs from shortage of operater on the line and operator having to work on more equipment than was originally planned
No additional manpower cover for break time and uncertainty
12. Distribution losses
Distribution losses occurs due to transport of of materials, processed product, dollies - trolleys from one machine to another machines
13. Measurement and adjustment losses
This losses occurs due to frequent measurement and adjustment to prevent the the reoccurrence of of nonconformity problems
(C) production resources related losses
14. Energy losses
Losses due to ineffective utilisation of input energy (electricity, gas, fuel, oil etc) in in processing.
15. Die, tool and jig losses
It occurs due to repairs of of dies, jigs, and tools due to aging beyond service life or breakage
16. Yield losses
This is the total loss between the input of raw material and output finished goods
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