16 Losses in Production (TPM losses) Major

16 major looses, 16 major production loses,

What are 16 Major Losses in TPM?

  1. Losses in the product process mean the top most recourses are wasted in  your industries
  2. In Total Productive Maintenance (TPM), there are 16 defined set of criteria related to different losses, which is known as 16 Major Losses of  tpm.
  3. The names of these losses might be different in different Industries,  but the nature of the losses remain same.
  4. These 16 Major Losses in Total Productive maintenance (TPM) impact on Product Quality, productivity, and profitability of the company. So we need to identify and remove  these 16 major losses from the company.
  5. Some of the reasons for the losses can be epitomized as below
  6. We’re running product for redundant timing.
  7. Product is intruded or stopped
  8. Non- value- adding activity  is performed
  9. The machine is idle for so  many reason.
  10. When a machine isn’t running as per the design rated speed
  11. The machine is consuming fresh time, plutocrat, energy than the specified demand.

The 16 Major Losses in Production

The 16 Major losses in Total Productive Conservation (TPM) are further divided into different orders as mentioned below

  1. Losses Impacting on Machine availability -8 Losses ( Relate 1 to 8 Losses in the below list)
  2. Losses Impacting on Performance-5 Losses ( Relate 9 to 13 Losses in the below list)
  3. Losses Impacting on Coffers Consumption-3 Losses ( Relate 14 to 16 Losses in the below list)

For better understanding, You can relate to Overall Equipment Efficiency.

The 16 Major losses in TPM are as below

  1. Equipment Failure ( Breakdown) Loss
  2. Set up & Adjustment Loss
  3. Cutting Tool/ Blade Change Loss
  4. Start-up Loss
  5. Minor Stoppage & Idling Loss
  6. Speed Loss
  7. Defects and  Rework Loss
  8. Shutdown loss  (Planned Maintenance Loss)
  9. Operation Loss
  10. Stir Loss or Operating Stir Loss
  11. Line Organization Loss
  12. Distribution/ Logistic Loss
  13. Measurement & Adjustment Loss
  14. Energy Loss
  15. Consumable Loss
  16. Yield Loss

8 Types of Losses- affecting on Madhine availability. 

01. Machine  Failure ( Breakdown) Loss

  • Machine  Failure means the machine is under any kind of breakdown and not suitable to operate.
  • We can also include the failure-if the machine isn’t suitable to operate at rated capacity due to a any issues
  • Our target is zero breakdowns.
  • For this kind of failure generally, we’re doing Breakdown maintenance
  • We can exclude Equipment failure by enforcing a Preventative Maintenance  Plan.

02. Set up & Adjustment Loss

  • While we’ve any transfiguration on the machine at that time we’ve a loss that’s called setup and change over loss.
  • The change includes product change, Tool change,
  • We can use the Single Minute Exchange of Die (SMED) fashion for minimizing Setup & Adjustment Loss.

03. Cutting Tool/ Blade change Loss

  • While we’re changing or replacing the cuting tool or cuting  blade at that time the loss is created that’s known as a Cutting Tool/ Blade change loss.
  • We’re changing various  tools like a drill bit, grinding wheel, valve, rammer, knife, etc.
  • We can use the Single Minute Exchange of Die (SMED)  to minimize Setup & Adjustment Loss.
  • Also, alternately, we can develop a further durable cutting tool or can do Kaizens for reducing this loss.

04. Start-up Loss

  • this loss occurs while we’re starting the machine.
  • It includes stabilize the product and need to take approval from QA before continuing the product.
  • So this loss considers as a start up loss until the machine runs at rated speed.
  • As per the manufacturing product, the start- up  process may include the production set up,  process, cleaning, etc.
  • We can reduce this loss by homogenizing the processes and parameters.

05. Minor Stoppage & Idling Loss

  • While machine stops constantly for a veritably small time period and this exertion occurs multiple times in a shift that’s considered the minor stoppages and Idling Loss.
  • Minor stoppages might be possible due to malfunction of detectors, jamming of product, resetting parameters, etc.
  • Occasionally we stop machines for a job removing or resetting .

06. Speed Loss

  • If the machine is running lower than the design speed also it’s considered as the speed loss.
  • So our target should be the machine must be running at the design speed for minimizing the speed loss.

07. defect and Rework Loss

  • If the machine is producing a imperfect product and we’re spending time to rework the imperfect product that’s called the  Rework Loss.
  • For barring this loss we need to regularize processes and parameters.
  • For better understanding, you can relate to the 5S Methodology.

08. Shut down Loss (Planned Conservation Loss)

  • When Equipment is shut down for the Planned maintenance, the loss is considered a Shut down loss  or Planned maintenance Loss.
  • Occasionally, the outfit should be shut down due to periodic examination, statutory or nonsupervisory compliance.

5 Types of Losses- affecting on Performance

09. Management Loss

  • The staying losses that are caused by operation are called Management  Loss.
  • Some exemplifications of management losses are waiting for resource such as material, tools, instruction.

10. Motion Loss or Operating Motion Loss

  • If we take excess motion / movement  for any process so that’s known as a motion Loss or Operating motion Loss.
  • This happens substantially due to imbalance in process layout.
  • To minimize or exclude this loss we need to apply  optimize the process layout and way.

11. Line Organisation  Loss

  • Line balancing loss is the waiting loss at the process position.
  • Line balancing means if any product is manufactured in No of step then, speed of all steps need to be same.
  • The product shouldn’t be ideal at any stage of the process.
  • To exclude 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 product, semi finished products, or finished products from one position to another.
  • To exclude this kind of loss we can apply robotization for material/ product transportation at different situations.

13. Measurement & Adjustment Loss

  • The man-hour loss is due to frequent dimension & adaptation of machine settings to help the quality blights is called a Measurement & Adjustment Loss.
  • That’s passing during nonstop product.
  • So we can minimize this kind of loss by enforcing various Poka- Yoke and Process Standardizations.

3 Types of Losses- affecting on Coffers Consumption

14. Energy Loss

  • The losses because of ineffective application of input energy like electric, gas, energy canvas, brume, air, and water, etc in processing is called Energy Loss.
  • Exemplifications of Energy Loss are losses due to heat radiation, leakage of energy, leakage of air, Leakage of canvas, 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 form and repair and replacement of any spare, die, tool, etc is called Consumable loss.
  • Spare parts  get damaged after the service life so we need to change it-this is coming under the consumable loss.

16. Yield Loss

  • Occasionally the weight of the finished product is more than the design specification that’s due to maintaining the good quality of the product but it’s a loss of the is called Yield Loss.
  • if we keep more material means we need more processing to remove extra material.
  • For better understanding we take one illustration- Increase casting wall consistence to avoid blow- holes disfigurement leading to further machining time and loss of material.

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