The 16 Losses PDF

The 16 Losses In Total Productive Maintenance
To help identify all losses in a process system (man/machine/material), and thus,

eliminate them, they have been divided into 16 categories, and can be grouped
accordingly, as shown in Figure 1, with orange representing the equipment related
losses, blue representing the losses relating to manpower and yellow representing
the losses relating to resource consumption.
Figure 1: The 16 big losses
Equipment Losses
1. Breakdown loss: (unit time e.g. hours)

The equipment breaks down causing the function of the line or process to stop.
Often this is considered as a sporadic failure, typically caused by equipment
component failure.
Examples: Bearing failure due to wear, electrical fault, snapped belt.
2. Set up & adjustment loss: (unit time e.g. hours)

This loss occurs during a changeover between products. Set up time is defined
as the amount of time taken to change a process over from the last part of a
production run to the first good, repeatable part of the next production run.
Adjustment within the set up time is often hidden, and involves tweaking settings
until optimal run conditions are achieved.
Examples: Changing products, changing packaging, adjusting the feed rate.
3. Cutting blade replacement loss: (unit time e.g. hours)

The time loss incurred swapping any consumable tooling item when it has
become worn/ineffective or damaged.
Industry Forum 2015 All Rights Reserved

Examples: Time spent replacing saw blades, cutting/grinding tools, and lathe
tools.
4. Start-up loss: (unit time e.g. hours)

The loss incurred whilst starting up equipment, to get to steady state operating
conditions, after planned or unplanned shutdown.
Examples: Time spent warming/cooling equipment to operating temperature,

compressor/hydraulic power pack run-up time.
5. Minor stoppage & idling loss: (unit time e.g. hours)

These are typically small stoppages not logged as breakdowns and issues
causing the machine to pause or idle for short periods. They are often chronic
losses, regularly repeated, often not recorded and usually less than 1 minute
duration.
Examples: Waiting for a machine to index, emptying a mould during press

operation, a sensor fault or product blockage.
6. Speed reduction loss: (unit rate e.g. tonnes per hour)

This loss occurs from operating at a speed less than the design speed.
Examples: Line speed reduced due to quality issues or mechanical problems,

gaps in the product on conveyors.
7. Defect & rework loss: (unit to match rate e.g. tonnes)

This is the loss of defective product i.e. Not Right First Time which requires
rework, repair or scrap.
Examples: Out of spec product, low weight product requiring top-up, poor surface
finish, incorrect labelling.
8. Shutdown loss: (unit time e.g. hours)

The loss incurred by deliberately shutting down the equipment within the
production plan.
Examples: Routine maintenance, periodic overhaul, cleaning, statutory

inspections.
Manpower Losses
9. Management Loss: (Unit = Time & )

These are waiting time losses generated by management problems.
Examples: Failure to provide materials, spare parts, manpower resource, utilities,

work instructions.
10. Motion Loss: (Unit = Time & )

Losses are created due to unnecessary/excessive operator movement and
transportation, as a result of poor layout and work organisation.
Examples: Walking loss, wasted motion e.g. unnecessary reaching and lifting
11. Line Organisation Loss: (Unit = Time & )

This loss results from a shortage of operators on the line and operators having to
work on more equipment than was originally planned.
Examples: No additional cover or contingency for break times, training and time
spent off the line
12. Distribution Loss: (Unit = Time & )

This loss is the wasted time that is experienced in the incorrect or inefficient
delivery of raw materials, packaging or products to and from the factory or the
production line.
Example: Incorrect delivery of materials from supplier to store, late deliveries,

excessive handling of deliveries (double handling)
13. Measurement and Adjustment Loss: (Unit = Time & )

This loss is caused by the frequent measurement and adjustment to prevent the
recurrence of problems.
Example: Excessive inspection integrated in the process as a result of poor

quality and failure to find root cause. Adjustment loss is experienced when
adjusting equipment back to the standard after routine cleaning and periodic
consumable changes (e.g. labels, film, and ink).
Yield, Energy & Tooling Loss
14. Yield Losses: (Unit = )

This is the total loss between the input of raw material and the output of finished
goods.
Examples: over-pack, giveaway, mass balances
15. Energy: (Unit = )

Energy loss is the input energy which cannot be used effectively for processing
Examples: Start-up losses, Idling losses.
16. Die, Tool and Jig Losses: (Unit =)

This is the cost of the physical consumption of the spare parts or the
refurbishment/maintenance of items that are used on the line.
Examples: Cost of spares, cost of replacement and maintenance to tooling, dies

and jigs.

The 16 Losses PDF

Uploaded by

Copyright:

Available Formats

The 16 Losses PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

The 16 Losses PDF

Uploaded by

Copyright:

Available Formats

The 16 Losses In Total Productive Maintenance

To help identify all losses in a process system (man/machine/material), and thus,

Figure 1: The 16 big losses

1. Breakdown loss: (unit time e.g. hours)

Examples: Bearing failure due to wear, electrical fault, snapped belt.

2. Set up & adjustment loss: (unit time e.g. hours)

Examples: Changing products, changing packaging, adjusting the feed rate.

3. Cutting blade replacement loss: (unit time e.g. hours)

Industry Forum 2015 All Rights Reserved

4. Start-up loss: (unit time e.g. hours)

Examples: Time spent warming/cooling equipment to operating temperature,

5. Minor stoppage & idling loss: (unit time e.g. hours)

Examples: Waiting for a machine to index, emptying a mould during press

6. Speed reduction loss: (unit rate e.g. tonnes per hour)

Examples: Line speed reduced due to quality issues or mechanical problems,

7. Defect & rework loss: (unit to match rate e.g. tonnes)

8. Shutdown loss: (unit time e.g. hours)

Examples: Routine maintenance, periodic overhaul, cleaning, statutory

9. Management Loss: (Unit = Time & )

Examples: Failure to provide materials, spare parts, manpower resource, utilities,

10. Motion Loss: (Unit = Time & )

Industry Forum 2015 All Rights Reserved

11. Line Organisation Loss: (Unit = Time & )

12. Distribution Loss: (Unit = Time & )

Example: Incorrect delivery of materials from supplier to store, late deliveries,

13. Measurement and Adjustment Loss: (Unit = Time & )

Example: Excessive inspection integrated in the process as a result of poor

Yield, Energy & Tooling Loss

14. Yield Losses: (Unit = )

Examples: over-pack, giveaway, mass balances

15. Energy: (Unit = )

Examples: Start-up losses, Idling losses.

16. Die, Tool and Jig Losses: (Unit =)

Examples: Cost of spares, cost of replacement and maintenance to tooling, dies

Industry Forum 2015 All Rights Reserved

You might also like