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    16 Types of Loss in Gemba

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    shivendrakumar
    The document outlines 16 types of losses that can occur in manufacturing. It discusses 8 types of availability losses such as breakdown losses, planned maintenance time losses, setup losses, tool change losses, start up losses, minor stoppage losses, reduced speed losses, and defects and rework. It also describes 5 major losses that can impede worker efficiency including management losses, operating motion losses, adjustment and measurement losses, line organization losses, and logistics losses. Finally, it lists 3 major losses that can impede efficient use of production resources: energy losses, die/tool losses, and yield losses.

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    16 Types of Loss in Gemba

    Uploaded by

    shivendrakumar
    105 views5 pages
    The document outlines 16 types of losses that can occur in manufacturing. It discusses 8 types of availability losses such as breakdown losses, planned maintenance time losses, setup losses, tool change losses, start up losses, minor stoppage losses, reduced speed losses, and defects and rework. It also describes 5 major losses that can impede worker efficiency including management losses, operating motion losses, adjustment and measurement losses, line organization losses, and logistics losses. Finally, it lists 3 major losses that can impede efficient use of production resources: energy losses, die/tool losses, and yield losses.

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    The document outlines 16 types of losses that can occur in manufacturing. It discusses 8 types of availability losses such as breakdown losses, planned maintenance time losses, setup losses, tool change losses, start up losses, minor stoppage losses, reduced speed losses, and defects and rework. It also describes 5 major losses that can impede worker efficiency including management losses, operating motion losses, adjustment and measurement losses, line organization losses, and logistics losses. Finally, it lists 3 major losses that can impede efficient use of production resources: energy losses, die/tool losses, and yield losses.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    105 views5 pages

    16 Types of Loss in Gemba

    Uploaded by

    shivendrakumar
    The document outlines 16 types of losses that can occur in manufacturing. It discusses 8 types of availability losses such as breakdown losses, planned maintenance time losses, setup losses, tool change losses, start up losses, minor stoppage losses, reduced speed losses, and defects and rework. It also describes 5 major losses that can impede worker efficiency including management losses, operating motion losses, adjustment and measurement losses, line organization losses, and logistics losses. Finally, it lists 3 major losses that can impede efficient use of production resources: energy losses, die/tool losses, and yield losses.

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    16 types of loss in Gemba

    BY KII - 2014-06-02

    8 Availability Losses

    Breakdown loss (failure losses)

    Losses due to failures. Type of failure include sporadic function stopping failures and
    function – reduction failure in which the function of the equipment drop below normal
    levels like replacement of parts and repair, cases requiring 5 minute or more for repair.
    Target is zero failures
    To attain zero failure, it is necessary to correct the misconception about breakdown
    maintenance that failures are unavoidable

    Planned Maintenance Time Loss (Shut Down Loss)

    Time when equipment is shut down for maintenance. However shut down related work
    generally affect the operating time rate of equipment. Shutdown related work must be
    regarded as a loss and reduction of shutdown work time must be sought.

    Setup Loss

    e.g. Change of Dies, machining fixtures etc.


    Setup and adjustment losses refers to time losses from the end of the production of a
    previous items through product – change adjustment to the point where the production of
    the new item ic = s completely satisfactory. SMED must. Adjustments how to reduce,
    eliminate? One slot adjustment or trial or error till 3-4 components is tried.

    Tool Change Loss / cutting blade losses

    e.g. Change of Drill, tap, rammer, cutter etc.

    Stoppage losses caused by changing the cutting blade due to breakage or caused by
    changing the cutting blade when the service life of the grinding stone, cutteror bites has
    been reached
    What is your tool change loss? 5 or > 10 %.
    Normally a fix number of time is set but if the tool breaks before that – it leads to change,
    adjustment and a new sort over all again.

    Start up Loss

    e.g. furnace, paint shop oven etc.

    Start up losses are define as time losses from:

    1. Start up after periodic repair


    2. Start up after suspension (long time stoppage)
    3. Start up after holidays
    4. Start up after lunch breaks

    When starting production, the losses that arise until equipment starts up, running and
    production processing conditions stabilize.
    Do your machines have ‘Monday Disease?

    Minor stoppage loss

    i.e. Frequent stoppage for short time from seconds to less than 5 minutes for recovery
    e.g. Component stuck to die while stamping etc.

    Losses that occurs when the equipment temporarily stops or idles due to sensor
    actuation or jamming of the work The equipment will operate normally through simple
    measures (removal of the work and resetting)
    The definition of these losses is as follows;

     Losses that are accompanied by temporary functional stoppage


     Losses allowing functional recovery through simple measures (removal of
    abnormal work pieces and resetting)
     Losses that do not require part exchange or repair

    To reduce minor stoppage, it is important to adequately analyze the phenomena involved


    and thoroughly eliminate minor defects. The target number of minor defects is zero.

    Reduce speed loss

    e.g. 50 parts produced against standard of 53 parts as a cycle time increased to 9 min
    from 8.5 due to less speed/feed

    These are losses that occur because of equipment speed is slow. They can be defined
    as follows;
    Losses due to a difference between the design speed (or standard speed for the item
    concerned) and the actual speed
    Losses caused when design speed is lower than present technological standards or the
    desirable conditions
    If the design speed is 60 seconds and actual cycle time is 65 seconds then the loss is 5
    seconds.
    The target is to reduce the difference between design speed and actual speed to zero

    Defects and rework

    i.e. any reworked or rejected product shows direct time loss due to poor quality

    Sporadic defects are easily fixed, so they are rarely left uncorrected. Chronic defects in
    contrast, are often left as they are, because their causes are difficult to perceive and
    measures to correct them are seldom effective to realize zero defects, it is necessary to
    radically review defective phenomena.

    5 major losses that impede workers efficiency

    Losses impeding human efficiency

    Management losses

    e.g. Row material/ persons not available esp. poor planning.

    Waiting losses that are caused by management, such as waiting for material, waiting for
    a dolly, waiting for tools, waiting for instructions, waiting for repairs of breakdowns, etc.

    Operating Motion Loss (OML)


    e.g. Excess motion like walking, bending, stretching etc.

    These include motion losses due to violation of motion economy, losses that occur as a
    result of skill differences, and walking losses attributable to an inefficient layout.

    Adjustment & Measurement loss

    e.g. Frequent tool adjustment after few components.

    Work losses from frequent measurement and adjustment in order to prevent the
    occurrence and outflow of quality defects.

    Line organization loss (LOL)

    e.g. 75% manpower utilization due to poor line balancing

    These are waiting time losses involving multi – process and multi stand operators and
    line balance work in conveyor work

    Logistics loss/ distribution losses/ losses resulting from failure to automate.

    e.g. operator travels/ waits for want of material on stage.

    Distribution man hour losses due to transport of materials products (proceed products)
    and dollies.
    These are also personal losses resulting from non replacement with automated systems,
    although such replacement could be done. They include for instance case in which
    automated loading and unloading leading to manpower reduction is not implemented,
    although it could be done.
    Losses of costs – three major losses that sat can impede effective use of production
    resource

    3 major losses that impede efficient use of production subsidiary resources

    Losses of cost

    Energy losses

    e.g. losses due to heat radiation, leakage of fuel, air, oil, losses, due to ineffective
    utilization of input energy (electric, gas, fuel oil, steam, air and water etc) in processing .
    Etc.
    Because of electricity, fuel, utility cost represents a high percentage of the total cost, all
    companies are striving to reduce them

    Die/ Tool loss

    e.g. lose of tool due to regrinding, poor life of molds etc, repairs of Dies/ Tools FOS
    consumables

    These are monetary losses resulting from the mfg and repair of dies, jigs and tools
    necessary for the production of products
    Mfg new modules, replacement at the end of service life, breakdown, repair is expensive.
    To reduce mfg costs it is absolutely necessary to extend MTBF of mould repair, to
    prevent product breakage and to extend the service life of replacement parts

    Yield loss

    e.g. Excess material stock/ weight, Exclusive splashes etc…Material losses due to
    differences in the weight of the input materials and the weight of the quality products.

    Increase casting wall thickness to avoid below holes leading to more machining time and
    loss of material.

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