16 Major Losses identified by TPM

1. Breakdown Loss : Loss of time wherein machine has stopped on it's own, machine has been stopped e.g. due to quality issue, speed loss, etc. For calculation of OEE, a part of breakdown, which has resulted in loss of opportunity of production, shall be considered. e.g. If machine is repaired on a holiday, repair time shall be included in breakdown time, howe er such time shall not be considered for OEE calculation. !ll repairs that are not part of planned maintenance "based on annual plan# are part of breakdown loss. e.g. If a bearing has failed prematurely, its replacement shall be breakdown loss. 2. Planned Maintenance Loss:

$he acti ity that is pre%decided "annual calendar# with a realistic estimate. e.g. in the year F&', spare parts of the machines will be replaced with a specific predetermined periodicity, irrespecti e of the life left ( failure occurred due to the spare part in question "$ime bound maintenance#. It will also include specific predetermined o erhaul program. 3. Set ! Loss:

$he loss attributed to change of setup from one component to other component. "ote) It shall include time for remo al, fi*ing, ad+ustment(repair. ,etting is complete when - st +ob is as per specifications. e.g. .hange of /igs 0 fi*ture "as applicable in machining area#, .hange of die "as applicable in stamping area 0 foundry#. #. Tool c$ange Loss:

$ool change loss is defined as a loss occurred while changing tools 0 tooling in running production till -st ok part is produced. "ote) $ime lost in changing drills, bushes, dressing wheels, etc. %. Start ! Loss:

$he time required for the equipment to attain optimal operating condition. e.g. Paint s$o! & o en temperature is e*pected to reach ' o( before baking can start. )eat Treat*ent & Furnace should attain + o( before charge is put inside. ,o ndry P- & 1ie is heated to . o( before start of production. 6. Minor Sto!s:

It is a performance%related loss "usually less than a minute# that results in stoppage of material mo ement. e.g. Limit switch is manually operated to restore operating condition, .omponent has stuck to die while stamping % it is re*o/ed by one to c$. 0. S!eed Loss :

Loss due to increase in on line and(or auto cycle time due to reduction in speed, feed. e.g. .ycle time of 2idma 3orer has gone up from 4.5 min to 6.5 min due to feed ariation.

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2efects :

7umber of parts that are not confirming to specification. e.g. 8ework, 8e+ection. 3. Manage*ent Loss :

Loss due to wrong planning. e.g. $ools, 9aterial, Instructions are not a ailable. 14. 5!erating Motion Loss : Loss that reduces human efficiency. e.g. 2alking of operator is more because of inefficient layout, Operator's motion economy is iolated due to skill difference, operator is wasting some time in searching tools(tooling etc., operator's morale is low, and it affects his performance. 11. 6dj st*ent Loss : $ime required to ad+ust tool and(or equipment in order to restore component accuracy. e.g. $ool is ad+usted after e ery 7'7 cycles to ad+ust si:e. 12. Line 5rganisation Loss : Loss in ol ing line balancing, multi machine operations. e.g. Line '!' is not balanced properly 13. Logistics Loss : Loss due to non%a ailability of material. e.g. Finished 0 !ccepted .rank .ases are ready but not sent to assembly line due to some reason which results in loss of Engine !ssembly. 1#. +ield Loss : Loss of raw material in any form. e.g. 3lanks generated in stamping operation, .hips generated in machining operation, ,lurry of paint, runners(risers in foundry application. 1%. 8nergy Loss : Loss of energy in the form of heat, power, air, water, fuel due to leakage and or o erload. It is to be measured by consumption. 16. 2ie 9 Tool Loss : Loss resulting from manufacturing and repair of tools 0 tooling. It also includes consumption of FO, items and sand.