Six Big Losses in OEE and TPM

Classification of Big Losses:

[1] Availability Losses:

[2] Performance Losses:

[3] Quality losses:

Classification of Six Big Losses in OEE

Breakdowns Setup and Adjustment Small Stops Reduced Speed Start-up Rejects Manufacturing Rejects

[1] Breakdowns:

[2] Setup and Adjustment:

[3] Small Stops:

[4] Reduced Speed:

[5] Start-up Rejects:

[6] Manufacturing Rejects:

Benefits of Elimination of Six Big Losses:

→ The Six Big Losses are responsible for productivity. We have to eliminate these to improve productivity.→ One of the major goals ofandis to reduce and eliminate Six Big Losses.→ This includes equipment failures or unplanned stops, set-up and changeovers, planned stops, etc.→ When we consider the availability of a process, it is a decision making parameter for understanding the reasons for that loss and to describe the time spent during unplanned stops.→ Decreasing the time spent on unplanned events will increase the available running time for manufacturing.→ Equipment failures or unplanned stops have a very severe impact on productivity.→ Set-up and changeovers are also responsible for the biggest cause of downtime.→ Changeovers are tackled with the help of using SMED (Single Minute Exchange of Dies) programs.→ The main reason for long changeover times may be the main adjustments, tooling adjustments, warm-up time, cleaning, and quality inspections, etc.→ This is due to machines or manpower are in ideal conditions, minor stoppages or small stops.→ We can eliminate this loss by taking precautionary action like line balancing and bottleneck analysis.→ On the other hand, we can prioritize the tasks by recording and analyzing the minor stoppages.→ For Reduced speed, the common reasons consist of dirty machines, damaged equipment, lubrication, environmental circumstances, worker experience, and usual startup and shutdown techniques.→ So we can improve productivity by identifying and eliminating the above causes.→ This includes scrap, rework, and all types of non-conformity of the product.→ However, being familiar with the quantity of the loss is not sufficient also we have to consider the quality of the loss for improving productivity.→ For improving the product quality we have to analyze the defect generation during the machine startup and during manufacturing.→ After analyzing the defect we can have an analysis of causes that are responsible for the defect generation. So by eliminating the causes, we can eliminate the defect.→ The breakdown comes under the Category - Downtime.→ Unplanned downtime elimination is critical.→ Preventive maintenance is a key weapon to kill unnecessary breakdowns.can be done on severe breakdowns.→ Timely validation of tools is also important in order to prevent unplanned downtime.→ Prediction of an equipment failure is a key skill of engineering that helps a lot in the prevention of downtime.➨ Examples of Breakdowns:⇢ Tooling Failure,⇢ Unplanned Maintenance,⇢ Equipment Failure,⇢ General Breakdowns, etc...→ Setup and Adjustment come under the Category - Downtime.→ It is generally called duration between the last good part produced before setup change and the first good part produced after the changeover.→ Tracking of adjustment timing is very important in reducing this loss.→ We can use the concept of SMED (Single Minute Exchange of Dies) for reducing the Setup and Adjustment timing.➨ Examples of Setup and Adjustment:⇢ Excess setup/change over timing,⇢ Material shortage,⇢ Operator shortage,⇢ warm-up timing, etc...→ Small Stops comes under the Category - Speed Loss.→ Recording of this type of loss is very difficult.→ Cycle time analysis to be used to identify this type of loss.→ Activity wise actual-time monitoring and micro-mapping of this data help in the identification of small stops and speed reduction.➨Examples of Small Stops:⇢ Component jam,⇢ Sensor blocked,⇢ Delivery blocked,⇢ Cleaning and Checking, etc...→ Reduced Speed comes under the Category - Speed Loss→ Recording of Reduced Speed is very difficult.→ It can be recorded by Cycle time analysis.➨ Examples of Reduced Speed:⇢ Poor planning,⇢ Machine wear and tear,⇢ Operator inefficiency,⇢ Under design capacity, etc...→ Start-up Reject comes under the Category - Quality Loss.→ “First Time Right” concept to be adopted during each startup of production.→ Effective use of production start-up check sheet can eliminate start-up rejects.→ The process parameter setting plays a vital role in the manufacturing of the good part at the first time.➨ Examples of the Start-up Rejects:⇢ Damage,⇢ Scrap,⇢ Rework,⇢ Incorrect assembly, etc..→ Manufacturing Reject comes under the Category - Quality Loss→ It is related to the rejection during the manufacturing➨ Examples of the manufacturing Rejects⇢ Damage,⇢ Scrap,⇢ Rework,⇢ Incorrect assembly, etc...→ It helps us to improve the process and product.→ It reduces the_losses and improves the profit→ Overall Equipment Effectiveness improves by reducing these_losses.