Industrial Losses

7/28/2019 Industrial Losses

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16 LOSSES

Training Material


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1. EQUIPMENT FAILURE / BREAKDOWN LOSS

Losses Description: 1A - Equipment Failure: TIME Lost due to a

Breakdown involving replacement of spares

Example: Seal replacement due to Hydraulic cylinder oil leakage in

Press

Losses related to: Equipment

Losses Affecting: OPE/OEE/Availability

Losses Description: 1BBreakdown: TIME Lost due to a

Breakdown without replacement of spares

Example: Correcting pressure regulating valve settings due toHydraulic pressure is low


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2. JOB CHANGE LOSS

Losses Description: 2A - Job Change - Auto: TIME Lost due to

Change over from one product to another

Example: Job change from Regulating Sleeve 0350 to 0507 in 50/4

Compaction Press.



Losses Description: 2B - Job ChangeManual: TIME Lost due to

Change over from one product to another

Example: Job change from Regulating Sleeve 0350 to 0507 in 40 TSizing press


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3. TOOL CHANGE LOSS

Losses Description: 3A - Tool Change: TIME Lost due to Change

over of any tool of the running product.

Example: Top Punch change in 0350 compacting press.



Losses Description: 3BCoil Change: TIME Lost due to Change

over of RM coil of the running product

Example: Raw Material bundle change in sawing Machine.

Losses Description:3CTool service: TIME Lost due to service /

service delays of running / new toolsExample: Top Punch Polishing in 0350 compacting press for flaking


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4. START-UP LOSS

Losses Description: Start - up: TIME Lost initially after switchingon an equipment till it is ready for production.

Example: Time required for the Sintering Furnace to reach the Set

Temperature for Heat Treatment Process.




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5. MINOR STOPPAGE & IDLING LOSS

Losses Description: Minor Stoppage: OUTPUT Lost due toequipment stopping for minor problems

Example: Vibrator bowl feeder setting in Press.


Losses Affecting: OPE/OEE/Performance Rate


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6. REDUCEED SPEED LOSS

Losses Description: Reduced Speed: OUTPUT Lost due to operatingthe machine below the rated / designed speed

Example:

1. Reducing the Strokes per minute from 18 to 16 to prevent weight

variation in 0350 Compaction Press.

2. Reducing the speed due to finish problem in CNC Machine.




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7. DEFECTS & REWORK LOSS

Losses Description: Defect / Rework: TOTAL QUANTITY rejectedand sorted out as OK/Rework/Scrap

Example:

1. Quantity rejected for under fill problem in CV inner upsetting

2. Crack in PM Parts




9/22

Losses Description: 8A - JH Activity: TIME Lost due to JH activities

done by stopping the machine

Example: JH Activities like Cleaning, Lubrication, Inspection etc

Losses Description: 8BPM Activity: TIME Lost due to PMactivities done as per PM calendar

Example: Preventive Maintenance carried out in a Machine

Losses Description: 8CMeetings: TIME Lost due to meetings held

by stopping the machine

Example: Daily Meetings / Circle Meetings / Medical Centre Visit

8. SCHEDULED DOWN LOSS


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Losses Description: 8D - Development: TIME Lost due to Booking of

machine for Development activities

Example: Development trail by PED


Losses Description: 8ENot Scheduled: If machine is not scheduledto run in a shift

Example: No Market Order / No Production Planning

8. SCHEDULED DOWN LOSS


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9. MANAGEMENT LOSS

Losses Description: 9A - Want of Tools: TIME Lost due to

Non-availability of Tools.

Example: Press Waiting for CV Inner Die from Tool Room.

Losses Description: 9BAwaiting Instruction: TIME Lost due todelay in giving Work order/Schedule/Instruction

Example: Wire Cut M/c waiting for CNC Programme / Work order

Losses Description: 9CWant of RM: TIME Lost due to delay in

giving RM to the machine

Example: Press Waiting for Slug from Coating Plant.


12/22

Losses Description: 9D - Want of Men: TIME Lost due to Non-

availability of Men on a schedule machine

Example: Operator Leave / Permission

Losses Description: 9EWant of Gas/Air/Oil: TIME Lost due toNon-availability of GAS (Air) supply to the machine

Example: Compressed Air not available for the press.

Losses Description: 9FWant of Power: TIME Lost due to

Non-availability of Electrical Power supply to the machine

Example: Electrical Power supply not available for the CNC M/c

9. MANAGEMENT LOSS


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Losses Description: 9G - Awaiting Inspection: TIME Lost in waiting

for first-off sample approving authority

Example: Waiting for first product approval from Quality

Losses Description: 9HWant of Order: If machine cannot run dueto Non-availability of orders

Example: No Market Order

Losses Description: 9TWant of Containers :TIME Lost due to

delay in giving tote box/trolley/half-drum/tray.

Example: Want of Trolley / Tray / Pallets

9. MANAGEMENT LOSS


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Losses related to: Man

Losses Affecting: OPE

9. MANAGEMENT LOSS


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10. OPERATING MOTIONS LOSS

Losses Description: Operating Motion: OUTPUT Lost due toUnnecessary movement of Materials, operators etc

(operator skills & Efficiency)

Example: Input Material / Tray kept at a long distance from the

machine.

Losses related to: Man Power



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11. LINE ORGANISATION LOSS

Losses Description: Line Organization: OUTPUT Lost due to idlingof line/multi-machine operations

Example: Machinewaiting due to delay in previous process /machine.




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12. LOGISTICS LOSS

Losses Description: Logistics: TIME Lost due to operator stoppingthe Machine to get load.

Example: Operators performing material movement instead of

running the machine.


Losses Affecting: OPE


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13. MEASUREMENT & ADJUSTMENT LOSS

Losses Description: 13A - Measurement: OUTPUT Lost due toInspection

Example: Machine stopped for inspecting the products while

running


Losses Description: 13BAdjustment: OUTPUT Lost due to

Adjustments to correct quality problems

Example: Die Position adjustment to correct concentricity problem



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14. ENERGY LOSS

Losses Description: Energy: Cost control for effective use of Energy

Example: Energy loss due to leakage from the Furnace door

Losses related to: Energy

Losses Affecting: Cost


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15. DIE & TOOL LOSS

Losses Description: Die/Jig/Tool/Spare: Cost control for effective useof indirect materials

Example: Repair losses for the broken tools

Losses related to: Material



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16. MATERIAL YIELD LOSS

Losses Description: Yield: Cost control for effective use of directmaterials

Example: Wastage of Material due to excess machining stock given

Losses related to: Material



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THANK YOU

FOR THEPARTICIPATION

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Industrial Losses