16 Major Losses

Category Loss No Loss Name

1 Equipment Failure Loss

2 Setup / Adjustment Loss

7 Major
Losses 3 Tool Change Loss
that
impede 4 Start Up Loss
Overall
Equipment 5 Minor Stoppages
Efficiency
6 Speed Loss

7 Defect & Rework Loss

Losses
that
impede
8 Scheduled Downtime Loss
Equipment
Loading
Time

9 Management Loss

5 Major 10 Operating Motion Loss

losses that
impede 11 Line Organization Loss
Worker
Efficiency 12 Logistics Loss

13 Measurement & Adjustment Loss

3 Major 14 Yield Loss

losses that
impede
efficient 15 Energy Loss
use of
Production
subsidiary 16 Die,Jig & Tool Loss
resources
 LOSS MATRIX
GROUP : ROLLING MILLS

Loss No Loss Name 4H1 4H2 4H3 6H 2H1 2H2

1 Equipment Failure Loss

2 Setup / Adjustment Loss X X X

3 Tool Change Loss

4 Start Up Loss X X X X X

5 Minor Stoppages

6 Speed Loss

7 Defect & Rework Loss

8 Schdeuled Downtime Loss

9 Management Loss

10 Operating Motion Loss

11 Line Organization Loss X X X X X X

12 Logistics Loss X X X X X

13 Measurement & Adjustment Loss

14 Energy Loss

15 Die,Jig & Tool Loss

16 Yield Loss
 LOSS MATRIX
GROUP : TUBE MILLS

Loss No Loss Name TM 1 TM 2 TM 3 TM 4 TM 5

1 Equipment Failure Loss

2 Setup / Adjustment Loss

3 Tool Change Loss

4 Start Up Loss X X X X X

5 Minor Stoppages

6 Speed Loss

7 Defect & Rework Loss

8 Schdeuled Downtime Loss

9 Management Loss

10 Operating Motion Loss

11 Line Organization Loss X X X X X

12 Logistics Loss

13 Measurement & Adjustment Loss

14 Energy Loss

15 Die,Jig & Tool Loss

16 Yield Loss
 LOSS MATRIX
GROUP : DRAW BENCHES

Loss No Loss Name E1E2E3C1C2D1D2D3D420T30T40T

1 Equipment Failure Loss X

2 Setup / Adjustment Loss

3 Tool Change Loss

4 Start Up Loss X X X X X X X X X X X X

5 Minor Stoppages

6 Speed Loss X X

7 Defect & Rework Loss X

8 Schdeuled Downtime Loss

9 Management Loss

10 Operating Motion LossX X X X X X X X X X X X

11 Line Organization Loss

12 Logistics Loss

13 Measurement & Adjustment Loss X

14 Energy Loss

15 Die,Jig & Tool Loss

16 Yield Loss
 LOSS MATRIX
GROUP : SLITTERS
18 15 10 35 45
00 00 00 0 0
Loss No Loss Name 35" 10"12 1/2"15"
M M M M M
M M M M M
1 Equipment Failure Loss

2 Setup / Adjustment Loss

3 Tool Change Loss

4 Start Up Loss X X X X X X X X X

5 Minor Stoppages

6 Speed Loss

7 Defect & Rework Loss

8 Schdeuled Downtime Loss

9 Management Loss

10 Operating Motion Loss

11 Line Organization LossX X X X X X X X X

12 Logistics Loss X X X X X X X

13 Measurement & Adjustment Loss

14 Energy Loss

15 Die,Jig & Tool Loss

16 Yield Loss
 LOSS MATRIX
GROUP : RHF FURNACES

600
600 3
KW 575
Loss No Loss Name RHF 1 RHF 2 KW T/H
Ne KW
Old r
w

1 Equipment Failure Loss

2 Setup / Adjustment Loss X X

3 Tool Change Loss X X X X X X

4 Start Up Loss

5 Minor Stoppages

6 Speed Loss

7 Defect & Rework Loss

8 Schdeuled Downtime Loss

9 Management Loss

10 Operating Motion Loss

11 Line Organization Loss X X X X X X

12 Logistics Loss

13 Measurement & Adjustment Loss X X X X X X

14 Energy Loss

15 Die,Jig & Tool Loss X X X X X X

16 Yield Loss
 LOSS MATRIX
GROUP : BELL FURNACES
Narrow Wide
Loss No Loss Name
Width Width
1 Equipment Failure Loss

2 Setup / Adjustment Loss X X

3 Tool Change Loss X X

4 Start Up Loss

5 Minor Stoppages

6 Speed Loss

7 Defect & Rework Loss

8 Schdeuled Downtime Loss

9 Management Loss

10 Operating Motion Loss

11 Line Organization Loss X X

12 Logistics Loss

13 Measurement & Adjustment Loss X X

14 Energy Loss

15 Die,Jig & Tool Loss X X

16 Yield Loss
 LOSS MATRIX
GROUP : PICKLING

Push
Wet
Loss No Loss Name Pull
Process
Pickling

1 Equipment Failure Loss

2 Setup / Adjustment Loss X

3 Tool Change Loss X

4 Start Up Loss

5 Minor Stoppages

6 Speed Loss

7 Defect & Rework Loss

8 Schdeuled Downtime Loss

9 Management Loss

10 Operating Motion Loss X X

11 Line Organization Loss X X

12 Logistics Loss

13 Measurement & Adjustment Loss X

14 Energy Loss

15 Die,Jig & Tool Loss X

16 Yield Loss
 LOSS MATRIX
GROUP : CENTRALISED MECH. MAINT. CONTROL

Floor
DG Compr-
Loss No Loss Name Crane Move.
Sets essor
Equip.

1 Equipment Failure Loss

2 Setup / Adjustment Loss X X X X

3 Tool Change Loss X X X X

4 Start Up Loss X

5 Minor Stoppages

6 Speed Loss

7 Defect & Rework Loss X X X X

8 Schdeuled Downtime Loss

9 Management Loss

10 Operating Motion Loss X X X X

11 Line Organization Loss X X X X

12 Logistics Loss X X

13 Measurement & Adjustment Loss X X X X

14 Energy Loss

15 Die,Jig & Tool Loss X X X X

16 Yield Loss X X