16 Major Losses

Category Loss No 1 2 7 Major Losses that impede Overall Equipment Efficiency 3 4 5 6 7 Losses that impede Equipment Loading Time Loss Name Equipment Failure Loss Setup / Adjustment Loss Tool Change Loss Start Up Loss Minor Stoppages Speed Loss Defect & Rework Loss

8

Scheduled Downtime Loss

9 5 Major losses that impede Worker Efficiency 10 11 12 13 3 Major losses that impede efficient use of Production subsidiary resources 14 15 16

Management Loss Operating Motion Loss Line Organization Loss Logistics Loss Measurement & Adjustment Loss Yield Loss Energy Loss Die,Jig & Tool Loss

LOSS MATRIX GROUP : ROLLING MILLS Loss No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Loss Name Equipment Failure Loss Setup / Adjustment Loss Tool Change Loss Start Up Loss Minor Stoppages Speed Loss Defect & Rework Loss Schdeuled Downtime Loss Management Loss Operating Motion Loss Line Organization Loss Logistics Loss Measurement & Adjustment Loss Energy Loss Die.Jig & Tool Loss Yield Loss X X X X X X X X X X X X X X X X X X X 4H1 4H2 4H3 6H 2H1 2H2 .

LOSS MATRIX GROUP : TUBE MILLS Loss No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Loss Name Equipment Failure Loss Setup / Adjustment Loss Tool Change Loss Start Up Loss Minor Stoppages Speed Loss Defect & Rework Loss Schdeuled Downtime Loss Management Loss Operating Motion Loss Line Organization Loss Logistics Loss Measurement & Adjustment Loss Energy Loss Die.Jig & Tool Loss Yield Loss X X X X X X X X X X TM 1 TM 2 TM 3 TM 4 TM 5 .

Jig & Tool Loss Yield Loss X .LOSS MATRIX GROUP : DRAW BENCHES Loss No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Loss Name E1E2E3C1C2D1D2D3D420T 40T 30T X Equipment Failure Loss Setup / Adjustment Loss Tool Change Loss Start Up Loss Minor Stoppages Speed Loss Defect & Rework Loss Schdeuled Downtime Loss Management Loss X X X X X X X X X X X X X X X Operating Motion Loss X X X X X X X X X X X X Line Organization Loss Logistics Loss Measurement & Adjustment Loss Energy Loss Die.

LOSS MATRIX GROUP : SLITTERS 18 00 M M 15 10 00 00 35" 10" 2 1/2" 5" 1 1 M M M M 35 0 M M 45 0 M M Loss No Loss Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Equipment Failure Loss Setup / Adjustment Loss Tool Change Loss Start Up Loss Minor Stoppages Speed Loss Defect & Rework Loss Schdeuled Downtime Loss Management Loss Operating Motion Loss Line Organization Loss X Logistics Loss X X X X X X X X X X X X X X X X X X X X X X X X Measurement & Adjustment Loss Energy Loss Die.Jig & Tool Loss Yield Loss .

LOSS MATRIX GROUP : RHF FURNACES 600 600 3 KW 575 RHF 1 RHF 2 KW T/H Ne KW Old r w Loss No Loss Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Equipment Failure Loss Setup / Adjustment Loss Tool Change Loss Start Up Loss Minor Stoppages Speed Loss Defect & Rework Loss Schdeuled Downtime Loss Management Loss Operating Motion Loss Line Organization Loss Logistics Loss Measurement & Adjustment Loss Energy Loss Die.Jig & Tool Loss Yield Loss X X X X X X X X X X X X X X X X X X X X X X X X X X .

LOSS MATRIX GROUP : BELL FURNACES Loss No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Loss Name Equipment Failure Loss Setup / Adjustment Loss Tool Change Loss Start Up Loss Minor Stoppages Speed Loss Defect & Rework Loss Schdeuled Downtime Loss Management Loss Operating Motion Loss Line Organization Loss Logistics Loss Measurement & Adjustment Loss Energy Loss Die.Jig & Tool Loss Yield Loss X X X X X X X X X X Narrow Wide Width Width .

Jig & Tool Loss Yield Loss X X X X X X X X .LOSS MATRIX GROUP : PICKLING Push Wet Pull Process Pickling Loss No Loss Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Equipment Failure Loss Setup / Adjustment Loss Tool Change Loss Start Up Loss Minor Stoppages Speed Loss Defect & Rework Loss Schdeuled Downtime Loss Management Loss Operating Motion Loss Line Organization Loss Logistics Loss Measurement & Adjustment Loss Energy Loss Die.

Jig & Tool Loss Yield Loss X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Floor DG ComprCrane Move.LOSS MATRIX GROUP : CENTRALISED MECH. CONTROL Loss No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Loss Name Equipment Failure Loss Setup / Adjustment Loss Tool Change Loss Start Up Loss Minor Stoppages Speed Loss Defect & Rework Loss Schdeuled Downtime Loss Management Loss Operating Motion Loss Line Organization Loss Logistics Loss Measurement & Adjustment Loss Energy Loss Die. . MAINT. Sets essor Equip.

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