Tangible Gains - PQCDSM

P - Productivity increase by

– OEE Improvement

– Improvement in manpower utilisation

Q - Quality Improvement through ZERO Defects

– By preventing Rework

– By eliminating inhouse Rejection.

– By eliminating customer complaints & warranty returns.

C - Cost Reduction through

– Cycle time reduction in Bottleneck Stages / Machines.

– Reduction of inventory on tools / nutrunners etc.

– Reduction in consumption of FOS Items, Oil, Gas, Fuel etc.

– Reduction of material cost.

D - Delivery performance improvement through

– Breakdown/Failure reduction to zero

– Improvement in lead time & W.I.P. reduction.

S - Safety, Health & Environment improvement

– Zero accident by identifying/correcting unsafe conditions/Acts.

– Elimination of Unhealthy & Unhygienic conditions.

– Identification & Elimination factors leading to Pollution.

M - To improve Morale of employees through

– Involvement & participation in TPM Circle activities

– By encouraging to generate Kaizens & rewarding for suggestions / Improvements carried

out

– By reducing percentage of Absenteeism

Availability Losses (5)

1) Break Down Loss e.g. Breakdown of hoist at body drop stage

2) Planned Maintenance Time Loss e.g. Shut down of 6 days

3) Setup Loss e.g. Change of Dies, machining fixtures etc

4) Tool Change Loss e. g. Change of Drill, tap, reamer, cutter etc.

5) Start Up Loss e.g.. Furnace , Paint Shop Oven etc.

Losses of Performance (2)

6) Minor Stoppage Loss i.e. Frequent stoppages for short time like Less than 1 min. e.g. Component
stuck to die while stamping etc.

7) Reduced Speed Loss e.g. 50 parts produced against standard of 53 parts as a cycle time increased
to 9 min. from 8.5 due to less speed/feed.

Loss due to Quality (1)

8) Defects & Rework i.e. any reworked or rejected product shows direct time loss due to poor Quality.

Losses Impeding Human Efficiency (5)

09) Management Losses e.g. Raw Matl./Person not available esp. poor planning

10) Operating Motion Loss (OML e.g. Excess motions like walking, bending, stretching etc.

11) Adjustment & Measurement Loss e.g. Frequent tool adjustment after few components.

12) Line Organisation Loss ( e.g. 75 % Manpower utilization due to poor line balancing.

13) Logistics Loss e.g. Operator Travels/waits for want of material on stage

Losses of Costs (3)

14) Yield Losss e.g. Excess material stock/weight, Excessive splashes etc.

15) Energy Loss e.g. Losses due to heat radiation, leakage of fuel,air, oil etc

16) Die/Tool loss e. g. loss of tool due to regrinding, Poor life of molds etc,Repairs of Dies/Tools, FOS
consumables.