31 May 2005

Dear Member,

Kobetsu Kaizen (Focussed Improvement) Seminar

for Process Industries
19th July 2005: CII Institute of Quality: Bangalore

The uniqueness of process industries are diverse production system with maximum use
of static equipment/units like rotary kiln, pumps, compressors, motors and turbines,
columns, tanks, heat exchangers, furnace, pipe. These are connected with electrical
and instrumentation systems.

The processes are monitored in a centralized DCS control room with the minimum
number of operators for the large area of operations. The process equipments are often
plagued by faults like cracking, ruptures, corrosion, seizure, fatigue, slack, parts falling
off, mis-operation. The most common problems in the process industries are leak,
corrosion and chock.

The losses in the process industries are not easily evident because of using stand by
equipment and by-pass lines. The maximum productivity achieved along with hidden
losses. This seminar helps to highlight all the hidden losses and find the way out to
enhance the profitability of the organization.

16 Major losses in Industries:

8 Major losses affecting equipment efficiency
5 Major losses affecting manpower efficiency
3 Major Losses affecting efficiency of material and energy utilization
Definition of 16 Major losses
1 Shutdown loss Time lost when production stops for planned
annual shutdown maintenance or periodic
servicing
2 Production Time lost when changes in supply and
adjustment loss demand require adjustments to production
plans
3 Equipment failure Time lost when equipment suddenly loses
loss its specified functions
4 Process failure loss Time lost in shutdown due to external
factors such as changes in chemical or
physical properties of materials being
processed, operating errors, defective raw
materials, etc.
5 Normal production Rate and time losses at plant startup,
loss shutdown, or changeover
6 Abnormal Rate loss occurring when plant under
production loss performs due to malfunctions and
abnormalities

7 Quality defect loss Losses due to producing rejectable product,

physical loss of rejected product, financial
losses due to product downgrading

8 Reproducing loss Recycling losses due to passing material

back through the process
9 Management Loss Loss due to awaiting for information or
instructions from the management like
material waiting, postponement of repair etc.
10 Operating Motion Motion losses include losses resulting from running
Loss counter to economic principles of motions, losses
arising from skill differences, and walking losses
stemming from a bad layout.
11 Line Line organization losses include waiting losses
Organization generating in the multiprocess and multi machine
Loss processing and also line balance losses in conveyor
work.

12 Logistics Loss Distribution man hour losses due to transport of

materials, products (input/in process/finished) and
dollies.

13 Measurement Man-hour losses resulting from frequent

and adjustment measurement and adjustment executed to prevent
loss (Set up quality defects from occurring and spilling over.
Loss)
14 Material Yield Over consumption of input material as compared to
Loss the specific standards.

15 Energy Loss The loss of energy, such as electrical power, fuel,

steam, air, and water (including treated waste water)

16 Equipment loss Loss due to temporary repair work, replacement of

(Repairing & non-quality spares and unskilled maintenance
Replacement) persons

The above losses are generally not understood in the industry and these losses grow
over a period of time. A need has been identified to disseminate the information on the
methodology to eliminate/minimize these losses. Responding to the need of building
skills in this area, a seminar has been designed with emphasis given to impart
knowledge to the participants through theory & classroom exercises.

Kobetsu Kaizen (Focussed Improvement) Seminar would cover;

 Defining and understanding what is a loss

 Understanding the 16 losses of TPM

 Structured approach for eliminating/minimizing these losses

 Methodology for preparing Loss tree analysis and loss cost matrix

 Identification of Kaizen and FI Projects

Target Audience

Heads & Managers of Manufacturing, Quality, Engineering, Process & Finance Divisions
from the industries.

Delegate Fee

 TPM Club Members & CII Members Rs.3,500/- Per Participant

 Non-Members Rs.4,000/- Per Participant

Members / Non-members are requested to kindly depute the concerned officials to

attend this very important Seminar and confirm their names vide the enclosed
REGISTRATION FORM.

Regards,

Yours sincerely,

16 Major losses

1. Shutdown loss

2. Production adjustment loss

3. Equipment failure loss

4. Process failure loss

5. Normal production loss

6. Abnormal production loss

7. Quality defect loss

8. Reproducing loss
 9. Management Loss

10. Operating Motion Loss

11. Line organization loss

12. Logistics loss

13. Measurement and adjustment loss (setup loss)

14. Material Yield loss

15. Energy loss

16. Equipment loss

REGISTRATION FORM

Please Email / fax to:

Ms Jayashree Das

CII Institute of Quality

Bharat Nagara, 2nd Stage, Magadi Main Road

Vishwaneedam Post,

Bangalore 500 091

Tel : 080 - 23289391/23287690; Fax: 080-23289388

E-mail: jayashree.das@ciionline.org

Kobetsu Kaizen (Focussed Improvement) Seminar

for Process Industries

19 July 2005: CII Institute of Quality, Bangalore

We nominate the following persons to attend the Seminar

Sl. No. Name Designation

01. ……………………………………
……………………………………………………

02. ……………………………………
……………………………………………………

03. ……………………………………
……………………………………………………

04. ……………………………………
……………………………………………………

05 ……………………………………
……………………………………………………

Enclosed please find a Cheque / Demand Draft No…………….. on

…………………. (Bank) dated ………… for Rs………… drawn in favour of
“Confederation of Indian Industry”, payable at New Delhi towards the
delegate(s) fee and couriered to us at Bangalore address.

Nominator Name .
…………………………………………………………………………

Designation:
…………………………………………………………………………………

Company…………………………………………………………………………………
…..
Address:………………………….
…………………………………………………………..

Tel
No…………………………………………………………………………………………

Fax No.………….……………………………………………………………………….
……

E- Mail………..
……………………………………………………………………………….

Coach facility is being provided from Hotel Central Park (Manipal Centre, Off MG
Road) to CII Institute of Quality. (The coach starts at 0745 hrs)
The delegate (s) will avail the coach will not avail the coach
(Please mark your preference  )

*Delegate fee is non-refundable but changes in nominati

P Rajesh

Counsellor - TPM