6 BIG LOSSES IN

MANUFACTURING
THEIR CAUSES AND SOLUTIONS

1. AVAILABILITY LOSSES:
1. BREAKDOWN LOSS - Unplanned stop due to
the machine failure which requires a repair or
replacement. It causes the material and manpower to
wait and also stops the upcoming processes.

2. SETUP & ADJUSTMENT LOSS - Planned

stop due to major adjustments, tool settings,
planned maintenance, and quality inspection.

CAUSES
unplanned stops are caused by poor
maintenance
Leads to a waste of time and manpower and in
addition stagnation of materials.

SOLUTIONS
Implement lean tools like Andon system, 5S
and TPM
Autonomous Maintenance - Train your
operators on different roles to perform
cleaning, lubrication activities, and small
maintenance tasks
Preventive Maintenance - Checking the
machines and equipment on scheduled basis

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 6 BIG LOSSES IN
MANUFACTURING
THEIR CAUSES AND SOLUTIONS

2. PERFORMANCE LOSSES:
3. MINOR STOP LOSS - Small stoppages due to
tool, insert changes, filling oil, and periodic quick
cleaning. It leads to unwanted movement and wasting
time.

4. SPEED LOSS - Speed loss occurs when the

machine runs at a slower speed than the ideal cycle
time. It leads not to satisfy the customer for not
producing the product in takt.

CAUSES
Inefficiencies (both process and operator-
wise)
Leads to increased costs and lower
productivity.

SOLUTIONS

To identify and eliminate the bottlenecks and

inefficiencies in the processes,
Implement lean tools like SMED (Single
Minute Exchange of Dies), Pokayoke and
Andon system.
Implement process improvements such as
automation and standardization.

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implement lean tools and improve the Productivity

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 6 BIG LOSSES IN
MANUFACTURING
THEIR CAUSES AND SOLUTIONS

3. QUALITY LOSSES:
5. DEFECT & REWORK LOSS - Wasting time &
cost by producing the defective parts and loading the
parts for the rework process.

6. STARTUP LOSS - Producing defective parts

during startup, trial run, and early production stages.

CAUSES
Product rejections are caused by producing
defective parts and producing parts by using
defective raw materials.
Leads to costly rework, time waste, and
damage to a company’s reputation.

SOLUTIONS
To reduce defects
Implement lean tools such as Pokayoke
(error proofing), Kaizen and 5S.
quality control process like regular
inspections, and invest in training and
equipment that can help to improve the
accuracy and consistency of the products.

Addressing six big losses and their causes in manufacturing

can improve productivity, quality, profitability, and efficiency
for companies. By implementing the solution outlined above,
companies can improve their operations and meet the needs
of their customers.

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implement lean tools and improve the Productivity

Click here to join the course