The 7 Major Equipment Losses: Breakdown Loss

TPM Loss Structure: Breakdown Loss

As these losses are due to sporadic/chronic breakdowns, they are accompanied by time losses
(output decline) and volume losses (occurrence of defects).
A problem with any discussion of breakdowns is that their definition is unclear. Usually, a trend
toward an increase in breakdowns is witnessed during the initial stage of TPM activities. This is
not because the number of breakdowns cases has actually increased but because cases
previously not counted as breakdowns are included, for lack of clear-cut definition.
Therefore, the definition of breakdown is as follows:

Cases accompanied by function stop or decline

Cases requiring replacement of parts or repair in order to recover function
Cases requiring 5-10 minutes or more for repair

Sporadic losses are bound to attract attention, and therefore countermeasures are readily
adopted. Frequent chronic losses, however, may remain unamended because various
countermeasures are ineffective. Since these losses account for the largest weight, each plant
takes countermeasures on a priority basis, but the current status seems to be that correction
cannot be achieved as desired. To address failure losses, it is necessary to study measures to
raise the reliability of equipment and its maintainability to reduce downtime.

At any rate, failures must be reduced to zero. This can be attained at little cost, although some
short-term investment may be necessary. To attain zero failures, it is necessary to correct the
conventional misconception about BM (breakdown maintenance) that failures are unaviodable
 TPM Loss Structure: Steup and Adjustment Loss

Setup and adjustment loss refers to time losses from the end of the production of a previous
item through product change adjustment to the point where production of the new item is
completely satisfactory.

Setting up means a series of operations from the removal of jigs and fixtures following the end
of production, clearing up and cleaning, through the preparation of jigs/tools and metal fixtures
necessary for the next product, to their attachment, adjustment, trial processing, readjustment,
measurement, production and finally the ability to produce quality products.

Adjustment is an intractable task, often not thoroughly improved. It is necessary however, to

classify individual cases into avoidable and unavoidable ones.

The final objective of setup/adjustment loss is to realize "one-shot machining" or "first run right"
in which quality is possible on the first run after changing tools to accommodate production of
the next product. Recently, the list of zero loss cases in this process is growing.

To realize one-shot defect free changeover, it is essential to reduce adjustment to zero.

Various steps are studied to shorten the setup time, but only a handful of companies have
adopted approaches for eliminating adjustment and reducing trial manufacturing to zero.
TPM Loss Structure: Cutting Blade (Tool) Loss

The loss incurred by stopping a machine in order to change a cutting tool such as a
grindstone, saw blade, cutter wire or lathe tool when it has become worn out or damaged.

Examples of these losses are the time for cutting tip change, grindstone change, post-
replacement workpiece measurement, rework in the case of tip damage, defective product
disposal, and the quality stabilization time required after replacement.

Cutting-blade losses are decresed due to material and shape studies for longer blade life,
but this loss still poses a problem requiring further studies.

For each blade, certain replacement standards are defined. In many cases, however,
breakage or chipping occurs before the defined number is reached, causing defects;
therefore, the blade is unavoidably replaced or the number is lessened to avert such a
development.
TPM Loss Structure: Startup Loss

This loss is incurred when produciton starts, throughout the run-up to steady-state operation
until processing conditions have stablized.

At a machining shop, the demension dispersions are likely to happen during the morning
startup. This causes frequest adjustment, rework and sometimes breakdown of cutting blade.
Warm-up or idling operation is taken to prevent these malfunctions. However, the root-cause
analysis should be considered on a basis of theoretical apporach.

TPM Loss Structure: Minor Stops and Idling Loss

This is called Choko (Minor) Tei (Stop) in Japanese.

Unlike breakdown losses, these are the losses resulting from stopping-and-starting, and
transient problems, which require a machine to be paused or idled for short periods. Minor
Stops are not lined with equipment (mechanism) failure.
The 7 Major Equipment Loss: Speed Loss
Speed losses arise when equipment operates slower than it could. They consist of the time lost
(less output).
1. when equipment works at a lower speed than its design speed (the standard speed for
the product).
2. when its design speed is lower than the current technical standard or the maximum
possible speed.

The 7 Major Equipment Loss: Quality Defect and Rework Loss

Quality defect and rework losses consist of

1. The material wasted by producing defective products that have to be scrapped (material
loss)
2. The time lost (less output) when reprocessing defective products that can be turned into
good ones (time loss)

The 1 Big Loss affecting Utilisation: Shutdown Loss

This is the loss incurred by deliberately shutting down the equipment within the production plan,
for periodic overhaul, statutory inspections and so forth.