Six Major Losses to Overcome Using TPM
O.E.E. (Overall Equipment
Effectiveness) is used to identify and attack what are called the Six Major
Losses. These losses are the most common causes of lost time and
efficiency of production equipment.
1. Breakdowns and Failures
It is a loss of equipment function
needed to perform a operation.
Causes:
Ø Overloading
the machine
Ø Loose
bolts and nuts
Ø Excessive
wear
Ø Lack
of oil
Ø Contamination
2. Set-up and Adjustments
It is the
time lost during changeover from the current product to the next product, or
changing the settings during a run.
Causes:
Ø Remove
tooling
Ø Find
tooling
Ø Attaching
new tooling
Ø Adjust
new settings
3. Idling and Minor Stop
Brief
stoppages are due to 'insignificant' problems.
Causes:
Ø Parts
stuck in a chute
Ø Removing
chips
Ø Malfunction
of sensors
Ø Program
error
4. Reduced Speed
These are
loss when machine operates below design standard speeds.
Causes:
Ø Machine
wear
Ø Human
intervention
Ø Tool
wear
Ø Overloading
machine
5. Defects
Time lost to making scrap, doing rework, or managing
defective parts.
Causes:
Ø Manual
error
Ø Bad
material
Ø Tool
breakage
6. Startup and Yield
Time it takes a machine to 'warm up' to full production
after a period of downtime.
Causes
Ø Slowly
bringing machines up to speed
Ø Raising
ovens to set temperature
Ø Running
off excess material & Process
related loss of material
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