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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