Downloaded 12 times
![KK
KK
AEL - N1 TPM - Together Towards World Class Through TPM Slide No. 10 of 23
Loss Structure During Production Activities (16 Major Losses)
[Manpower
Efficiency]
[Equipment Efficiency]
5
Major
Losses
Preventing
Efficiency
of
Manpower
Waiting
instruction loss
Waiting material
loss
Equipment
downtime loss
Equipment
performance
loss
Method/
procedures loss
Skills and
morale loss
Line
organization
loss
Unautomated
system loss
9. Management
loss
12. Logistics loss
13. Measurement and
adjustment loss
Excluding man-
hour (Supported
by other
departments)
Production
Man-hour
loss
Line
organisa
-tion
man-
hour
loss
<Equipment>
Man-hour Elapsed time
<person>
8. Shutdown loss
1. Equipment
failure loss
2. Set-up loss
4. Start - up loss
Other downtime loss
5. Minor stoppage &
idling loss
6. Reduced speed
7. Defects and
rework loss
3. Cutting blade and
jig change loss
Operated man-hour
Duty hour
Loading man-hour Loading time
Net operational
Man-hour Operating time
Effective
man-hour
Net Operating
time
Valued man-hour
(man-hour for
turnout)
Valued
operating time
Scheduled
downtime
Scheduled
downtime
Downti
me loss
Performan
ce loss
Defects
quality
loss
(Adjustment
of measurement)
Cleaning
checking
Waiting
instruction
Quality
confirmation
Waiting
personnel
distribution
Waiting
materials
Start-up loss
Overload loss
Radiation loss
15. Energy loss
Input energy Loading time
Effective energy
No. of qualified
products
Weight of
qualified products
<Energy> <Materials>
Start-up loss
Cutting loss
Losses in weight
Losses in excesses
(increased commission)
14. Yield loss
Defects quality loss
[Efficiency of material and energy] ………
3 Major Losses Preventing Efficiency of Material and Energy.
16. Die and Tool loss
8
Major
Losses
Preventing
Efficiency
of
equipment
10. Operating
motions loss
Defects
in man-
hour
loss
11. Line organisation
loss](https://image.slidesharecdn.com/costlossmethodology-250117145118-3932aba6/85/Lost-Cost-Cost-Loss-Methodology-for-KK-Pillar-10-320.jpg)
![KK
KK
AEL - N1 TPM - Together Towards World Class Through TPM Slide No. 10 of 23
Loss Structure During Production Activities (16 Major Losses)
[Manpower
Efficiency]
[Equipment Efficiency]
5
Major
Losses
Preventing
Efficiency
of
Manpower
Waiting
instruction loss
Waiting material
loss
Equipment
downtime loss
Equipment
performance
loss
Method/
procedures loss
Skills and
morale loss
Line
organization
loss
Unautomated
system loss
9. Management
loss
12. Logistics loss
13. Measurement and
adjustment loss
Excluding man-
hour (Supported
by other
departments)
Production
Man-hour
loss
Line
organisa
-tion
man-
hour
loss
<Equipment>
Man-hour Elapsed time
<person>
8. Shutdown loss
1. Equipment
failure loss
2. Set-up loss
4. Start - up loss
Other downtime loss
5. Minor stoppage &
idling loss
6. Reduced speed
7. Defects and
rework loss
3. Cutting blade and
jig change loss
Operated man-hour
Duty hour
Loading man-hour Loading time
Net operational
Man-hour Operating time
Effective
man-hour
Net Operating
time
Valued man-hour
(man-hour for
turnout)
Valued
operating time
Scheduled
downtime
Scheduled
downtime
Downti
me loss
Performan
ce loss
Defects
quality
loss
(Adjustment
of measurement)
Cleaning
checking
Waiting
instruction
Quality
confirmation
Waiting
personnel
distribution
Waiting
materials
Start-up loss
Overload loss
Radiation loss
15. Energy loss
Input energy Loading time
Effective energy
No. of qualified
products
Weight of
qualified products
<Energy> <Materials>
Start-up loss
Cutting loss
Losses in weight
Losses in excesses
(increased commission)
14. Yield loss
Defects quality loss
[Efficiency of material and energy] ………
3 Major Losses Preventing Efficiency of Material and Energy.
16. Die and Tool loss
8
Major
Losses
Preventing
Efficiency
of
equipment
10. Operating
motions loss
Defects
in man-
hour
loss
11. Line organisation
loss](/p?url=https%3A%2F%2Fimage.slidesharecdn.com%2Fcostlossmethodology-250117145118-3932aba6%2F85%2FLost-Cost-Cost-Loss-Methodology-for-KK-Pillar-10-320.jpg&__src=https%3A%2F%2Fwww.slideshare.net%2Fslideshow%2Flost-cost-cost-loss-methodology-for-kk-pillar%2F274936501&__type=image)
Uploaded byAshweeniTiwari
PPT, PDF539 views
Lost Cost Cost Loss Methodology for KK Pillar
The document presents a comprehensive overview of the Total Productive Maintenance (TPM) approach, focusing on identifying and reducing losses within an organization to enhance profitability. It categorizes various types of losses, including machine, man, and cost-related losses, while detailing specific causes and effects on productivity and efficiency. The document includes strategies for addressing these issues through methods like kaizen and cost loss analysis to improve operational performance.
