A Loss-Cost Matrix

A Loss-Cost Matrix
Loss Structure
Cost Structure
Planned Shutdown Loss
Breakdown Loss
Setup and Adjustment loss
Startup Loss
Minor Stops Loss
Speed Loss
Idling Loss
Quality Defect Loss
Rework Loss
Replanning Loss
Management Loss
Motion Loss
Line Balance Loss
Non-Automation Loss
Adjustment Loss
Inventory Loss
Energy Loss
Consumables Loss
Yield Loss
E
q
u
i
p
m
e
n
t

E
f
f
e
c
t
i
v
e
n
e
s
s
Downtime
Losses
Performance
Losses
Quality
Losses
Labour
Effectiveness
Resource
Consumption
Effectiveness
R
a
w
-
M
a
t
e
r
i
a
l
s
C
o
s
t
s
F
u
e
l

C
o
s
t
s
P
o
w
e
r

C
o
s
t
s
C
o
n
s
u
m
a
b
l
e
s

C
o
s
t
s
D
i
r
e
c
t

L
a
b
o
u
r

C
o
s
t
s
I
n
d
i
r
e
c
t

L
a
b
o
u
r

C
o
s
t
s
D
i
e

C
o
s
t
s
M
a
i
n
t
e
n
a
n
c
e

a
n
d

R
e
p
a
i
r

C
o
s
t
s
I
n
t
e
r
e
s
t
C
h
a
r
g
e
s
A
d
m
i
n
i
s
t
r
a
t
i
v
e

C
o
s
t
s
L
o
g
i
s
t
i
c
s

C
o
s
t
s
Total
Losses
(million yen)
130
250
370
25
30
25
45
35
15
20
150
95
130
75
85
8
15
10
35
1548 Total Loss
Total Manufacturing Costs
Production Costs
General
Administrative Costs
Variable Costs Fixed Costs
1
A Loss-Cost Tree
Labour Costs
Maintenance and
Repair Costs
Raw-Materials
Costs
Supplementary-
Materials Costs
Utilities Costs
Internal Logistics
Costs
Fixed Costs
Variable Costs Logistics Costs
Total Costs and Losses
M
a
n
u
a
l

W
o
r
k

L
o
s
s
U
t
i
l
i
s
a
t
i
o
n

L
o
s
s
B
r
e
a
k
d
o
w
n

L
o
s
s
P
l
a
n
n
e
d
-
S
h
u
t
d
o
w
n

L
o
s
s
D
e
f
e
c
t
i
v
e
-
I
n
s
t
a
l
l
a
t
i
o
n

L
o
s
s
S
p
a
r
e
-
P
a
r
t
s

L
o
s
s
Q
u
a
l
i
t
y
-
D
e
f
e
c
t

L
o
s
s
Y
i
e
l
d

L
o
s
s
M
a
n
u
a
l

P
a
c
k
i
n
g

L
o
s
s
S
t
o
r
a
g
e

L
o
s
s
P
o
w
e
r

L
o
s
s
F
u
e
l

L
o
s
s
S
u
n
d
r
y

M
a
t
e
r
i
a
l
s

L
o
s
s
P
a
c
k
a
g
i
n
g

L
o
s
s
T
r
a
n
s
p
o
r
t
a
t
i
o
n

L
o
s
s
S
p
i
l
l
a
g
e

L
o
s
s
W
a
t
e
r

a
n
d

C
o
m
p
r
e
s
s
e
d
-
A
i
r

L
o
s
s
Total Loss
Loss-Reduction Target
Progress Towards Target
External Logistics
Costs
Total Cost
2