Annexure I

16. Major Losses identified by TPM

1. Breakdown Loss:
Loss of time wherein machine has stopped on its own, machine has been stopped e.g. due
to quality issue, speed loss, etc.
For calculation of OEE, a part of breakdown, which has resulted in loss of opportunity of
production, shall be considered
e.g. If machine is repaired on a holiday, repair time should be included in breakdown
time, however such time shall not be considered for OEE calculation.
All repairs that are not part of planned maintenance (based on annual plan) are part of
breakdown loss.
e.g. If a bearing has failed prematurely, its replacement shall be breakdown loss.

2. Planned Maintenance Loss:

The activity that is pre-decided (annual calendar) with a realistic estimate.
e.g. in the year 2011, spare part of the machine will be replaced with a specific
predetermined periodicity, irrespective of the life left/ failure occurred due to the spare
part in question (Time Based Maintenance). It will also include specific predetermined
overhaul program.

3. Set up loss:
The loss attributed to change of set up from one component to the other component.
Note: It shall include time for removal, fixing, adjustment/repair. Setting is complete
when 1st job is as per specifications.
e.g. Change of Jigs & fixture (as applicable in machining area), Change of die (as
applicable in stamping area & foundry).

4. Tool change Loss:

Tool change loss is defined as a loss occurred while changing tools & tooling in running
production till 1st ok part is produced.
Note: Time lost in changing drill, bushes, dressing wheels, etc.

5. Start up Loss:
The time required for the equipment to attain optimal operating condition.
e.g. Paint shop – oven temperature is expected to reach X ºC before baking can start.
Heat Treatment – Furnace should attain Y ºC before charge is put inside.
Foundry PU – Die is heated to Z ºC before start of production.

6. Minor Stops:
It is a performance-related loss (usually less than a minute) that results in stoppage of
material movement.
e.g Limit switch is manually operated to restore operating condition, Component has
stuck to die while stamping – it is removed by one touch.
7. Speed Loss:
Loss due to increase in on line and/or auto cycle time due to reduction in speed, feed.
Eg. Cycle time of Widma Borer has gone up from 6.5 min to 9.5 min due to feed
variation.

8. Defects:
Number of parts that are not confirming to specification.
Eg. Rework, Rejection

9. Management Loss:
Loss due to wrong planning.
Eg. Tools, Material, Instructions are not available.

10. Operating Motion Loss:

Loss that reduces human efficiency
Eg. Walking of operators is more because of inefficient layout, Operator’s motion
economy is violated due to skill difference, operator is wasting some time in searching
tools/tooling etc.

11. Adjustment Loss:

Time required to adjust tool and/or equipment in order to restore component
accuracy.
Eg. Tool is adjusted after every ‘X’ cycles to adjust size.

12. Line Organization Loss:

Loss involving line balancing, multi machine operations.
Eg. Line ‘A’ is not balanced properly.

13. Logistics Loss:

Loss due to non-availability of material.
Eg. Finished & Accepted Crank Cases are ready but not sent to assembly line
due to some reason which results in loss of Engine Assembly.

14. Yield Loss:

Loss of raw material in any form.
e.g. Blanks generated in stamping operation, Chips generated in machining
operation, Slurry of paint, runners/risers in foundry application.

15. Energy Loss:

Loss of energy in the form of heat, power, air, water, fuel due to leakage and or
overload. IT is to measure by consumption.

16. Die & Tool Loss:

Loss resulting from manufacturing and repair of tools & tooling. It also includes
consumption of FOS items and sand.