6 Major Equipment Losses

SIX MAJOR EQUIPMENT LOSSES

• Major Stops
• Minor Stops
• Change-Over Loss
• Start-Up / Shut-Down Loss
• Speed Loss
• Quality Loss

Definitions

MAJOR STOPS

• Any stoppage that is greater than 10 minutes
• Note:  is sometimes broken into Equipment Breakdown (Breakdown) and Procedural loss (Major Stops)
• Measures:  Number of Occurrences and Duration (mins)

MINOR STOPS

• Any stoppage that is less than 10 minutes
• Measures:  Number of Occurrences

CHANGE-OVER LOSS

• The time from when the last case of a run was produced to the first case of the next run.
• Note: C/O loss and Start-Up Loss are closely related
• Measure:  Time (mins)

START-UP / SHUT-DOWN LOSS

• The time required to reach ‘normal’ running condition after a change-over or beginning of the week, or after PM.  (Shut-down is the time taken to ramp down during a shutdown for C/O, PM, or end-of-week).
• Note:  ‘Normal’ running condition needs to be defined
• Measure:  Time (mins)

– ChangeOver vs. Start-Up –

QUALITY LOSS

• Any defective production
• Note:  In the food industry usually we have both packages rejects (re-work) and product going on hold (DMRs)
• Measure: Number of cases on hold, Number of packages rejected from check weigher, metal detector

SPEED LOSS

• The percentage difference in actual speed vs. standard speed ie. 102 ppm vs. 105 ppm is a 2.8% loss
• Note:  Not all the SKUs have the same standard speed
• Measure: ppm (packages per minute) or % loss

After reviewing Major Losses, time to discuss a case study from your workplace.