6 Major Equipment Losses

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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 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 checkweigher, 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 case study from your workplace.

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