Losses Overview

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1. Identify Functions

  • Manufacturing Support is divided across several Functions at a site
  • Each Business Process within these Functions should be clearly identified

Some Traditional Functions:

In TPM, the functions listed above are some of the traditional focus areas for Manufacturing Support (formerly “TPM in the office”). This focus on optimizing Business Processes eventually rolls into more traditional areas of SHE, Engineering, Maintenance, Quality, Amenities etc.

2. Identify Business Processes by Function

Functions are further defined where necessary:

Functions and Business Processes within each will likely differ site by site.

3. Set up Loss Metrics by Function

Typical Loss measures for Planning:

On Time In Full Orders – %

Plan accuracy – %

Number of plan changes – No.

Time to process an order/change – Hours

Number of signatures/authorizations – No.

Cost of processing an order – $

Distance covered by documents – M

4. Measure Losses by Function

Typical Loss measures for Planning:

5. Set up Countermeasures

Kaizens Teams should be set up to address/improve/eliminate the biggest losses and work through the loss tree:

Kaizens Teams should be set up to address/improve/eliminate the biggest losses and work through a typical loss tree for IT:

Kaizens Teams should be set up to improve/eliminate the biggest losses and work through a typical loss tree for Administration Support:

6. Implement Kaizens

Kaizens Teams should carry out the agreed countermeasure actions where appropriate:

7. Review Results

Kaizens Teams should review results to check that countermeasures put in place has in fact had a positive effect in reducing/eliminating losses.

Manufacturing Support Final Points

  • Several Loss Measures can be applied to all Functions
  • Some Loss Measures are specific to certain Functions
  • The process of loss reduction follows the CAPDO approach
  • 5S Principles should be applied to all Functions and physical areas across the site (both Production and Office areas)
  • Other TPM Pillar principles can be applied to Manufacturing Support e.g. AM, EEM, FI, E&T, PM

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