The 16 Losses In Total Productive Maintenance To help identify all losses in a process system (man/machine/material), and thus, eliminate them, they have been divided into 16 categories , and can be grouped, accordingly, as shown in Figure 1, with orange representing the equipment related, losses, blue representing the losses relating to manpower and yellow representing, the losses relating to resource consumption. Figure 1: The 16 big losses Equipment Losses 1. Breakdown loss: (unit time e.g. hours) The equipment breaks down causing the function of the line or process to stop. Often this is considered as a sporadic failure, typically caused by equipment component failure. Examples: Bearing failure due to wear, electrical fault, snapped belt. 2. Set up & adjustment loss: (unit time e.g. hours) This loss occurs during a changeover between products. Set up time is defined as the amount of time taken to change a process over from the last part of a production run to th...
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