16 Big Losses in Total Productive Maintenance (TPM)
Before knowing 16 Big Losses in Total Productive Maintenance (TPM) you should know what is TPM. TPM is abbreviated as Total Productive Maintenance or Total Productive Management. It is so-called because all the people in an organization are involved in TPM activities. It is very important to learn to develop any organization.
Benefits of TPM:Periodic and preventative maintenance models can boost your company’s overall production and alleviate downtime It guarantees availability, performance, and quality. Some benefits are mentioned below.1. Creates Safer work environments by maintaining a proper 5S foundation. 5S foundation means S: Sorting, S: Setting in order, S: Shining, S: Standardizing, and S: Sustaining.2. TPM aims to achieve zero defects, breakdowns, or accidents. Thus it is a Proven impact on efficiency.3. This is the system of improving staff morale because in this system employees from all levels or departments in the company to fully involved in the same goal with different activities.4. It increases job satisfaction by establishing a safe workplace. Employee morale and efficient production all come with adopting productive maintenance. This approach could bring about measurable, lasting benefits such as proactive company culture, reduced changeover, improved quality output, and a longer manufacturing maintenance regime.
16 Big Losses in TPM:To 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.
- Breakdown Loss
- Setup and adjustment loss
- Cutting Tool Replacement loss
- Startup Loss
- Minor Stops and Idling Loss
- Speed Loss
- Quality Defect and Rework Loss
- Shutdown Loss
- Management Loss
- Motion Loss
- Line Organisation Loss
- Internal Logistic Loss
- Measurement and adjustment Loss
- Yield Loss
- Energy Loss
- Consumable Loss
Short Briefings of 8 big Equipment losses in Total Productive Maintenance (TPM)8 big equipment losses in TPM are –
- Breakdown Loss: (unit time e.g. minutes)
- Reduction in machine’s capacity to function.
- Time loss
- Reduction in output
- Physical losses caused by the increase in defectives and rework
- Arising from sporadic or chronic failure.
- Setup & Adjustment Loss: (unit time e.g. minutes
- Incurred from the last good product of the previous run comes off the line until changeover, adjustment & test processing are completed.
- The first good product of the next run emerges together with the physical losses (quality loss) created by test processing.
- Cutting tool Replacement Loss: (unit time e.g. minutes)
- Stopping a machine in order to change a cutting tool when it has become worn out or damaged.
- Cutting tool such as grindstone, saw blade, cutter wire or lathe tool.
- Startup Loss (unit time e.g. minutes)
- Minor Stops and Idling Loss (unit time e.g. minutes & Numbers)
- Speed Loss (unit rate e.g. tonnes per hour)
- Quality Defect and Rework Loss (Unit – Quantity, time, money)
- The physical loss (defective and rework)
- Time loss (time lost by having to reprocess defective product to make it acceptable)
- Shutdown Loss (Unit – Time, quantity)
- The time loss (reduction in output)
- Shutting equipment down deliberately for maintenance
- The physical losses (defective & rework) arising when the equipment is started up again.
5 big Manpower losses in Total Productive Maintenance (TPM)
- Management Loss: (Unit = Time & £)
- Motion Loss: (Unit = Time & £)
- Line Organisation Loss: (Unit = Time & £)
- Distribution Loss: (Unit = Time & £)
- Measurement and Adjustment Loss: (Unit = Time & £)
3 big Yield, Energy & Tooling Loss in Total Productive Maintenance (TPM)
- Yield Losses: (Unit = £)
- Energy: (Unit = £)
- Die, Tool and Jig Losses: (Unit =£)
Calculation of OEE ( Overall Equipment Efficiency ) in TPM:The calculation of OEE relates to the relationship of 7 big Equipment losses & OEE. The calculation formula is given below – Now the term to calculate overall equipment efficiency (OEE) by the following equation –
Causes of Downtime Losses:
- Setup – adjustment
- Cutting tool replacement
Causes of Performance Losses –
- Minor Stops & idling
Causes of Quality Loss:
- Defectives and rework
Resource of this topic – JIPM, Dynaway & Industryforum-UKYou May also like to read –NOVEL CORONA VIRUS – How to protect YourselfHydroxychloroquine: Definition, uses and side-effects & Covid-19 treatment