The Six Big Losses & Equipment Efficiency Analysis
Equipment Failure
Availability loss due to unplanned downtime and unexpected machine breakdowns.
Setup & Adjustments
Production loss during changeovers, mold adjustments, and tooling setups.
Small Stoppages
Performance loss from jams, sensor errors, or brief idling (micro-stops).
Reduced Speed
Loss incurred when the equipment runs slower than its designed ideal cycle time.
Process Defects
Quality loss resulting from scrap, rejected parts, and products requiring rework.
Reduced Yield
Losses during warm-up or the initial production phase until stability is reached.
Loss Management & Improvement Methods
Prioritizing major loss categories using data-driven OEE metrics,
Implementing TPM (Total Productive Maintenance) to prevent failures through autonomous care,
Minimizing setup and adjustment times by applying SMED techniques,
Eliminating micro-stops permanently through systematic 5 Whys root cause analysis.
Loss Analysis Lexicon
OEE, Availability, Performance, Quality, Downtime, Speed Loss, Micro-stops, Rework, Scrap Rate, TPM, SMED, MTBF (Mean Time Between Failures), MTTR (Mean Time to Repair).