16 Losses of TPM ( Total Productive maintenance) / Types of Wastes can reduce productivity and efficiency in production system.
In the system productive maintenance of equipment with the participation of all personnel. (Total Productive Maintenance – TPM) specialists of the Japan Association of Manufacturing Japan Institute of Plant Maintenance (JIPM) allocate 16 Losses of TPM (The main types of losses). That reduce the efficiency of production systems.
Below the characteristics of these 16 Losses of TPM are as below. Which are divide into three groups:
Loss of equipment functioning time, Loss of working time, loss of energy, raw materials, materials and time due to inventory repairs.
[1] Breakdown
Losses caused by breakdowns of machines and mechanisms, caused by disruption of the operation of the equipment, leading to a decrease in the number of manufactured products and increased time spent on its repair and technical service. The number of identified equipment breakdowns as a result of the introduction of TPM, as a rule, it increases. Breakdowns JIPM experts propose to classify as follows:
- Breakdowns accompanied by loss of functionality of the equipment, the elimination of which requires a complete stopping production;
- The breakdowns, elimination which are carrying out by replacing parts;
- Breakdowns, to eliminate of which equipment readjustment is requires (usually carried out in within 5 – 10 minutes).
To achieve “zero” breakdown levels need to be identified as directions to improve reliability equipment and increasing its maintainability, as well as reducing the time for elimination of individual defects.
[2] Setup & Adjustment
Losses due to adjustment Hardware related with the time spent on reconfiguration of equipment when changing the type of production Products. This entails the need to dismantle the elements of the equipment, intended for the production of the previous type of product, inspection, cleaning and lubrication of machines and mechanisms, verification of instrumentation, installation equipment necessary for the production of a new type of product.
[3] Tools change
Losses due to replacement Cutting tool tied with the need to replace blades, circular saws and other cutting machines. The material from which they are produce eventually becomes unusable. For elimination of this type of loss is recommend to use alloys of increased hardness in the manufacture of cutting tools and improvement of its working conditions (reducing vibration, establishing the optimal cutting speed, etc.).
[4] Start up
The Startup losses equipment is time spent on the initial start-up of the equipment, as well as losses due to release of defective products on unconfigured equipment. Losses of this species are observe when the equipment starts after overhaul or stopping at maintenance, after holidays, as well as shift and lunch Breaks.
[5] Short-term Shutdown
These losses due to short-term shutdown of the equipment and its operation at idle speed are due to the time spent on temporary shutdown of equipment for adjustment, adjustment and minor repairs from 2-3 seconds to 5 minutes. Unlike breakdowns, short-term stops equipment and its idling are caused by temporary reasons.
For example, incorrect arrangement of parts on the conveyor or detection of defective ones Products. To eliminate this type of loss, an analysis of their causes is first carrying out. And then individual improvements are complete to the design of the equipment.
[6] Performance Loss
The performance Loss due to the difference between the planned in the project and the actual performance of the equipment, or the difference between the maximum possible and the real number of products produced for unit of time. Eliminating performance losses is key the direction of increasing the overall efficiency coefficient of the equipment and intensification of production.
[7] Defects & Rework
These losses due to defects and the need to refine the products is due to loss of resources for the elimination of defects and the refinement of substandard products, as well as the time spent on these works.
[8] Schedule Downtime
The Losses due to planned equipment shutdowns are associated with the time spent on stopping the equipment for carrying out scheduled repairs. Such losses are fundamentally irreparable, since any the equipment needs maintenance. However, reduce the loss of time due to planned equipment shutdowns still real by improving quality of repair, improvement of staff safety and provision reliability of the machines.
[9] Management
Due to management shortcomings are cause by making incorrect or untimely management decisions Production.
These include losses due to downtime caused by management. enterprises, as well as losses due to exceeding the normative duration of repairs equipment and limits on staff training costs.
[10] Irrational Transport performance
These losses due to irrational transport performance related with shortcomings in the organization of the transport system of the enterprise. They can be are also associated with a low speed of loading and unloading operations.
[11] Operating Motion
Losses due to shortcomings in the organization of production work are associated with waiting times multi-machine operators, as well as losses due to uncoordinated operation Equipment.
[12] Low Level Automation
Losses due to low level of automation of production entail a loss of human resources. Implementation of automated Systems is an important area for improving efficiency production systems, conservation of labor resources and improvement of conditions Labor.
[13] Monitoring
Losses due to shortcomings of production monitoring are due to the cost of working time for frequent measurement and adjustment to prevent defects and irregularities Process.
[14] Yield
Loss of finish Products are define by the difference in the mass of raw materials and finish products. Losses of this species increase with an increase in the share of waste, imperfection of production technologies, malfunctions of cutting equipment. These losses may also be related with the ingress of contaminants into the finished product, for example, sand, that leads to an underestimation of the share of useful product.
[15] Energy
Energy losses combine losses of different types of energy or energy carriers, e.g. electrical energy, fuel, steam, hot air or water. Since the cost of electricity, fuel and others types of energy carriers make up a significant part of the total costs, companies are interest in reducing energy losses. Although most major sources losses of this type at the enterprises of Japan and the United States have been eliminate. There is a reserve further improvements by reducing small energy losses.
For example, in in the case of hydraulic equipment, this concerns the selection of the optimum pressure working fluid in the pistons and the time when the equipment is under load. Than higher than both indicators, the greater the energy consumption of the hydraulic system.
[16] Inventory
Losses due to the need to repair production equipment depend on the costs of inventory production, renewal and repair, replacement worn parts, etc. The more often the inventory is repaire, the more these loss. The cost of consumables, lubricating oils sometimes also is takes into account when calculating the amount of losses due to inventory repairs. It is recommending to present the amount of these losses per article.
These 16 Losses of TPM really need to isolate in the production lines.