WHAT ARE THE

"SIX BIG
LOSSES"
IN MANUFACTURING?

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 MEANING

6 Big Losses are the most

common productivity losses (in a
plant) caused due to the
equipment. The concept is a part
of Total Productive Maintenance
(TPM) and was developed by
Seiichi Nakajima.

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1. Unplanned stops: The causes for
unplanned stoppages could be
equipment breakdowns, tool
failures, unscheduled maintenance,
lack of power, raw materials, or
other required consumables. We
must analyze the root cause and
identify proactive measures to
prevent recurrences or similar
occurrences.

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2. Planned stops: These may happen
for scheduled maintenance, quality
checks, tool adjustments, planned
breaks, and changes in input
materials. It would be economical to
sync up these activities to happen in
parallel, apart from the efforts to
decrease the time for the activities
that consume more extensive
duration.

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3. Small Stops: It usually happens
for problems that the operator
attends to. It could be minor
cleaning of sensors, correcting
minor misalignment, blockages,
wrong feeding of raw material, etc.

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4. Reduced speed: Possible
reasons could be wear & tear of
the equipment, lubrication issues,
operator skill to handle the
equipment, influence by raw
material or operating conditions.
Identification and stratification of
causes can be carried out with
Root cause analysis methods.

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5. Production defects: Any output
that is not ‘First-time right’ is
considered defective. The reasons
could be inadequate process
capability, improper setting of the
machine, improper handling, or
defective raw materials.
Incorporating robust detection,
control, and prevention methods
would help improve the First Pass
Yield (FPY).

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6. Start-up defects: These are
defects that occur during the
start of a setting. It could be due
to warm-up cycles, improper
settings, or a changeover process.
Training using obvious standard
operating procedures with
validated checkpoints based on
historical learning would minimize
the start-up defects.

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 INQUIRE NOW!

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