Breakdowns – Losses that are a result of a functional loss (mechanical, chemical, or electrical) or function reduction (e.g., one spindle not operating on a multi-spindle drill) on a piece of equipment requiring maintenance intervention.
Setup and Adjustment – Losses that are a result of setup procedures such as retooling, changeover, die/mold change, etc. Adjustments include the amount of time production is stopped to adjust process or machinery to avoid defect and yield losses, requiring operator or jobsetter intervention.
Idling and Minor Stoppage – Losses that are a result of minor interruptions in the process flow, such as a process part jammed in a chute or a limit switch sticking, etc., requiring only operator or jobsetter intervention. Idling is a result of process flow blockage (downstream of the focus operation) or starvation (upstream of the focus operation). Idling can only be resolved by looking at the entire line/system.
Reduced Cycle – Losses that are a result of differences between the ideal cycle time of a piece of machinery and its actual cycle time. Ideal cycle time is determined by: a) Original design speed; b) Optimal conditions: and c) Highest cycle time achieved on similar machin-ery.
Start-up Losses – Losses that occur during the early stages of production after extended shutdowns (weekends, holidays, or between shifts), resulting in decreased yield or increased scrap and rejects. (This may also include non-value activities required prior to production, such as bringing process to temperature.)
Defective Parts – Losses that are a result of process part quality defects resulting in rework, repair, and/or non-useable parts.
Tooling – Losses that are a result of tooling failures/breakage or deterioration/wear (e.g., cutting tools, fixtures, welding tips, punches, etc.).