2. What is Six Loss? It would feel odd to drive a car without a
dashboard 6 loss Analysis is like the dashboard, providing useful
information for making decisions at different times in your
journey. Example: When there is an indication that you are low on
fuel you will fill it up When the Revs are too high you will change
gear
3. Why use Six Loss? Six Loss allows you to accurately pinpoint
the area of focus that will impact on the performance of the
equipments output. To reduce each loss there is an improvement
tool. All the Six Loss is doing is breaking down the equipments
overall loss into six clear categories, to which, you can apply
certain techniques to improve. It is what you do with this
information makes the difference. Speed of Execution and
intervention followed by monitoring is critical. Combine Six Loss
data with using the right tools on the biggest loss and accelerate
the speed of execution - This WILL improve the performance of your
equipment. Many manufacturing plants spend a lot of time in
measuring and recording data and dont use most of it. Sometimes
less is more!!! This is a key part of your Manufacturing
Strategy
4. Set Up/Planned downtime Losses Planned Downtime This is the
period of time between the last piece from one product run and the
first piece of the next product run. That is: All time for flavour
changes, CIPs , hygienes etc. that are necessary to fulfill the
production plan. The way we can reduce the impact on output is to
get smarter in the operation to reduce the time taken. Calculation
to work out impact is: - Planned Downtime/(Paid time-NRFP)
5. Breakdown Losses Breakdowns This is the amount of time lost
at the bottleneck machine due to large stops (typically > 5mins)
on any machine. This may be electrical or mechanical and is assumed
to be a stoppage where a component has failed and has been repaired
or replaced. Calculation to work out impact is: - Stoppage to
critical machine/(Paid time-NRFP)
6. Minor Stops Minor Stops This is the amount of time lost at
the bottleneck machine due to small stops (typically < 5mins )
on any machine with an assumption that these events would not
normally be a component failure, it is more likely to be an
adjustment or a jam up, etc.
7. Speed Loss Speed loss This is the amount of time lost
between the start and finish of a production run due to the
bottleneck machine / Critical machine running below its rated
speed. The formula for calculating this loss is: -
8. Quality loss on start up Quality loss on start up This is
the run up period after a changeover when settings need final
adjustments to bring the product into exact specification to enable
running. That is: Alterations to saturation pressures or brix
adjustments etc. that ensure product specification. As this is an
exceptionally hard area to calculate automatically it is split out
into the other areas of loss.
9. Quality loss during running Quality Loss in Process This is
a loss of product during a production run where quality does not
meet specification. All non re-workable rejects. That is: A low
filled bottle, a poorly fitted cap etc.
10. The Six Loss Tool Kit Six loss category OEE measure Reason
for Loss Countermeasures Planned downtime or external unplanned
event Availability Changeovers Planned maintenance Material
shortages Labour shortages Planned Downtime Management 5S Workplace
Organisation ABC Planning Breakdowns Availability Equipment failure
Major component failure Unplanned maintenance Kaizen Blitz ProACT
Root cause analysis Asset Care Minor stops Performance Fallen
product Obstruction Blockages Misalignment Cleaning 5S Workplace
Organisation Adjustments Line Minor stop audits Speed loss
Performance Running lower than rated speed Untrained operator not
able to run at nominal speed Line Balance Optimisation Adjustments
Production rejects Quality Product out of specification Damaged
product scrap Six Sigma Error proofing Root Cause Analysis Rejects
on start up Quality Product out of specification at start of run
Scrap created before nominal running after changeover Damaged
product after planned maintenance activity Planned Downtime
Management 5S Workplace Organisation Standard Operating Procedures
Precision settings
11. Calculating Six Loss Six Loss Category Calculation Total
Production Time = Total Time - NRFP Planned downtime or external
unplanned event Planned Downtime Total Production Time Breakdowns
(>5mins) Time Loss at Critical Machine due to stoppages
>5mins Total Production Time Minor stops (