16 Big Losses That Effect Your OEE

Definitions of the 8 big equipment losses

Breakdown loss :

The breakdown is a loss of or reduction in the capacity of the machine to function.

Breakdown loss is the time losses (reduction in output ) and physical losses (increase in defectives and rework) arising from sporadic or chronic failures.

Setup and adjustment loss:

Time losses (reduction in output ) incurred from when the last product of the previous run comes off the line until changeover, adjustment and test processing are completed and the first good product of the next run emerges, together with the physical losses (defectives and rework) created by test processing. 

Cutting tool replacement loss:

The loss incurred by stopping a machine in order to change a cutting tool such as grindstone, sawblade, cutter wire or lathe tool when it has become worn out or damaged

Start-up loss:

The loss incurred when production starts, throughout the run-up to steady-state operation until processing conditions have stabilized.

Minor stops and idling loss:

Unlike breakdown losses, these are the losses resulting from stopping-and-starting, and transient problems, which require a machine to be paused or idled for short periods.  

Speed loss:

The loss horizon from the difference between the equipment design speed and speed at which the actually operates

Quality defect and rework loss:

The physical losses (defective and rework) and the time losses (the time lost by having to reprocess a defective product to make it acceptable) are created by defectives and rework.

Shut down loss:

The time losses (reduction in output) incurred by shutting equipment down deliberately for maintenance, and the physical losses (defectives and rework) arising when the equipment is started up again.