TPM-Element: Focused Improvements

Elimination / Minimization of the "16 losses"

The pillar “focused improvement” is the most important pillar in the Lean TPM system. As Zero-error-processes are aspired, it’s first necessary to acquire and visualize all errors and losses. The development of a key performance indicator system covering an area down to team / employee level transpires with the basic indicators

• Q – quality
• C – costs
• D – delivery service

which is the basis of this evaluation.

With this as a basis, it’s possible to visualize detailed information about losses and wastes using the structure of the “16 losses”.

Structure of Losses

The 3 Main Categories of Losses are:

• 8 Main Losses due to the Machine
• 5 Losses due to Human Work
• 3 Losses due to Processes

Only through priorization of losses and wastes by interdisciplinary enhancement-teams is an enduring enhancement of the information system possible and quantifiable.

PDCA cycle by W.E Deming

Losses at a machine

Mini PDCA

Example: Mini PDCA

Problem description

• „lost products“
• Quantification of loss: EUR 50.000,-- p.a.

Root Cause Analysis

• Method: 5 Why
• Construction defect
• Poor material handling

Problem solving

• Installation funnel
• Cost: EUR 3.500,--

Lösungsüberprüfung

• Target: „0“ losses
• Achievement: - 98%