what are the 6 big losses in oee(Overall equipment effectiveness)?

what are the 6 big losses in oee(Overall equipment effectiveness)?

In the context of Overall Equipment Effectiveness (OEE), the “Six Big Losses” refer to common sources of inefficiency and productivity loss in manufacturing processes. These losses are categorized as follows:

  1. Equipment Failure: This refers to unplanned downtime caused by equipment breakdowns, malfunctions, or failures. It includes time lost due to equipment repairs, maintenance, and adjustments.
  2. Setup and Adjustment Time: This loss occurs when equipment is being set up for production runs, changed over from one product to another, or adjusted to meet new specifications. Setup and adjustment time can result in idle equipment and decreased productivity.
  3. Idling and Minor Stoppages: Idling and minor stoppages refer to short pauses or interruptions in production that are typically less than 10 minutes in duration. These stoppages may be caused by minor equipment malfunctions, material shortages, or operator issues.
  4. Reduced Speed: Reduced speed losses occur when equipment operates at less than its maximum capable speed. This can be due to factors such as equipment wear and tear, suboptimal operating conditions, or process bottlenecks.
  5. Defects and Rework: Defects and rework refer to products or parts that do not meet quality standards and require rework, repair, or scrap. Defects can result from equipment malfunctions, process variability, or human error, leading to wasted time and resources.
  6. Start-up Rejects: Start-up rejects occur during the initial stages of production runs when equipment is being brought up to operating speed. These rejects may result from equipment calibration issues, material inconsistencies, or process instabilities.

Identifying and addressing these Six Big Losses is essential for improving overall equipment effectiveness and maximizing productivity in manufacturing operations. By minimizing downtime, optimizing equipment performance, and reducing waste, businesses can enhance efficiency and profitability.


About user

Milind patel is an experienced practitioner and thought leader in the field of Business Process Management (CI) and 0.4 lean application. He co-founded Pro lean academy, a consulting company focusing on performance improvements and appropriate digitalization application in manufacturing process