Six Big Losses
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The six big losses are the primary categories of equipment productivity loss that TPM targets: breakdowns, setup, idling, speed loss, defects, and startup.
Definition
The six big losses are the major categories of equipment productivity loss that TPM aims to eliminate. They map directly to OEE components: Availability losses include breakdowns and setup/adjustment time. Performance losses include idling/minor stops and reduced speed. Quality losses include defects/rework and startup losses. By categorizing losses, organizations can prioritize improvement efforts and track progress systematically. Eliminating these losses is the path to achieving OEE improvement.
Examples
A bottling line tracked the six big losses over a month: Breakdowns: 8%, Setup: 12%, Idling: 6%, Speed: 5%, Defects: 2%, Startup: 3%. Total losses: 36%. Setup time was the dominant loss—SMED techniques became the improvement priority.
Key Points
- Availability losses: Breakdowns (equipment failures) and Setup/Adjustments
- Performance losses: Idling/Minor Stops and Reduced Speed
- Quality losses: Defects/Rework and Startup/Yield Losses
- Data collection enables prioritization of improvement efforts
Common Misconceptions
All losses are equally important. Losses vary dramatically in magnitude and improvability. A 15% setup loss with proven SMED solutions differs from a 3% defect rate requiring major quality investigation. Prioritize by impact and feasibility.
The six losses are the only losses. The framework covers equipment-related losses but not all productivity losses. Material shortages, labor absences, and scheduling issues affect output but fall outside the six big losses. Comprehensive improvement addresses all loss categories.