What are the Six Big Losses?

The Six Big Losses show you the biggest factors that contribute to such production losses by covering the reason codes and cost implications of the top two performance, availability and quality losses each.

Upon careful analysis of the Six Big Losses table, you will be easily be able to discern the operational constraints and recurring errors in a line that needs fixing, maintenance or training.

Elements of the Six Big Losses Table

Performance Loss

The performance loss section of the Six Big Losses table displays the reason codes and cost implications of such performance losses. Performance loss shows you where your line is achieving less than the maximum production speed due to various reasons.

Availability Loss

Availability loss in a shift indicates the events that hinder and stop the targeted production for a predetermined length of time. The Availability section of the table will display the reason codes for such losses along with their cost impact.

Quality Loss

The last factor of quality loss takes into account any occurrence that creates output not up to the quality benchmarks. You can find the reason codes as well as the monetary burden such losses create in the table.

The Six Top Reasons for Performance, Availability, and Quality Loss:

  • Equipment Failure
  • Setup and adjustments

  • Idling and Minor Stops

  • Reduced Speed

  • Process Defects
  • Reduced Yield


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