Page 107 - TPM A Route to World-Class Performance

88 TPM-A Route to World-Class Perfmmance

Level 1 Level 2
Losses from minor stoppages unrecognized 1 Minor stoppage losses analysed
and unrecorded quantitatively by: frequency and lcmtion
of occurrence; volume lost
Unstable operating conditions due to 2 Losses categorized and analysed; preventive
fluctuation in frequency and location of measures taken on mal and error basis
losses
LRvel3 L.evel4
All causes of minor stoppages are analysed; 1 Zero minor stoppages (unmanned
all solutions implemented operation possible)

Figure 5.9 OEE assessment: idling and minor stoppage losses

Level 1 Level 2
1 Equipment specifications not well understod 1 Problems related to speed losses analysed:
mechanical problems, quality problems
2 No speed standards (by product and 2 Tentative speed standards set and
machinery) maintained by product
3 Wide sped variations across shifts/operators 3 Speeds vary slightly
Level 3 Level 4
1 Necessary improvements being implemented 1 Operation speed increased to design speed
or beyond through equipment improvement
2 Speed is set by the product. Cause and 2 Fmal speed standards set and maintained by
effect relationship between the problem product
and the precision of the equipment 3 Zero speed losses
3 small speed losses

Figure 5.10 OEE assessment: speed losses

Level I
1 Chronic quality defect problems are 1 Chronic quality problems quantified by:
neglected details of defect, frequency; volume lost
2 Many reactive and unsuccessful remedial 2 Losses categorized and reasons explained;
actions have been taken preventive measures taken on trial and error
basis
Level 3 Level 4
1 AU causes of chronic quality defects 1 Quality losses from 0.1% to zero
analysed; all solutions implemented,
conditions favourable
2 Automatic in-process detection of
defects under study

Figure 5.11 OEE assessment: quality defect and rework losses