six big losses

**Six big losses** is the **classic TPM loss framework that categorizes the primary causes of OEE erosion across downtime, speed loss, and quality loss** - it provides a practical map for diagnosing where production capability is being lost. **What Is Six big losses?** - **Definition**: Six standardized loss types: breakdowns, setup and adjustment, idling and minor stops, reduced speed, process defects, and reduced startup yield. - **Category Mapping**: The first two impact availability, the next two impact performance, and the last two impact quality. - **Analytical Use**: Converts diverse operational issues into a common taxonomy for trend and Pareto analysis. - **Improvement Link**: Each loss category maps to specific engineering and maintenance countermeasures. **Why Six big losses Matters** - **Problem Structuring**: Prevents vague discussions by forcing losses into measurable categories. - **Prioritization Speed**: Teams can quickly identify which loss class dominates OEE decline. - **Cross-Site Consistency**: Shared taxonomy improves benchmarking across lines and factories. - **Program Focus**: Helps avoid over-investment in low-impact activities. - **Training Value**: Creates common language between operators, technicians, and engineers. **How It Is Used in Practice** - **Loss Coding**: Ensure every stop and quality event is tagged to one of the six categories. - **Pareto Reviews**: Track cumulative loss by category and shift resources to highest-impact buckets. - **Countermeasure Library**: Maintain standard response playbooks aligned to each loss type. Six big losses is **a proven framework for OEE diagnostics and action planning** - classification discipline makes improvement work faster, clearer, and more scalable.