Reduce Six Big Losses of Equipment (TPM) with the help of M-Box

Improve TPM by targeting Six Big Losses

Total Productive Maintenance (TPM) arises from Japan as a system designed to eliminate equipment’s Six Big Losses related to their condition. Its purpose is to maximize availability according to the production schedule, generating products at the highest capacity, according to the expected quality, and without unscheduled stops.

Six Big Losses

To achieve improvements in production, maintenance, quality, and engineering at your factory, the Six Big Losses that need to be addressed are the following:

1. Equipment Failure Loss

Equipment Failures caused by damages that require repair and that are generated during the time scheduled for production

2. Minor stops/idle loss

Minor stoppage and idle loss that occur during the operation and that are caused by events such as obstructions, small interruptions, etc.

3. Speed Loss

Reduced Speed caused by the decreased cycle time of the equipment, meaning the equipment does not work at its maximum capacity

4. Setup and adjustments loss

Setup and machine adjustments generated by changes in the operation condition, such as the start of production runs, change of shift, change of product, moving the machines, manufacturing process adjustments, etc.

5. Start-up / Yield loss

Reduced Yield due to defective units produced from startup until stable production is achieved

6. Defect and rework loss

Defects and rework of the process caused by products that are out of specification or defective, which generate losses due to the need to reprocess or complete activities

Losses of equipment have a negative effect on productivity and profitability

In each of the above cases, the machine is considered unproductive, affecting its efficiency and capacity, increasing costs of production, and reducing profits.

Failures of equipment and minor stops affect the machine’s availability. A machine with poor availability idles without generating profits.

Minor stops and reduced speed affect the execution, and use of the capacity of the machine. Equipment whose capacity is underutilized is unproductive and unable to comply with the production plan because it does not work at the speed for which the plan was designed.

Reduced yield, defects, and rework of the process affect the profitability of the business since the benefits obtained are affected when analyzing the total resources used.

Reliable data as a key factor to address the Six Big Losses of equipment efficiency

The timely analysis of accurate and reliable data related to the Six Big Losses of production equipment determines the success of the actions implemented to counteract them. A significant challenge is the availability and reliability of the manufacturing data according to these criterions:

  • Real-time
  • Unbiased
  • Accessability
  • Level of detail

The visibility of the manufacturing data is crucial to proper handling of possible problems on the shop-floor.
Advanced technology to monitor the manufacturing process plays a fundamental role in guaranteeing this visibility. Identifying problems and their indicators helps to target the real losses and their root causes, which is essential to preventing a repetition of these costly events.

A reliable production monitoring system proves to be the best solution

The data related to each of the Six Big Losses of your equipment can be easily obtained in detail with the M-Box production monitoring system. This will set you on the right track of improvement to further advance your OEE (Overall Equipment Effectiveness) through consistent concentration on solving the real problems with your equipment.

M-Box is one of its kind in terms of its:

easy setup

Its ready-made modules for different segments of the making industry get you up and running in a matter of hours. No programming required

External sensors

These monitor machine activity without connecting to PLCs (100% hacking protection)


It has a low hardware and subscription cost. Monitor any machine for less than US $100 per year