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Big Six Losses Defined

• Shutdown Loss: Preventive maintenance breaks and lunches, training exercises, other miscellaneous production stops.

• Operational Loss: Adjustments, material replenishment or related equipment losses, and normal operations that shut down the line.

• Changeover: Capacity lost during changes in material, equipment, or product.

• Equipment Failure: Equipment unexpectedly becomes dysfunctional or inoperable.

• Process Failure: Stops due to defective raw materials, operating errors, lack of raw or packaging material, waiting.

• Scrap and Rework: Reprocessing, rework, scrap materials, and stops related to poor quality of the final product.

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