email   phone 91-80-23289391   +91-80-23289391

Kobetsu Kaizen (KK) Methodology of TPM

How to Improve Business Competitiveness through Kobetsu Kaizen (KK) Methodology of TPM

Implementation of TPM in the true essence would increase financially both the top and the bottom line of any organisation. One of the key essences of TPM is to eliminate the losses that are occurring in the organization there by incurring the bottom line. The losses are of 2 types; first those that are measured like the breakdowns, Quality defects etc. and the second like setup and change over, Minor stoppages, lesser resources utilization etc which are generally missed.

Kobetsu Kaizen or the Focused Improvement pillar of TPM addresses both these types of losses with the activities that maximize the overall effectiveness of equipment, process and plant through uncompromising elimination of 16 types of losses and improvement of performance. Focused Improvement activity is a priority in the TPM development programme with activities performed by cross-functional team. These teams identify and design activities to eliminate/ minimize the 16 losses, which are carefully measured and evaluated.

Definition of 16 Major Losses

A. Seven major losses that impede overall equipment efficiency: 


Failure losses (Breakdown)

Losses due to failures. Types of failures include sporadic function-stopping failures, and function-reduction failures in which the function of the equipment drops below normal levels.


Set up and adjustment losses

Stoppage losses that accompany set-up changeovers


Cutting blade change losses

Stoppage losses caused by changing the cutting blade due to breakage, or caused by changing the cutting blade when the service life of the grinding stone, cutter or bite has been reached.


Start-up losses

When starting production, the losses that arise until equipment start-up, running-in and production processing conditions stabilize.


Minor stoppage and idling losses

Losses that occur when the equipment temporarily stops or idles due to sensor actuation or jamming of the work. The equipment will operate normally through simple measures (removal of the work and resetting).


Speed losses

Losses due to actual operating speed falling below the designed speed of the equipment.


Defect & rework loss

Losses due to defects & reworking


B. Losses that impede equipment loading time :


Shutdown (SD) losses

Losses that arise from planned equipment stoppages at the production planning level in order to perform periodic inspection and statutory inspection


C. Five Major losses that impede workers efficiency :


Management losses

Waiting losses that are caused by management, such as waiting for materials, waiting for a dolly, waiting for tools, waiting for instructions etc.


Motion losses

Man-hour losses arising from differences in skills involved in etc.


Line organization losses

Idle time losses when waiting for multiple processes or multiple platforms.


Distribution losses

Distribution man-hour losses due to transport of materials, products (processed products) and dollies.


Measurement and adjustment losses

Work losses from frequent measurement and adjustment in order to prevent the occurrence and outflow of quality defects.


D.Three major losses that impede efficient use of production subsidiary resources :


Energy losses

Losses due to ineffective utilization of input energy (electric, gas, fuel oil, etc) in processing.


Die, jig and tool losses

Financial losses (expenses incurred in production, regarding renitriding, etc.) which occur with production or repairs of dies, jigs and tolls due to aging beyond services life or breakage.


Yield losses

Material losses due to differences in the weight of the input materials and the weight of the quality products


Kobetsu Kaizen (Focused Improvement) Training would cover

  • Defining and understanding what is a loss
  • Understanding the 16 losses of TPM
  • Structured approach for eliminating/minimizing these losses
  • Methodology for calculating Overall Equipment Efficiency (OEE)
  • Loss Tree & Exercise
  • Cost Tree & Exercise
  • Cost Loss Matrix & Exercise
  • Theme matrix & Exercise
  • Kaizens registration
  • Kaizen execution methodology & Exercise
  • Industrial Engineering topics (IE)
  • Concept of Ergonomics (Assembly work related methodologies)
  • Concept of TAKT, TIME
  • VA, NVA & IW

Why this program is important for you?

The above mentioned 16 losses are generally not understood/noticed in the industry and these losses grow over a period of time which seriously affect the bottom-line of the company . This 2-day training is designed to disseminate the information on the methodology to eliminate/minimize these losses. Responding to the need of building skills in this area, the programme has been designed with emphasis given to impart knowledge to the participants through theory & case study.


Who Should Attend?

  • Manufacturing Heads, Quality Heads, Engineering Heads, Process Heads
  • Engineers, Senior Managers, and Managers from Manufacturing, Process, Engineering and Quality
  • Operators, Supervisors, Pillar Chairmen and TPM Coordinators.

This is useful to Non-TPM practicing companies also.

The programme will start at 0900 hrs with registration and ends at 1730 hrs on both the days.


  • Online Pre-registration and advance payment is mandatory for participation. Delegate fee is non-refundable. However, change in nomination is acceptable. NEFT/ RTGS payment options are also available. Please click on this link to register:
  • Direct competitors to the Host Organisation (Thirt Agro) are restricted to this programme

CII & TPM Club India

Fee per participant*

GST @ 18%

Total fee payable

Large & Medium Member

Rs. 11,000/-

Rs. 1980/-

Rs 12,980/-

SSI Member

Rs. 10,000/-

Rs. 1800/-

Rs 11,800/-



Rs.  2,160/-



* As a group of three or more delegates from a single organisation entitled for 10% discount.

Members are requested to kindly depute the officials concerned to attend this very important Workshop.

Best Regards,

Abdul Wadood
Principal Counselor & Head
TPM Club India
CII Institute of Quality

For Registration / more details, please contact:
K K Sudarsan
Mobile: +91-9972711066
Tel: 080-23286085/7690/9391

Total Productive Maintenance
Upcoming Training Programs
TPM / Best Manufacturing Practice Study Mission to Japan

Sun 15 to Sat 21 Mar, 2020, Japan

Read More Download Brochure

Workshop on Strategic Process for Operators Involvement in Improvement Process Deployment of Jishu Hozen

Thu 19 to Fri 20 Mar, 2020, Bengaluru

Read More Download Brochure

33rd TPM Facilitators Course (5 - Days Certification Program)

Mon 13 to Fri 17 Apr, 2020, Pune

Read More Download Brochure

Achieving Zero Break Down : Workshop on Planned Maintenance

Mon 23 to Tue 24 Mar, 2020, Pune

Read More Download Brochure


CII - Institute of Quality

icon 1Near Bharat Nagara, II Phase Magadi Main Road

icon 1Vishwaneedam P.O. Bengaluru 560091

icon 2 91-80-23289391

icon 3

Upcoming Training Programmes Business Excellence Quality Management Systems Education Excellence Lean Six Sigma BE Training Programs TPM Training Programs QMS Training Programs Edu. Excellence Training Programs LSS Training Programs