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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

1 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.
2 Set up and adjustment losses Stoppage losses that accompany set-up changeovers
3 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.
4 Start-up losses When starting production, the losses that arise until equipment start-up, running-in and production processing conditions stabilize.
5 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).
6 Speed losses Losses due to actual operating speed falling below the designed speed of the equipment.
7 Defect & rework loss Losses due to defects & reworking
B Losses that impede equipment loading time
8 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
9 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.
10 Motion losses Man-hour losses arising from differences in skills involved in etc.
11 Line organization losses Idle time losses when waiting for multiple processes or multiple platforms.
12 Distribution losses Distribution man-hour losses due to transport of materials, products (processed products) and dollies.
13 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
14 Energy losses Losses due to ineffective utilization of input energy (electric, gas, fuel oil, etc) in processing.
15 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.
16 Yield losses Material losses due to differences in the weight of the input materials and the weight of the quality products

The above losses are generally not understood in the industry and these losses grow over a period of time. A need has been identified to disseminate the information on the methodology to eliminate/minimize these losses. Responding to the need of building skills in this area, a seminar has been designed with emphasis given to impart knowledge to the participants through theory & a case study.

The programme will start at 0900 hrs with registration and ends at 1730 hrs.

Kobetsu Kaizen (Focused Improvement) Seminar 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

Target Audience: Manufacturing Heads, Quality Heads, Engineering Heads, Process Heads, Engineers, Senior Managers, and Managers from Manufacturing, Process, Engineering and Quality from the industries.

Faculty: Mr S Narasimhan, Senior Counsellor, TPM Club India

Pre-registration and pre-payment is essential for participation. Cheque/DD towards delegate fee should be drawn in favour of “CII Institute of Quality”, payable at Bangalore. Delegate fee is nonrefundable, however, change in nomination is acceptable. NEFT payment is also accepted, if required we will provide the necessary information

Members / Non-members are requested to kindly depute the concerned officials to attend this very important Workshop. The brochure and nomination form is enclosed herewith for your perusal and to send nominations.

For Registration contact

Abdul Wadood
Principal Counsellor and Head - TPM Club India
CII - Institute of Quality Near Bharat Nagara Ilnd Phase Magadi Main Road, Vishwaneedam P.O.
Bengaluru - 560091 Phone: 91-80-23289391 / 23580638 Fax: 91-80-23289388 / 23580314 Website:

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CII - Institute of Quality

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