Maximize productivity

Maximizing Manufacturing Efficiency: The Six Big Losses Analysis for Real-time Production Improvement


Production leakages can have a significant impact on the productivity and profitability of manufacturing processes. To quantify these losses and identify areas for improvement, many companies are turning to the Six Big Losses analysis.


The Six Big Losses are six categories of production waste that account for the majority of production downtime and inefficiencies. They are:  

1. Equipment Failure 

2. Set-up and Adjustments 

3. Idling and minor stoppages 

4. Reduced speed 

5. Process Defects 

6. Reduced Yield


By categorizing production losses into these six categories, manufacturers can identify the root causes of inefficiencies and take targeted actions to reduce them. This methodology can also help prioritize improvement efforts based on the greatest potential impact on production output and profitability. 


Real-time monitoring and analysis of production data can enable manufacturers to identify and quantify these six big losses as they occur, providing immediate feedback for continuous improvement. By using advanced analytics and machine learning, manufacturers can also predict and prevent future losses and can improve OEE


A Production Monitoring System is critical for analyzing and mitigating the “Six Big Losses” in manufacturing operations. This system allows for real-time data collection and analysis of key performance indicators (KPIs) such as downtime, setup time, cycle time, and scrap rates. By continuously monitoring production processes, the system can identify and quantify the losses caused by breakdowns, setups, minor stops, reduced speed, startup rejects, and quality defects. This data can then be analyzed to identify patterns, trends, and root causes of the losses, enabling timely corrective actions to be taken. A production monitoring system provides valuable insights for optimizing processes, reducing waste, improving efficiency, and maximizing productivity, ultimately leading to improved operational performance and increased profitability.


The Andon System is a powerful tool used in manufacturing and processing improvement to identify and address the “Six Big Losses.” The Andon system allows operators to quickly alert supervisors or maintenance personnel when an issue arises, triggering an immediate response to resolve the problem. This system provides real-time visibility into production issues, enables root-cause analysis, and facilitates timely decision-making. By addressing the Six Big Losses through the effective use of an Andon system, companies can optimize their operations, reduce waste, improve quality, and enhance overall efficiency, ultimately resulting in increased customer satisfaction and competitiveness in the market. 


For real-time Production Monitoring and Andon Solutions, look no further than Compucare India Private Limited. Contact us now to learn more about our offerings and how they can benefit manufacturing operations.


Overall, the Six Big Losses Analysis is an effective tool for quantifying and addressing production leakages in real time, helping manufacturers improve efficiency, reduce costs, and increase profitability. By continuously monitoring and improving their production processes, manufacturers can remain competitive in today’s dynamic and fast-paced business environment.