AM Step 4 Loss Mapping Training

Step 4 loss
mapping
training
This document contains proprietary, confidential, and copyrighted (under the laws of the United States and other countries) materials
of The Procter & Gamble Company (P&G), under license from P&G. This document may not be duplicated, and the licensed information
therein may not be used or disclosed in whole or in part for any purpose other than as authorized by P&G. Any use or disclosure in
whole or in part of licensed information without the express written permission of P&G is prohibited.
Loss maps and loss summary
sheets Autonomous
Maintenance
BUNDLER UNIT-OP LOSS MAP
No.s 1, 2, 3, 4, 5, 6 No.s 12, 13, 14
TOP MAINT. AREAS

1) Poly infeed belts
2) Knives BREAKDOWNS
3) Heater belts 1) Knife failures
4) Carton infeed belts No.s 7, 8, 9, 10, 11 2) Poly infeed belts
5) Elevators, chain drives 3) Carton infeed belts
and pusher linkages
4) Elect. “problems” (Gemco and flat bar switch)
LABEL TOP MINOR STOP AREAS 5) Hopper; spring wall rod failed
1) Carton infeed brake assembly 1) Flat cartons 6) Failed rod end
2) Carton infeed conveyor 2) No poly detect

3) Starwheel assembly 3) Top pusher O/L
4) Carton infeed belts and assembly 4) Poly reel empty
5) Top pusher and hopper area 5) Operator stop
6) Cam box area 6) Poly off registration
7) Knife assembly
POTENTIAL QUALITY // GMP
8) Poly infeed area
PROBLEM AREAS Equipment owner loss analysis and goal setting sheet
9) Bottom sealer
1) Hopper area 1. Based upon your experience and data tracking, what are the big losses in your Equipment - Ownership Area?
10) Fold box area
2) Knife area ► You may not have losses in all of these areas.
11) EMP unit
3) EMP unit ► Your Dept may provide a “Cost Resource Guide” to help estimate the cost of the losses.
12) Heater belt section
4) Heater sections
Minor Stops or Touches Breakdowns: Process Failures:
13) Discharge conveyor
5) Reject system
Annual Cost Annual Cost Annual Cost
14) Reject assembly
1. ___________ $___________ 1. __________ $___________ 1. ___________ $___________
2. ___________ $___________ 2. __________ $___________ 2. ___________ $___________
3. ___________ $___________ 3. __________ $___________ 3. ___________ $___________
Housekeeping Losses Quality Losses:

Annual Cost
Equipment Owner: Annual Cost
1. ___________ $___________ Equipment Area: 1. ___________ $___________
2. ___________ $___________ 2. ___________ $___________
3. ___________ $___________ 3. ___________ $___________
Material Losses: Utility Losses: Other Losses:

1. ___________ $___________ 1. __________ $___________ 1. ___________ $___________
2. ___________ $___________ 2. __________ $___________ 2. ___________ $___________
3. ___________ $___________ 3. __________ $___________ 3. ___________ $___________
2. What will be your Loss Elimination Goals for AM Step-4? (as agreed to by Dept Leadership)
Loss Focus Target
Page 2 This document contains proprietary, confidential and copyrighted materials of The Procter & Gamble
Company (P&G), under license from P&G. The licensed information therein may not be used or
disclosed in whole or in part for any purpose other than as authorized by P&G.
Step 4 implementation process
Loss maps and loss summary sheets Autonomous
Maintenance
Understand loss Complete

Step 4 overview Prepare Machine
goals and make loss Work Point
training Quality Matrix
map & summary Analysis
Readiness
check
General Inspection:
Create
► Find Defects
Component Develop Component
► Fix Defects
Education & Training component map Inspection Standard
► Improvements
& Know Why OPLs
► Visual Controls
Audit and begin

next component
Purpose of this training
Autonomous
Maintenance
To understand your loss elimination goals for

step-4 and develop a loss map and loss
summary sheet for your zone ownership
area.
Loss Summary Loss Reduction Skills

Loss Summary Loss Reduction
Baseline
Baseline
Goal
Goal QD
QD 54
My BD BD7 7 0 0 BD BD
32
1
areaMy MS MS33 33 4 4
QD QD2 2 1 1 MS MS
Area
Loss Map Inspection Time # of Improvements
Loss Map Inspection Time # of Improvements
BD
Reapplied
BD MS Reapplied
MS QD Developed
QD Developed
Purpose of a loss map
Autonomous
Maintenance
1. Provides a visual summary of the losses within

your aone.
Loss Map
BD
MS
QD
2. Insures that Step-4 activities are loss focused

Baseline Goal QD
BD 7 0 BD
MS 33 4
QD 2 1 MS
Loss goals and loss map
Autonomous
Maintenance
► Why is it important to develop a loss map for

your zone?
► Why do you need loss elimination goals?
Department
Department
Loss
Master Plan
Analysis
Department
CBN
Equipment/ Equipment/
Zone Zone Owner
Loss Map Work Plan
Where are my What does

remaining losses? the
Department
expect me
to deliver?
Current best approach
Autonomous
Maintenance
Creating a loss map and loss elimination goals:

1. Sketch a block flow diagram of your zone or
equipment (use an existing document sketch a
diagram yourself, use vendor diagrams)
BUNDLER UNIT-OP
Product flow
Autonomous
Maintenance
2. Gather loss information and data. The following

is a list of some of the types of information that you
will need to gather:
Minor stops data

Touches data
Breakdown data
Process failures
Quality defects
Effort losses
Utility losses
Material losses
Other losses (leaks, etc.)
Dept. Specific loss themes (from dept. loss analysis data)
Note: Some of this data may be retrieved through computer

systems, such as Proficy, SAP & QW. Some of this data may be
found in equipment “paper” files. While some data may only be a
“ballpark” number based on input from experienced resources.
Autonomous
Maintenance
3. Create a summary of the losses in your zone

► Survey the equipment or zone
► Document known losses on the loss map
BUNDLER UNIT-OP LOSS MAP
No.s 1, 2, 3, 4, 5, 6 No.s 12, 13, 14
Top maint. Areas

1) Poly infeed belts
2) Knives Breakdowns
3) Heater belts 1) Knife failures
4) Carton infeed belts No.s 7, 8, 9, 10, 11 2) Poly infeed belts
5) Elevators, chain drives 3) Carton infeed belts
and pusher linkages
4) Elect. “problems” (Gemco and flat bar switch)
Top minor stop areas 5) Hopper; spring wall rod failed
Label 1) Flat cartons 6) Failed rod end
1) Carton infeed brake assembly 2) No poly detect
2) Carton infeed conveyor 3) Top pusher O/L
3) Starwheel assembly 4) Poly reel empty
4) Carton infeed belts and assembly 5) Operator stop
5) Top pusher and hopper area 6) Poly off registration
6) Cam box area
7) Knife assembly Potential quality // GMP
problem areas
8) Poly infeed area
1) Hopper area
9) Bottom sealer
2) Knife area
10) Fold box area
3) EMP unit
11) EMP unit
4) Heater sections
12) Heater belt section
5) Reject system
13) Discharge conveyor
14) Reject assembly
Autonomous
Maintenance
4. List known losses on the loss summary sheet
Equipment owner loss analysis and goal setting sheet

1. Based upon your experience and data tracking, what are the big losses in your Equipment - Ownership Area?
► You may not have losses in all of these areas.
Use your dept.’s

► Your Dept may provide a “Cost Resource Guide” to help estimate the cost of the losses.

cost reference sheet 1. ___________
2. ___________
$___________
$___________
1. __________
2. __________
$___________
$___________
1. ___________
2. ___________
$___________
$___________
to aid you in 3. ___________ $___________ 3. __________ $___________ 3. ___________ $___________
calculating the Housekeeping Losses

Annual Cost
Equipment Owner:
Quality Losses:
Annual Cost
annual cost of your 1. ___________
2. ___________
$___________
$___________
Equipment Area: 1. ___________
2. ___________
$___________
$___________
zone’s losses. 3. ___________ $___________ 3. ___________ $___________

1. ___________ $___________ 1. __________ $___________ 1. ___________ $___________
2. ___________ $___________ 2. __________ $___________ 2. ___________ $___________
3. ___________ $___________ 3. __________ $___________ 3. ___________ $___________
2. What will be your Loss Elimination Goals for AM Step-4? (as agreed to by Dept Leadership)
Loss Focus Target
5. Review your loss summary with your dept.

leadership and get alignment on your loss
elimination goal(s) and timing that you will work on
during Step 4.
Zone owner loss analysis and
goal setting sheet Autonomous
Maintenance
1. Based upon your experience and data tracking, what are the big losses in
your equipment – ownership area?
► Your Dept may provide a “Cost Resource Guide” to help estimate the cost of
the losses.
1. _________ $_________ 1. _________ $_________ 1. _________ $_________
2. _________ $_________ 2. _________ $_________ 2. _________ $_________
3. _________ $_________ 3. _________ $_________ 3. _________ $_________
Effort Losses: Quality Losses:

Zone Owner:
Annual Cost Annual Cost
1. _________ $_________ 1. _________ $_________
Zone Area:
2. _________ $_________ 2. _________ $_________
3. _________ $_________ 3. _________ $_________

(broke, scrap, etc.) (power, leaks, etc.)
1. _________ $_________ 1. _________ $_________ 1. _________ $_________
2. _________ $_________ 2. _________ $_________ 2. _________ $_________
3. _________ $_________ 3. _________ $_________ 3. _________ $_________
2. What will be your Loss Elimination Goals for AM Step 4? (as agreed to by
Dept. Leadership)
Loss Focus Target
Maintenance
1. Based upon your experience and data tracking, what are the big losses in your equipment –
ownership area?
► Your Dept. may provide a “Cost Resource Guide” to help estimate the cost of the losses.

1. Mandrel Jams $12,556 1. Saw Blades $1320 1. _________ $_________
2. Wet Web Occurrence $2044 2. Cam Followers $290 2. _________ $_________
3. _________ $_________ 3. _________ $_________ 3. _________ $_________

Equipment Owner:
AM Step 4 Team
1. _________ $_________ 1. Bad Blade Cuts $134
2. _________ $_________ Equipment Area: 2. Bad Glue Application $_________
3. _________ $_________ C9 Coremaking Line 3. _________ $_________

1. Stub Rolls $5724 1. _________ $_________ 1. Effort – straightening $9580
cores
2. _________ $_________ 2. _________ $_________ $101
2. Cleaning code dater

3. _________ $_________ 3. _________ $_________
2. What will be your Loss Elimination Goals for AM Step 4? (as agreed to by Dept. Leadership)
Loss Focus Target

When assessing root causes of Mandrel jams, saw blade wear and bad blade cuts, we fond that the
glue unit’s reliability was critical to preventing/reducing these losses.
► Reduce mandrel Jams by 20% by Nov.
► Increase Saw Blade Life by 15% Nov
Maintenance
1. Based upon your experience and data tracking, what are the big losses in your Equipment –
Ownership Area?

3. _________ $_________ 3. _________ $_________ 3. _________ $_________
Both of these losses

Annual Cost
are Equipment
common themes
Owner:
Annual Cost
AM Step 4 Team
1. _________ $_________ across all coremaking 1. Bad Blade Cuts $134
2. _________ $_________ – and are

lines Equipment Area:recco’s 2. Bad Glue Application $_________
3. _________ $_________ for FI’sLine

C9 Coremaking 3. _________ $_________

cores
2. _________ $_________ 2. _________ $_________ $101

3. _________ $_________ 3. _________ $_________
Loss Focus Target

► Increase Saw Blade Life by 15% by Nov.
Maintenance
Ownership Area?

3. _________ $_________ 3. _________ $_________ 3. _________ $_________
Effort Losses: Once this is agreed

Equipment Owner:to by the Quality Losses:
1. _________ $_________
Zone Owner
AM Step & their Dept.
4 Team
1. Bad Blade Cuts $134
2. _________ $_________
leadership, this becomes
Equipment Area: 2. Bad Glue Application $_________
apart of the Zone Owner’s W&DP

3. _________ $_________ C9 Coremaking Line 3. _________ $_________

cores
2. _________ $_________ 2. _________ $_________ $101

3. _________ $_________ 3. _________ $_________
Loss Focus Target

Maintenance
Ownership Area?

3. _________ $_________ 3. _________ $_________ 3. _________ $_________
In determining your losses, your loss

information
Effort Losses: mayEquipment
be a combination
Owner: ofQuality Losses:
1. _________
actual “hard” data
Annual Cost
$_________
AMand
Step 4 experience.
Team
Annual Cost
1. Bad Blade Cuts $134
2. _________ Do not underestimate

$_________ the
Equipment information
Area: 2. Bad Glue Application $_________
3. _________ from your resource’s

$_________ experiences.
C9 Coremaking Line 3. _________ $_________
We found that in (power,

Material Losses:
(broke, scrap, etc.)
our
Utility Leadership
Losses:
leaks, etc.)
model,
Other Losses:
we Annual
hadCost
no “hard” data Annualfor some
Cost of our Annual Cost
1. Stub Rolls
losses but had a lot of data from
$5724 1. _________ $_________ 1. Effort – straightening
cores
$9580
2. _________
experience.
$_________ 2. _________ $_________

$101
3. _________ $_________ 3. _________ $_________
Loss Focus Target

Autonomous
Maintenance
6. Set up a chart to track progress against your loss

elimination goals (use existing system, if
applicable). Keep your tracking sheet in your Zone
Owner Book.

Baseline Goal QD
BD 7 0 BD
MS 33 4
QD 2 1 MS
Inspection Time # of Improvements
Reapplied
Developed
Loss goals must be tracked else no one will know if or when a

loss has been eliminated.
This tracking will also aid the Z.O. in determining if further work
is required and if outside resources are needed.
Watch-outs
Autonomous
Maintenance
Do not try to attack all losses at once.
You must be choiceful and reasonable.
Zero Loss Mentality: The goal is to eliminate all

losses eventually, however, we do not have the time
and/or resources to attack all losses at one time.
Keep the tracking of the loss goal simple!

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Step 4 loss

BUNDLER UNIT-OP LOSS MAP

No.s 1, 2, 3, 4, 5, 6 No.s 12, 13, 14

TOP MAINT. AREAS

1) Carton infeed brake assembly 1) Flat cartons 6) Failed rod end

2) Carton infeed conveyor 2) No poly detect

2. ___________ $___________ 2. __________ $___________ 2. ___________ $___________

3. ___________ $___________ 3. __________ $___________ 3. ___________ $___________

Housekeeping Losses Quality Losses:

2. ___________ $___________ 2. ___________ $___________

3. ___________ $___________ 3. ___________ $___________

Material Losses: Utility Losses: Other Losses:

2. ___________ $___________ 2. __________ $___________ 2. ___________ $___________

3. ___________ $___________ 3. __________ $___________ 3. ___________ $___________

Loss Focus Target

Understand loss Complete

Audit and begin

To understand your loss elimination goals for

Loss Summary Loss Reduction Skills

1. Provides a visual summary of the losses within

2. Insures that Step-4 activities are loss focused

Loss Summary Loss Reduction

► Why is it important to develop a loss map for

Where are my What does

Creating a loss map and loss elimination goals:

2. Gather loss information and data. The following

Minor stops data

Note: Some of this data may be retrieved through computer

3. Create a summary of the losses in your zone

BUNDLER UNIT-OP LOSS MAP

No.s 1, 2, 3, 4, 5, 6 No.s 12, 13, 14

Top maint. Areas

4. List known losses on the loss summary sheet

Equipment owner loss analysis and goal setting sheet

Use your dept.’s

Minor Stops or Touches Breakdowns: Process Failures:

cost reference sheet 1. ___________

to aid you in 3. ___________ $___________ 3. __________ $___________ 3. ___________ $___________

calculating the Housekeeping Losses

annual cost of your 1. ___________

zone’s losses. 3. ___________ $___________ 3. ___________ $___________

Material Losses: Utility Losses: Other Losses:

2. ___________ $___________ 2. __________ $___________ 2. ___________ $___________

3. ___________ $___________ 3. __________ $___________ 3. ___________ $___________

Loss Focus Target

5. Review your loss summary with your dept.

2. _________ $_________ 2. _________ $_________ 2. _________ $_________

3. _________ $_________ 3. _________ $_________ 3. _________ $_________

Effort Losses: Quality Losses:

3. _________ $_________ 3. _________ $_________

Material Losses: Utility Losses: Other Losses:

2. _________ $_________ 2. _________ $_________ 2. _________ $_________

3. _________ $_________ 3. _________ $_________ 3. _________ $_________

Minor Stops or Touches Breakdowns: Process Failures:

2. Wet Web Occurrence $2044 2. Cam Followers $290 2. _________ $_________

3. _________ $_________ 3. _________ $_________ 3. _________ $_________

Effort Losses: Quality Losses:

2. _________ $_________ Equipment Area: 2. Bad Glue Application $_________

3. _________ $_________ C9 Coremaking Line 3. _________ $_________

Material Losses: Utility Losses: Other Losses:

2. _____ $_ 2. $_ 2. _ $_____

3. _____ $_ 3. $_ 3. _ $_____

2. _____ $_ 2. _ $_____

3. _____ $_ 3. _ $_____

2. _____ $_ 2. $_ 2. _ $_____

3. _____ $_ 3. $_ 3. _ $_____

to aid you in 3. _____ $_ 3. $_ 3. _ $_____

zone’s losses. 3. _____ $_ 3. _ $_____

2. _____ $_ 2. $_ 2. _ $_____

3. _____ $_ 3. $_ 3. _ $_____

2. _____ $_ 2. _ $_ 2. _ $_____

3. _____ $_ 3. _ $_ 3. _ $_____

3. _____ $_ 3. _ $_____

2. _____ $_ 2. _ $_ 2. _ $_____

3. _____ $_ 3. _ $_ 3. _ $_____

2. Wet Web Occurrence $2044 2. Cam Followers $290 2. _ $_

3. _____ $_ 3. _ $_ 3. _ $_____

2. _____ $_ Equipment Area: 2. Bad Glue Application $_____

3. _____ $_ C9 Coremaking Line 3. _ $_____

2. _____ $_ 2. _ $_____ $101

2. Wet Web Occurrence $2044 2. Cam Followers $290 2. _ $_

3. _____ $_ 3. _ $_ 3. _ $_____

2. _ $_ – and are

3. _ $_ for FI’sLine

2. _____ $_ 2. _ $_____ $101

2. Wet Web Occurrence $2044 2. Cam Followers $290 2. _ $_

3. _____ $_ 3. _ $_ 3. _ $_____

2. _____ $_ 2. _ $_____ $101

2. Wet Web Occurrence $2044 2. Cam Followers $290 2. _ $_

3. _____ $_ 3. _ $_ 3. _ $_____

3. _____ $_ 3. _ $_____