1. Process Stop v. Breakdown

2. Process Stops
A Process Stop is when the production stops for a time greater than 10 minutes due to an external influence.
Example: human error, lack of raw materials, quality issues, etc. Common occurrences of process stops may be a bottle jam or low fills due to incorrect settings or set up, raw material issues, etc.
Abatement of Process Stops is done by developing/improving SOP’s, Work Aids, Work Instructions, SPL, Quick Wins, Quick Kaizens, etc.

3. Breakdowns
A Breakdown is when the equipment stops for a time greater than 10 minutes due to an equipment malfunction.  For example, there is a failure within the equipment such as a chain has broken or a belt is worn and slipping and must be changed in order to operate effectively. A breakdown typically will require either a part or electrical/mechanical intervention in order to restore the equipment to operating condition.
Abatement of Breakdowns is done by developing/improving PM’s tasks, PdM tasks, and other maintenance related practices driven by Breakdown Analysis

4. Why is it important to differentiate??
Differentiating losses delivers a faster resolution
TPM aligns losses to the proper resource(s)
Minor Stops - Autonomous Maintenance Pillar
Process Stops – Focused Improvement Pillar
Breakdowns – Professional Maintenance Pillar
Builds employee empowerment and engagement

5. Exercise – What Type of downtime/failure is it ???
Seamer Jams for 14 mins and Maintenance is called to help clear jam
Air Conveyor blower VFD trips and needs to be reset – 12 mins downtime
Kister runs out of film and maintenance is called to re-wind – down 18 mins
After changing over Mead machine – maintenance is called to adjust rails – down 11 mins
Replace filling valve – down 12 mins
Glue pot runs out of glue – down 21 mins
Palletizer reflector breaks off bracket – down 13 mins
Coder runs out of ink – down 32 mins – with 30 mins of re-work
Lightning storm knocks out transformer – down 3 days
Flavor change – down 17 mins

6. Exercise – What Type of downtime/failure is it ???
Seamer Jams for 14 mins and Maintenance is called to help clear jam Process
Air Conveyor blower VFD trips and needs to be reset – 12 mins downtime BD
Kister runs out of film and maintenance is called to re-wind – down 18 mins Process
After changing over Mead machine – maintenance is called to adjust rails – down 11 mins Process
Replace filling valve – down 12 mins BD
Glue pot runs out of glue – down 21 mins Process
Palletizer reflector breaks off bracket – down 13 mins BD
Coder runs out of ink – down 32 mins – with 30 mins of re-work -Process
Lightning storm knocks out transformer – down 3 days – Other/Unplanned
Flavor change – down 17 mins - Planned