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How do you identify and eliminate speed losses in TPM?

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Speed losses are one of the six big losses categories that affect the overall equipment effectiveness (OEE) in Total Productive Maintenance (TPM). Speed losses occur when the actual operating speed of a machine or process is lower than the designed or ideal speed. This reduces the output rate and the productivity of the equipment. In this article, you will learn how to identify and eliminate speed losses in TPM using a four-step approach.

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1 Measure the actual and ideal speed

The first step is to measure the actual and ideal speed of the equipment or process. The actual speed is the average output rate per unit time, such as pieces per hour or liters per minute. The ideal speed is the maximum output rate that the equipment or process can achieve under optimal conditions, such as no defects, no breakdowns, no adjustments, and no operator interventions. You can find the ideal speed from the equipment specifications, manuals, or benchmarks. You can measure the actual speed by using sensors, counters, timers, or manual observations.

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Marty Brummett

Oak Ridge
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In my experience the people getting the cycle times do not spend enough time recording real time cycle times for all the different product variations. And after the time studies the operators are not give the tools they need to accomplish the perfect cycle times.

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Luis A. Ibarra

General Manager
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Also speed is affected for the effective standard work implementation, specific value added activities to perform by the operator, focused to keep machine efficiency.

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2 Calculate the speed loss percentage

The second step is to calculate the speed loss percentage, which is the ratio of the difference between the ideal and actual speed to the ideal speed, expressed as a percentage. For example, if the ideal speed of a machine is 100 pieces per hour and the actual speed is 80 pieces per hour, the speed loss percentage is (100 - 80) / 100 x 100 = 20%. The speed loss percentage indicates how much potential output is lost due to suboptimal performance.

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3 Analyze the root causes of speed losses

The third step is to analyze the root causes of speed losses, which are the factors that prevent the equipment or process from reaching the ideal speed. Common causes include wear and tear of parts, inadequate lubrication or maintenance, improper settings or alignments, variations in raw materials, inputs, or environmental conditions, operator errors or behaviors, and design flaws. To identify and prioritize these root causes, you can use Pareto charts, fishbone diagrams, 5 whys, surveys, interviews, or audits.

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Luis A. Ibarra

General Manager
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Good example to follow to determine causes is the 6M"s... Manpower, Method, Material, Machine, Mother Nature & very important measurement or in other words lack of metrics...

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4 Implement countermeasures and monitor results

The fourth step is to implement countermeasures and monitor results. Countermeasures are the actions or solutions that address the root causes of speed losses and improve equipment or process performance. This could involve replacing, repairing, or upgrading parts, components, or tools; improving lubrication, cleaning, or maintenance routines; optimizing settings, adjustments, or alignments; standardizing raw materials, inputs, or environmental conditions; training, coaching, or empowering operators; and/or redesigning, simplifying, or streamlining the equipment or process. It's important to measure the actual and ideal speed again and calculate the new speed loss percentage in order to evaluate the impact of the countermeasures on quality, availability, and safety. Results should be documented and communicated to celebrate any achievements.

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Luis A. Ibarra

General Manager
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Agree. Also create a supporting work environment and teamwork to integrate all departments Production, Maintenance, Engineering, Quality, Materials etc. Common actions and goals!!.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Georges Gumy

TPM Expert
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They are few major categories of speed loss: 1. Ramp up after a Change-over, the setting is not done perfectly creating multiple micro-stop and fine-tuning. The nominal speed is reach after hours of run. The solution is to have a perfect change-over standard, highly qualified operators to execute it. Setting instead adjustment. 2. Speed volontary reduced because the right quality is not reached at the nominal speed. Solution is to identify and eliminate the root causes of the problem. 3. Speed voluntary reduced because excess of vibration, temperature or other at the nominal speed. Same solution than above. 4. Speed voluntary reduce because the operator has the freedom to do so, without reason. Solution put an alarm for low speed.

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How do you identify and eliminate speed losses in TPM?

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1 Measure the actual and ideal speed

2 Calculate the speed loss percentage

3 Analyze the root causes of speed losses

4 Implement countermeasures and monitor results

5 Here’s what else to consider

Total Productive Maintenance (TPM)

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