Downtime & the Six Big Losses

Finding, classifying, and shrinking the stops that eat your shifts — including the ones nobody writes down.

Well-worn paper downtime log sheet clipped beside a machine control station
Downtime & the Six Big Losses·7 min read

Why Operators Stop Logging Downtime (and How to Fix It)

Every downtime tracking effort starts with clean sheets and good intentions. Six weeks later the logs say 'misc — 45 min.' The decay is predictable, which means it's preventable.

Operator reaching into a conveyor to clear a jammed container while the line waits
Downtime & the Six Big Losses·7 min read

Micro-Stops: The Downtime Nobody Writes Down

A 30-second jam doesn't feel like downtime. It feels like part of the job. Multiply it by ninety occurrences a shift and it's your biggest loss — and it's completely absent from your records.

Maintenance technician kneeling beside an open machine panel with tools laid out on the floor
Downtime & the Six Big Losses·8 min read

The Six Big Losses, With Examples You'll Recognize

The six big losses sound like textbook material until you realize you can name a machine in your plant for every single one. A tour of all six, with the examples the textbooks leave out.

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Shift lead reviewing live OEE data on a tablet on the plant floor