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Free tool · 2 minutes

How much does your line lose each year without anyone seeing it?

Product that is thrown away or reworked, people watching the line, stoppages, format changeovers and customer complaints. Fill in what you know about your line, switch on the losses that affect you and see straight away how much money is slipping away and how much you could recover.

1 · Your line

The three figures in green are an example: replace them with your own. Fill in the rest yourself.

2 · Quality: defects, rework and complaints

Count whoever checks the product by hand on the line, whoever sorts, relabels, repacks or recovers rejects, and whoever checks pallets before dispatch. For half a shift, enter 0.5.

3 · Other line losses (switch on the ones that affect you)

These are the big losses measured by OEE in continuous improvement (LEAN and TPM). Only tick the ones you know: anything you leave off is not counted.

When the inspection (manual or a poorly tuned camera) rejects units that were fine. It is good product that gets thrown away or checked again.

Time the line is stopped without it being planned: a breakdown, a jam, missing material. It is valued as production that does not get made.

From the last good unit of one product to the first good unit of the next, including adjustments.

Short stops of seconds or a few minutes (a fallen container, a sensor tripping) that nobody records but add up by the end of the day.

When the line runs slower than it can, for fear of jams, because one machine cannot keep up, or out of habit.

Product that is not right until the line stabilises: at the start of a shift, after a changeover or after a stop.

When a batch has to be taken off the market because of a label, allergen, date or closure error. The cost is spread over the three years.

Overfilling to avoid being underweight, product that expires in the warehouse or is thrown away when cleaning the line.

Weekend shifts or extended shifts to make up what was not produced on time.

Ovens, tunnels, compressors and motors that keep consuming while the line waits.

4 · Your own items (up to 5)

If your line has another loss not listed above, add it with its cost per year.

Savings assumptions (you can change them)

These are cautious assumptions, not a promise: every line is different. Automatic inspection does not stop a defect from happening: it always detects it and records the data to find its cause. The other losses fall when they are measured and their causes tackled, which is what continuous improvement does.

Full report · free

Your report, with the detail and what to tackle first

We send you the breakdown of your figures, the losses that weigh most on a line like yours and the three measures that pay off most. A TIVOX engineer reviews it before it is sent and, if you wish, we can go through it in a 20-minute call, with no obligation.