A Loss-Cost

A Loss-Cost Matrix Matrix Production Costs

Total Manufacturing Costs

General
Variable Costs Fixed Costs Administrative Costs

and Repair Costs

Indirect Labour

Administrative
Raw-Materials

Logistics Costs
Cost Structure Total

Direct Labour
Consumables

Maintenance
Power Costs
Losses

Fuel Costs

Die Costs

Charges
Interest
(million yen)
Loss Structure

Costs

Costs

Costs

Costs

Costs
Planned Shutdown Loss 130
Downtime Breakdown Loss 250
Equipment Effectiveness

Losses Setup and Adjustment loss 370

Startup Loss 25
Minor Stops Loss 30
Performance Speed Loss 25
Losses
Idling Loss 45
Quality Quality Defect Loss 35
Losses Rework Loss 15
Replanning Loss 20
Management Loss 150
Labour
Motion Loss 95
Effectiveness
Line Balance Loss 130
Non-Automation Loss 75
Adjustment Loss 85
Inventory Loss 8
Resource
Consumption
Energy Loss 15
Effectiveness
Consumables Loss 10
Yield Loss 35
Total Loss 1
1548
 A Loss-Cost Tree
Total Costs and Losses Total Cost
Total Loss
Loss-Reduction Target
Progress Towards Target

Fixed Costs Variable Costs Logistics Costs

Maintenance and Raw-Materials Supplementary- Internal Logistics External Logistics

Labour Costs Repair Costs Utilities Costs
Costs Materials Costs Costs Costs

Sundry Materials
Spare-Parts Loss
Installation Loss
Breakdown Loss

Manual Packing
Utilisation Loss

Shutdown Loss

Transportation
Quality-Defect

Compressed-Air
Manual Work

Spillage Loss

Storage Loss
Power Loss
Defective-

Packaging
Yield Loss

Fuel Loss
Planned-

Water and
Loss
Loss

Loss

Loss

Loss
Loss
Loss
2