Loss and cost management: Turn hidden losses into visible profits

Loss and cost management is the practice of finding where a plant loses money, putting a cost on each loss and removing the biggest ones first. LeanSuite gives you one structure for downtime, cost of poor quality and waste, costs each loss and ranks them so you know where to start.

You upload loss or defect data from a spreadsheet and map its columns once. LeanSuite sorts each record into a cost bucket and a causal or resultant loss, builds a loss tree ranked by cost, and lets you start a Kaizen from any loss.

A loss tree breaks your total losses down into their causes and puts a cost on each causal loss. LeanSuite builds it from your data for any date range and ranks your biggest improvement opportunities.

The six big losses are the main causes of lost equipment productivity, grouped under the three OEE factors. Equipment failures and setups reduce availability, idling, minor stops and reduced speed reduce performance, and process defects and startup losses reduce quality.

A causal loss is the original problem, such as a machine breakdown. Resultant losses are the costs it sets off elsewhere, such as idle operators downstream, overtime or scrap at restart. LeanSuite sorts each loss record into causal or resultant, so costs trace back to the problem worth fixing.

Your existing loss data. Upload files from spreadsheets, your ERP or MES and map the columns once, or connect your existing data lake.

The Top Losses report ranks losses by cost, the Glidepath shows closed, projected and carried-over savings against target month by month, and the Project Pipeline shows the savings still to come.

Set yearly savings targets for each department, with seasonality by month. LeanSuite tracks hard savings from every project against those targets.