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Why Loss Tracker ?

We are committed to significantly enhancing production line stability and achieving our Target Operation Rate (OR) of 90%.To do this, we must accelerate our Kaizen initiatives for faster, more effective process improvement.

Traditional methods

(manual time and problem tracking by Line leader )

  • Recurring Problems > Unresolved root causes keep issues repeating.
  • Incomplete Visibility > Hidden and night-shift issues go unnoticed.
  • Lack of Shared Understanding > Unclear data hinders team alignment.

KAIZEN with Loss Tracker

helps you identify problems and level up

  • Flag Abnormalities > Instantly highlight areas needing action.
  • Reveal Hidden Issues > Expose unclear causes and unseen problems.
  • Foster Collaboration > Align teams for faster PDCA cycles.

PROBLEM SOLVES AT SOLWER

Result by
Loss Tracker

How it work ?

Root Cause Analysis

Compares Target Output vs. Actual Output to pinpoint losses

Real-Time Monitoring

Detects Cycle Time using sensors or direct machine signals

Records video evidence linked to cycle time signals for easy verification

Real-Time Monitoring

Detects Cycle Time using sensors or direct machine signals

Records video evidence linked to cycle time signals for easy verification

Data Insight Report

DENSO doesn’t focus only on machine downtime, but also analyzes and evaluates production losses caused
by various hidden factors — including human operations — which are often difficult to assess but have a significant impacton overall production efficiency.These data are then prioritized using Pareto charts to identify key causesand drive continuous improvement initiatives.

DENSO doesn’t focus only on machine downtime, but also analyzes and evaluates production losses caused by various hidden factors — including human operations — which are often difficult to assess but have a significant impact on overall production efficiency.These data are then prioritized using Pareto charts to identify key causes and drive continuous improvement initiatives.

Part 1: OEE Trend (Dayshift & Nightshift)

Analysis term; 28/04/25 – 04/05/25

OEE Trend (Dayshift and Nightshift)

Gain a clear overview and detailed insight into production performance across day and night shifts.

Part 2: Loss Analysis Summary

Loss Analysis Summary

Converts massive raw data into actionable insights for both management and the production floor, enabling quicker and more accurate Kaizen improvements.

Lean KAIZEN Success Cases

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