A semi$-$automated assembly machine, assembles and welds automotive components for a single shift of $7\mathrm{.}5$ hours, $5$ days a week; planned throughput $=150$ units$/$hour; actual output $=2875$ units$/$week$.$ The following losses are encountered during

$1.$ Incorrect assembly causes the machine to stop and needs re$-$set on average $5$ times$/$hr$.$ where $1$ unit and $2$ minutes are lost. $($This leads to performance loss due to minor stoppage and also quality loss$)$

$2.$ Worn out electrodes are to be replaced once per week, it takes $1$ hour when $30$ units are scrapped $>($availability and quality losses$)$

$3.$ Burst out cooling hose causes a machine breakdown once in a month and

$4.$ Misaligned fixture causes a loss of $220$ units$/$ week m$>($quality loss$)5.$ For different size parts, fixtures to be removed and replaced and electrode position to be adjusted $3$ times$/$week which takes $2\mathrm{.}25$ hours where $24$ units are scrapped each time $=>($availability and quality losses$)$

$6.$ Actuating cylinder sometimes sticks for $30$ minutes$/$d causing production

$,$ oue cyce tme $=>($pertormance loss$)$ machine at the

start and end of the day takes $5$ minutes each time $=>($minor stoppages thereby performance loss$)$

$8.$ Limit switches corrode once in every $6$ weeks stopping the machine and replacement takes $6$ hours $=>($availability loss$).$