What Is Abnormality? What is Fuguai in TPM?
→ Anything which is not normal that is called an abnormality
→ Fuguai is a Japanese word.
→ Fuguai means abnormality.
→ We can also say that the abnormality is a deviation from the standard requirement.
→ The abnormality is a very popular concept in Total Productive Maintenance (TPM).
→ Various types of abnormalities are the part of Jishu Hozen Pillar in TPM.
→ Abnormality classification Matrix is also prepared in the JH Pillar of TPM
→ Abnormalities create a negative impact on productivity, quality, cost, delivery, morale, and safety.
7 Types of Abnormalities in TPM
→ There are 7 Types of Abnormalities available in Jishu Hozen Pillar in Total Productive Maintenance (TPM).
→ The 7 Types of Abnormalities are mentioned below.
- Minor Flaws
- Unfulfilled Basic Conditions
- Inaccessible Places
- Sources of Contamination
- Sources of Quality Defects
- Unnecessary Items
- Unsafe Places
👉 7 Types of Abnormalities PDF File Download
7 Types of Abnormalities with Examples
→ The 7 Types of abnormalities with examples are explained below.
01. Minor Flaws
→ Minor Flaws is the abnormal condition that is related to any play, slackness, or damage part available in any mechanism.
→ Minor Flaws mainly we can found between the various rotating parts like shaft, bearings, couplings, and gearboxes.
Examples of Minor Flaws:
→ Crack, Crush, Damage, or Deformation of any part of drive or mechanism
→ Slackness in belt or chain mechanism
→ Play available between shaft, bearing, and gearbox. It may be tilt, center out, eccentricity problem, wear distortion, corrosion, etc.
→ We can identify Minor Flaw type of abnormalities by abnormal noise, vibration, overheating, the strange smell coming from part/machine, incorrect pressure or current.
02. Unfulfilled Basic Conditions
→ Unfulfilled Basic Conditions is the abnormal condition that is related to not fulfilling the basic condition of the machine to operate.
→ That is mostly related to Cleaning, Lubricating, & Tightening related things.
→ Before starting the production we need to check about the unfulfilled basic condition-related abnormalities.
Examples of Unfulfilled Basic Conditions
→ Dirt, dust, leakage, and damage part available at the machine.
→ Lubrication supply found dirty, damaged, or deformed.
→ Oil level indicator also found dirty, damaged, or in leakage condition.
→ Nuts and Bolts are in slack/loose condition, Nuts and Bolts are missing, Cross-threaded, damaged or too long found.
→ Washer, Wing Nut, Washer, Locknut not available in the necessary place.
03. Inaccessible Places
→ If we cannot access the machine or any area for cleaning, lubrication, inspection, retightening, or regular operation purpose, that is called Inaccessible Places.
→ For eliminating this kind of abnormalities we can implement some Kaizens at the working place.
→ Kaizens may be related to process change or design change.
Examples of Inaccessible Places
→ We cannot clean the machine, it might be due to machine construction, machine covers, machine layout, etc.
→ We can not lubricate the machine, it might be due to the position of lubricant inlet, construction, height, lubricant outlets, space.
→ The operator can not check the critical parameter, it might be due to construction, covers, layout, Instrument position, and Orientation.
→ The operator can not tightening of nut and bolts, it might be due to covers, construction, layout size, and, Space.
04. Sources of Contamination
→ Source of Contamination includes any types of leakages, spillage, scattering, or overflows of any material.
→ These kinds of abnormalities can create bad impacts on productivity, quality, and cost.
→ We can eliminate this by implementing various Standard Process Checklists.
Examples of Sources of Contamination
→ Leakage, Spillages, Scattering, or Overflows of any product, raw material, lubricants, or gases.
→ Scrap material like flashes, cutting chips/burrs, packaging materials, and non-conforming products are also considered as the sources of contamination because they can contaminate the machine or products.
→ Solid, Liquid, Gas, or Flude might be considered a contamination source if it contaminates the product or machine.
05. Sources of Quality Defects
→ Quality Defect generation source is known as a Source of Quality Defects.
→ It can be foreign particles, shocks, vibrations, moisture content, concentration, viscosity, etc.
→ The Source of Quality defects are very as per the process and products.
Examples of Sources of Quality Defects
→ Foreign particles of dust, rust, powder, chips, moisture, wire scraps, wood pieces, paper pieces, stones, etc. can create quality defects. So they are known as the sources of quality defects.
→ In machine dropping, collision, or vibration can also create defects.
→ Sometimes inadequate cooling, heating, machining, etc create quality defects.
06. Unnecessary Items
→ At working place if any non-required item is available then it is called unnecessary items.
→ Unnecessary items may be any spares, machinery, pipes, measuring instruments, electrical things, and any other products that are not necessary at a particular place but it is still available.
Examples of Unnecessary Items
→ Unwanted material is available at working place like different types of machinery e.g. pumps, fans, compressors, blowers, pipes, hoses, ducts, valves, dampers, etc.
→ Different types of measuring instruments are available at the machine but not required. e.g temperatures and pressure gauges, vacuum gauges, etc.
→ Various spares and electrical equipment are available in the machine area but it is not required. e.g. wire, switches, plugs, boards, etc
07. Unsafe Places
→ The working place having unevenness, cracks, holes, projections, peeling, or, the slipping surface that can create any accidents that are called unsafe places.
→ Sometimes unsafe places may create a bad impact on humans or on machines.
Examples of Unnecessary Items
→ Working place is too steep, irregular, slipping, having crakes, holes, etc. called unsafe places.
→ If the emergency stop is not available at the machine that its also an example of an unsafe place.
→ Broken or cracked wire or hooks are available.
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