7 Types of Abnormalities in TPM
Anything which isn’t normal that’s 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 much popular concept in Total Productive Maintenance (TPM).
- Several types of abnormalities are the part of Jishu Hozen Pillar in TPM
- Abnormality classify Matrix is also prepared in JH Pillar of TPM
- Abnormalities create a negative influence on productivity, quality, cost, delivery, morale, and safety
Also watch: https://www.youtube.com/watch?v=M-YccQYqRr4&t=33s
7 Types of Abnormalities in TPM
→ There are 7 Types of Abnormalities is there in Jishu Hozen Pillar in Total Productive Maintenance (TPM).
→ The 7 Types of Abnormalities are mention below.
- Unfulfilled Basic Conditions
- Sources of Contamination
- Sources of Quality Defects
- Unsafe Places
7 Types of Abnormalities with Example
- The 7 Types of abnormalities with example namaste are explained
01. Minor Flaws
- Minor Flaws is the abnormal condition that’s related to any play, slackness, or damage part available in any machine.
- Minor Flaws basically we can found between the several rotating parts like shaft, bearings, couplings, and gearboxes.
Exemplifications of Minor Flaws
- Crack, Crush, Damage, or Deformation of any part of operate or machine
- Slackness in belt or chain machine
- Play in between shaft, bearing, and gearbox. It may be tilt, center out, eccentricity problem, wear distortion, corrosion,etc.
- We can identify Minor Flaw types 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 are related to not fulfilling the basic condition of the machine to operate.
- That’s basically related to Cleaning, Lubricating, & Tightening related things.
- Before beginning the production we need to check about the unfulfilled basic condition-related abnormalities.
Examples of Unfulfilled Introductory Conditions
- Dirt, dust, leakage, and damaged part are available at the machine.
- Lubrication supply found dirty, damaged, or misshapen.
- Oil level indicator was also found dirty, damaged, or in leakage condition.
- Nuts and Bolts are in slack/lost condition, Nuts and Bolts are missing, Cross-threaded, damaged, or too long found.
- Washer, Wing Nut, Washer, Locknut not available in the required place.
- If we cannot access the machine or any area for cleaning, lubrication, examination, re-tightening, or regular operation purpose, that’s called Inaccessible Places.
- For barring this abnormalities, we can implement some Kaizen sat the working place.
- Kaizen may be related to process change or design change example of Inaccessible Places
- We can not clean the machine, it might be due to machine construction, machine covers, machine layout,etc.
- We can’t grease the machine, it might be due to the position of lubricant inlet, construction, height, lubricant outlets, space.
- The operator can’t check the critical parameter, it might be due to construction, covers, layout, Instrument position, and Orientation.
- The operator can’t tightening of nut and bolts, it might be due to covers, construction, layout size, and, Space.
4. 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 exclude this by implementing several Standard Process Checklists.
Example 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.
5. Sources of Quality Defects
- Quality defect generation source is known as a source of quality defects
- It can be foreign particles, shocks, atmosphere, moisture content, attention, density,etc.
- The Source of Quality defects are very as per the process and products.
Example 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’re known as the sources of quality defects.
- In machine dropping, collision, or vibration can also create defects.
- now and then inadequate cooling, heating, machining, etc create quality defects.
6. Unnecessary Items
- At working place if any non-required item is available also it’s called unnecessary items.
- Unnecessary items may be any spares, machinery, pipes, measuring instruments, electrical things, and any other products that aren’t necessary at a particular place but it’s still available.
Example 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.
- Several spares and electrical equipment are available in the machine area but it isn’t required . e.g. wire, switches, plugs, boards, etc
7. 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.
- Now and then unsafe places may create a bad impact on humans or on machines.
Example of Unnecessary Items
- Working place is too steep, irregular, slipping, having crakes, holes, etc. called unsafe places.
- If the emergency stop isn’t available at the machine that it’s also an illustration of an unsafe place.
- Broken or cracked wire or hooks are available.
- What Is 5s System& why 5s fail ➡ What Is 5s System Honest Video,
- How to Reduce Inventory, Inventory Management Tool & Tactics
- What Is Kaizen, What Is Kaizen With Example, non- value added activity, Kaizen muda
- One Point Lesson | one point lesson types & example |TPM one point lesson | OPL explain
- Learn The 7 Wastes Of Lean ➡ The 7 Wastes of Lean for Frontline Kaizen -Lean Manufacturing Training
- Overall Equipment Efficiency What Is OEE – Overall Equipment Effectiveness Solution
- What is Lean Manufacturing | Lean tool crash course | lean Manufacturing in 5 min | Lean in Hindi
- SMART Goal Setting in Six SigmaThe post SMART Goal Setting in Six Sigma appeared first on Greendot Management Solutions.
- 12 Step of TPM ImplementationThe post 12 Step of TPM Implementation appeared first on Greendot Management Solutions.
- Muda Mura MuriThe post Muda Mura Muri appeared first on Greendot Management Solutions.
- 7 Types of Abnormalities in TPMThe post 7 Types of Abnormalities in TPM appeared first on Greendot Management Solutions.
- 8 Wastes of Lean ManufacturingThe post 8 Wastes of Lean Manufacturing appeared first on Greendot Management Solutions.
- Cost of Quality vs Cost of Poor Quality (COPQ)The post Cost of Quality vs Cost of Poor Quality (COPQ) appeared first on Greendot Management Solutions.
- What is Lean Six Sigma ?The post What is Lean Six Sigma ? appeared first on Greendot Management Solutions.
- Six Big Losses in OEEThe post Six Big Losses in OEE appeared first on Greendot Management Solutions.
- Top Lean ToolsThe post Top Lean Tools appeared first on Greendot Management Solutions.
- 5S in the Workplace | 5S ImplementationThe post 5S in the Workplace | 5S Implementation appeared first on Greendot Management Solutions.