7 Types of Abnormalities in TPM

7 types of abnormalities in tpm

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.

  • MinorFlaws
  • Unfulfilled Basic Conditions
  • InaccessiblePlaces
  • Sources of Contamination
  • Sources of Quality Defects
  • UnnecessaryItems
  • 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.

3. InaccessiblePlaces

  • 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.

Also watch

  1. What Is 5s System& why 5s fail ➡ What Is 5s System Honest Video,
  2. How to Reduce Inventory, Inventory Management Tool & Tactics
  3. What Is Kaizen, What Is Kaizen With Example, non- value added activity, Kaizen muda
  4. One Point Lesson | one point lesson types & example |TPM one point lesson | OPL explain
  5. Learn The 7 Wastes Of Lean ➡ The 7 Wastes of Lean for Frontline Kaizen -Lean Manufacturing Training
  6. Overall Equipment Efficiency What Is OEE – Overall Equipment Effectiveness Solution
  7. What is Lean Manufacturing | Lean tool crash course | lean Manufacturing in 5 min | Lean in Hindi

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