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7 Types of Abnormalities | Abnormality Manual

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The 7 seven types of abnormalities listed below are genereally observed in every industry especially in manufacturing industries. Organizations must focus on the following described abnormalities in order to improve product and process quality, reduce breakdowns, defects, increase productivity, and enhance workplace safety.

  1. MINOR FLAWS
  2. UNFULFILLED BASIC CONDITIONS
  3. INACCESSIBLE PLACES
  4. CONTAMINATION SOURCES
  5. QUALITY DEFECT SOURCES
  6. UNNECESSARY AND NON-URGENT ITEMS
  7. UNSAFE PLACES
7 types of abnormalities

Identification of seven types of abnormalities is very necessary excercise that carried out in Lean Manufacturing industries.

MINOR FLAWS

ContaminationDust, Dirt, powder, oil, grease, rust, paint
DamageCracking, crushing, deformation, chipping, bending,
PlayShaking, falling out, tilting, eccentricity, wear, distortion, corrosion,
SlacknessBelts, Chains
Abnormal PhenomenonUnusual noise, overheating, Vibration, strange smells, discoloration, incorrect pressure or current
AdhesionBlocking, hardening, accumulation of debris, peeling, malfunction

UNFULFILLED BASIC CONDITIONS

LubricationInsufficient, Dirty, Unidentified, unsuitable, Leaking
Lubrication SupplyDirty, damaged or deformed lubricant inlets, faulty lubricant pipes
Oil level gaugesDirty, Damaged, leaking, No indication of correct level
TighteningNuts and Bolts slackness, Missing, Cross-threaded, Too long, Crushed, Corroded, Unsuitable washers, wing nuts on backward

INACCESSIBLE PLACES – Hard to access places

Cleaning Machine construction, Covers, Layout, footholds, Space
CheckingConstruction, Covers, Layout, footholds, Instrument position and Orientation, Operating – Range display
LubricatingPosition of lubricant inlet, construction, height, footholds, lubricant outlets, space
TighteningCovers, Construction, Layout size, Space
LOperationMachine layout, Position of valves, Switches and levers, Footholds
AdjustmentPosition of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.

CONTAMINATION SOURCES

Product Leaks, Spills, Spurts, Scattering, Overflow
Raw materialsLeaks, Spills, Spurts, Scattering, Overflow
LubricantsLeaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils, etc.
GasesLeaking compressed air, gases, steam, vapors, exhaust fumes, etc.
LiquidsLeaking water, Hot, Cold, half finished products, Waste water, Leaking supply lines etc.
ScrapFlashes, cuttings, packaging materials, and non conforming products.
OthersContaminants by people & Forklifts, Infiltration through cracked walls, broken windows etc.

QUALITY DEFECT SOURCES

Foreign Matter Dust, Rust, powder, chips, moisture, wire scraps, wood pieces, paper pieces, stones etc.
ShockDropping, Jolting, collision, Vibration etc.
MoistureToo little or too much, infiltration
Gain SizeAbnormalities in screens, Compressed air separators, centrifugal separators etc.
ConcentrationInadequate warming, heating, compounding, mixing, evaporation, stirring etc.
ViscosityInadequate warming, heating, compounding, mixing, evaporation, stirring etc.

UNNECCESSARY AND NON-URGENT ITEMS

MachineryPumps, fans, compressors, columns, tanks etc.
Piping equipmentPipes, hoses, ducts, valves, dampers etc.
Measuring instrumentsTemperatures, pressure gauges, vacuum gauges, ammeters etc.
Electrical equipmentWiring, piping, power leads, switches, plugs etc.
Jigs Fixtures & ToolsGeneral tools, cutting tools, jigs, molds, dies, frames etc.
Spare partsStandby equipment, spares, permanent stocks, auxiliary materials, etc.
Makeshift repairsTape, string, wire, metal plates etc.

UNSAFE PLACES

Floors Unevenness, ramps, projections, cracking, peeling, wear (steel deck plates)
StepsToo steep, irregular, peeling anti-slip covering, corrosion, missing handrails
LightsDim, out of position, dirty or broken covers, no safety or emergency stop devices
Rotating Machinary Displaced, fallen off or broken covers, no safety of emergency stop devices
Lifting gearWires, hooks, brakes, and other parts of
cranes and hoists.
OtherSpecial substances, solvents, toxic gases, insulating materials, danger sign, protective clothing etc.

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