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.
MINOR FLAWS UNFULFILLED BASIC CONDITIONS INACCESSIBLE PLACES CONTAMINATION SOURCES QUALITY DEFECT SOURCES UNNECESSARY AND NON-URGENT ITEMS UNSAFE PLACES
Identification of seven types of abnormalities is very necessary excercise that carried out in Lean Manufacturing industries.
MINOR FLAWS Contamination Dust, Dirt, powder, oil, grease, rust, paint Damage Cracking, crushing, deformation, chipping, bending, Play Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion, Slackness Belts, Chains Abnormal Phenomenon Unusual noise, overheating, Vibration, strange smells, discoloration, incorrect pressure or current Adhesion Blocking, hardening, accumulation of debris, peeling, malfunction
UNFULFILLED BASIC CONDITIONS Lubrication Insufficient, Dirty, Unidentified, unsuitable, Leaking Lubrication Supply Dirty, damaged or deformed lubricant inlets, faulty lubricant pipes Oil level gauges Dirty, Damaged, leaking, No indication of correct level Tightening Nuts 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 Checking Construction, Covers, Layout, footholds, Instrument position and Orientation, Operating – Range display Lubricating Position of lubricant inlet, construction, height, footholds, lubricant outlets, space Tightening Covers, Construction, Layout size, Space LOperation Machine layout, Position of valves, Switches and levers, Footholds Adjustment Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.
CONTAMINATION SOURCES Product Leaks, Spills, Spurts, Scattering, Overflow Raw materials Leaks, Spills, Spurts, Scattering, Overflow Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils, etc. Gases Leaking compressed air, gases, steam, vapors, exhaust fumes, etc. Liquids Leaking water, Hot, Cold, half finished products, Waste water, Leaking supply lines etc. Scrap Flashes, cuttings, packaging materials, and non conforming products. Others Contaminants 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. Shock Dropping, Jolting, collision, Vibration etc. Moisture Too little or too much, infiltration Gain Size Abnormalities in screens, Compressed air separators, centrifugal separators etc. Concentration Inadequate warming, heating, compounding, mixing, evaporation, stirring etc. Viscosity Inadequate warming, heating, compounding, mixing, evaporation, stirring etc.
UNNECCESSARY AND NON-URGENT ITEMS Machinery Pumps, fans, compressors, columns, tanks etc. Piping equipment Pipes, hoses, ducts, valves, dampers etc. Measuring instruments Temperatures, pressure gauges, vacuum gauges, ammeters etc. Electrical equipment Wiring, piping, power leads, switches, plugs etc. Jigs Fixtures & Tools General tools, cutting tools, jigs, molds, dies, frames etc. Spare parts Standby equipment, spares, permanent stocks, auxiliary materials, etc. Makeshift repairs Tape, string, wire, metal plates etc.
UNSAFE PLACES Floors Unevenness, ramps, projections, cracking, peeling, wear (steel deck plates) Steps Too steep, irregular, peeling anti-slip covering, corrosion, missing handrails Lights Dim, 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 gear Wires, hooks, brakes, and other parts of Other Special substances, solvents, toxic gases, insulating materials, danger sign, protective clothing etc.
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