7 Types of Abnormalities | Abnormality Manual

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

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 cranes and hoists.
Other	Special substances, solvents, toxic gases, insulating materials, danger sign, protective clothing etc.