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