Fugai/Abnormality?

WHAT
Abnormality:- Abnormality means which are against of machine Basic condition, Ignoring Quality
standard, avoiding Safety

असामान्यता का मतलब है जो मशीन की बनि

ु यादी स्थिति के खिलाफ है , गण
ु वत्ता मानक की अनदे खी, सरु क्षा से
बचना

WHEN
FUGAI STARTS IDENTIFYING FROM JISHU HOZEN STEP-01

WHY Abnormality/असामान्यता(7 Types)

Forced Deterioration

Breakdown
Accident
Defect
Tags Types

1. Who can Identify- Anyone 1. Who can Identify- Anyone

2. Where to identify- Equipment & its assembly 2. Where to identify- Equipment & its assembly2
3. Standard time to close- 7 days 3. Standard time to close- 2 days/48 Hrs
4. Responsibility of Closing - Maintenance 4. Responsibility of Closing - Production
07 TYPES OF FUGAI

1. Minor Flaws
2. Unfulfilled Basic Condition
3. Hard to Access PERFECTION
3.1 Hard to Clean
3.2 Hard to Lubricate DETECTION
3.3 Hard to Inspect
3.4 Hard to Tight
INSPECTION
3.5 Hard to Adjustment
4. Source Of Contamination
5. Quality Defect Source CLEANING

6. Unnecessary & Unwanted Items

7. Unsafe Place

3
Forced & Natural Deterioration

अच्छी स्तिथि

Machine Basic
Condition
Maintained
मशीन की स्तिथि

Machine Basic condition Not

Maintained

Less Life of ब्रेकडाउन

(Breakdown)
Machine Completes Full Life
मशीन परिचालन समय (machine operating time)
4
 TYPES OF FUGAI

MINOR FLAWS UNFULFILLED BASIC CONDITION

Dust, Dirt, powder, oil, grease,
Contamination Insufficient,Dirty,Unidentified,
rust, paint Lubrication
unsuitable, Leaking
Cracking, crushing, deformation,
Damage
chipping, bending,

Shaking, falling out, tilting, Lubrication Dirty, damaged or deformed lubricant

Play eccentricity, wear, distortion, Supply inlets, faulty lubricant pipes
corrosion,

Slackness Belts, Chains Oil level Dirty, Damaged, leaking, No indication

gauges of correct level
Unusual noise, overheating,
Abnormal Vibration, strange smells,
Phenomenon discoloration, incorrect pressure or Nuts and Bolts slackness, Missing,
current Cross-threaded, Too long, Crushed,
Tightening
Corroded, Unsuitable washers, wing
Blocking, hardening, accumulation nuts on backward
Adhesion
of debris, peeling, malfunction
5
 TYPES OF FUGAI

HTA – Hard to Access SOC- Source Of Contamination

Product Leaks, Spills, Spurts, Scattering, Overflow
Machine construction, Covers, Layout,
Cleaning
footholds, Space
Raw Leaks, Spills, Spurts, Scattering, Overflow
materials
Construction,Covers, Layout, footholds,
Checking Instrument position and Orientation,
Operating – Range display Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids,
Fuel oils, etc.
Position of lubricant inlet, construction,
Lubricating height, footholds, lubricant outlets, Gases Leaking compressed air, gases, steam,
space vapors, exhaust fumes, etc.
Covers,Construction,Layout size, Liquids Leaking water, Hot, Cold, half finished
Tightening
Space products, Waste water, Leaking supply lines
etc.
Machine layout, Position of valves,
Operation
Switches and leavers, Footholds Scrap Flashes, cuttings, packaging materials, and
non conforming products.
Position of pressure gauges,
Adjustment thermometers, flow meters, moisture Others Contaminants by people & Forklifts, Infiltration
gauges, vacuum gauges, etc. through cracked walls, broken windows etc.
6
 TYPES OF FUGAI

Unnecessary & Non

Quality Defect Source Urgent Items
Dust, Rust, powder, chips, moisture, Pumps, fans, compressors, columns,
Foreign Machinery
wire scraps, wood pieces, paper pieces, tanks etc.
Matter
stones etc.
Piping Pipes, hoses, ducts, valves, dampers
Dropping, Jolting, collision, Vibration equipment etc.
Shock
etc.
Measuring Temperatures, pressure gauges, vacuum
instruments gauges, ammeters etc.
Moisture Too little or Too much, infiltration
Electrical Wiring, piping, power leads, switches,
Abnormalities in screens, Compressed equipment plugs etc.
Gain Size
air separators, centrifugal separators,
General tools, cutting tools, jigs, molds,
Jigs & Tools
dies, frames etc.
Inadequate warming, heating,
Concentration compounding, mixing, evaporation,
stirring etc. Standby equipment, spares, permanent
Spare parts
stocks, auxiliary materials, etc.
Inadequate warming, heating,
Viscosity compounding, mixing, evaporation, Makeshift
stirring etc. Tape. String, wire, metal plates etc.
repairs 7
TYPES OF FUGAI

Unsafe Place
Unevenness, cracked, holes, projections, peeling, wear of steel
Floors chucker plates,
slipping.

Steps Too steep, irregular, slipping, missing handrails, etc.

Dim, out of position, dirty or broken covers, no explosion proofing,
Lights
etc.

Rotating Displaced, fallen oil or broken covers, not safe for emergency,
Machinery missing emergency stop devices

Lifting Devices Wires, hooks, brakes and other parts of cranes and hoists etc.

Special substances, solvents, toxic gases, insulating materials,

Others
danger signs, protective clothing etc.

8
Minor Defects/Flaws

Dust/Dirt Rust Damage Missing

Bend Bend Loosing Vibration

9
Unfulfilled Basic Condition
Lack of Cleaning

Lack of Lubrication

10
 HTA-Hard to Access
The places which are Hard to Clean, Hard to Lubricate, Hard to Inspect, Hard to tight, Hard to Adjust:
 Machine design/Layout, Covers & Guards.
 Position of indicators, valves, Switches, leavers, pressure gauges, thermometers, flow meters, moisture
gauges, vacuum gauges etc.
Hard to Clean Hard to Lubricate

Hard to Inspection

11
Source of Contamination

Overflow- Product Overflow of Lubricant Hyd. Oil Leakage Coolant Leakage

Lub. oil Leakage Chips scatter Chips scatter Chips scatter

12
Quality Defect Source
Ignoring standard Procedures

Over Heating Less Heating

13
Unwanted/Non Urgent Items
Unnecessary Cotton Unnecessary Gages Unnecessary Pipe

Unnecessary Bins Unnecessary wiring

14
Unsafe Place
No railings & unsafe platform Dark Tube/bulb missing

Sharp Edge Too Long bolt

15
Thank You

16