EDUCATION & TRAINING PILLAR

7 Types of Abnormalities FES - NAGPUR

1. MINOR FLAWS
2. UNFULFILLED BASIC CONDITIONS
3. INACCESSABLE PLACES (Hard to Access Area)
4. SOURCES OF CONTAMINATIONS
5. SOURCES OF QUALITY CONTAMINATION
6. UNNECESSRY AND NON-URGENT ITEMS AROUND THE MACHINE
7. UNSAFE PLACES

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 EDUCATION & TRAINING PILLAR
7 Types of Abnormalities FES - NAGPUR

1. MINOR FLAWS :-
Types Example
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 Unusual noise, overheating, vibration, strange
Phenomenon smells, discoloration,incorrect pressure or
current
Adhesion Blocking, hardening, accumulation of debris,
peeling, malfunction
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 EDUCATION & TRAINING PILLAR
7 Types of Abnormalities FES - NAGPUR

2. UNFULFILLED BASIC CONDITION :-

Types Example
Lubrication Insufficient, dirty, Unidentified, Unsuitable,
Leaking
Lubrication Dirty, Damaged or deformed lubricant inlets,
Supply faulty lubricant pipes
Oil Level Gauges Dirty, Damaged, Leaking, No Indication of
Correct Level
Tightening Nuts & Bolts Slackness, Missing, Cross-
threaded, Too Long, crushed, corroded,
Unsuitable washers, wing nuts on backward.

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 EDUCATION & TRAINING PILLAR
7 Types of Abnormalities FES - NAGPUR

3. INACCESSABLE PLACES (Hard to Access Area) :-

Types Example
Cleaning Machine Construction,covers, Layout,footholds, space
Checking Construction, covers, Layout, Footholds, Instrument
position & orientation, operating range display.
Lubricating Position of Lubricant inlet, Construction, height,
Footholds, lubricant outlets, space
Tightening Covers, Construction, Layout size, Space
Operation Machine layout, position of Valves, switches &
Leavers, Footholds
Adjustment Position of Pressure gauges, thermometers, flow
meters, moisture gauges, Vacuum gauges etc
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 EDUCATION & TRAINING PILLAR
7 Types of Abnormalities FES - NAGPUR

4. SOURCES OF CONTAMINATIONS :-
Types Example
Product Leaks, spills, Spurts, scattering, overflow
Raw Leak, spill, seeping oils, Hydraulic Fluid, Fuel oils etc.
Material
Lubricants Leaking, Spills, Seeping oils, Hydraulics Fluids, Fuel
Oils, etc
Gases Leaking Compressed air, gases, steam, vapours,
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. 5
 EDUCATION & TRAINING PILLAR
7 Types of Abnormalities FES - NAGPUR

5. SOURCES OF QUALITY CONTAMINATION :-

Types Example
Foreign Dust, Rust, powder, chips, moisture, wire, scarps,
Matter wood pieces, paper pieces, stones etc.
Shock Dropping, jolting, collision, vibration etc.

Moisture Too little or too much, infiltration

Grain Size Abnormalities in screens, compressed air separators,

centrifugal separators.
Concentrati Inadequate warming, heating , compounding,
on mixing, evaporation, stirring etc.
Viscosity Inadequate warming, heating, compounding, mixing,
evaporation, stirring etc.
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 EDUCATION & TRAINING PILLAR
7 Types of Abnormalities FES - NAGPUR

6. UNNECESSRY AND NON-URGENT ITEMS AROUND THE MACHINE:-

Types Example
Machinery Pumps, fans, compressors, columns, tanks etc.
Piping Pipes, hoses, ducts,valves dampers etc
equipments
Measuring Temperatures, pressure gauges, Vacuum gauges,
Instruments ammeters etc.
Electrical Wiring, Piping, powder leads, switches, plugs etc.
Equipment
Jigs & tools General tools, cutting tools, jigs, molds, dies, frames
etc.
Spare Parts Standby equipment, spares, permanent stocks,
auxiliary materials, etc.
Makeshift Tape, string, wire, metal plates etc.
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repairs
 EDUCATION & TRAINING PILLAR
7 Types of Abnormalities FES - NAGPUR

7. UNSAFE PLACES :-
Types Example
Floors Unevenness, cracked, holes, projections, peeling,
wear of steel chucker plates, slipping.
Steps Too steep, irregular, slipping, missing handrails, etc

Lights Dim, out of position, dirty or broken covers, no

explosion proofing, etc.
Rotating Displaced, fallen oil or broken covers, not safe for
machinery emergency, missing emergency stop devices
Lifting Wires, hooks, brakes and other parts of cranes and
Devices hoists etc.
Others Special substances, solvents, toxic gases, insulating
materials, danger signs, protective clothing etc.
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EDUCATION & TRAINING PILLAR
7 Types of Abnormalities FES - NAGPUR

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