Fuguai is a Japanese word means contamination or abnormalities. Fuguai mapping is machine map used to differentiate abnormalities focus area on the selected machine which normally covers the front of the machine, right view, left view, over view, back view, and base.

1. 23/10/2023 by Samsher Singh Copyright 2023 1
FUGUAI Basis, Awareness
and Implementation
Samsher Singh Chahal
+919803405101

2.  FUGUAI is a Japanese word which means ABNORMALITY
 Any deviation from the original condition of the equipment which deteriorates machine Performance
 Anything which is not normal
 Deviation from the standards
 It is the trigger point of Jishu Hozen (Autonomous Maintenance)
 There are 7 Types of Abnormalities
PRODUCTION
THROUGHPUT
What is Abnormality?
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3. Types of Abnormality
1. Minor Flaws
2. Unfulfilled Basic Conditions
3. Inaccessible Places
4. Sources of contamination
5. Sources of Quality Defects
6. Unnecessary Items
7. Unsafe Places
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4. Abnormality Details
1. Minor Flow
• Minor Flaw is the abnormal condition that is related to any play,
slackness or damaged part available in any mechanism.
• It can be identified by abnormal noise, vibration, overheating,
strange smell coming from part / machine, incorrect pressure or
current
• Crack, crush, damage or deformation of any part or drive or
mechanism
• Slackness in belt or chain mechanism
• Play available by shaft, bearing & gearbox; it may be tilt, center
out, eccentricity issue, wear distortion and many more
Example
Crack
Damage
Play
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5. Abnormality Details
2. Unfulfilled basic Conditions
• It is the abnormal condition that is related to non fulfilling the basic
condition of the machine to operate
• Mostly cleaning, lubricating, tightening related issues
• Before starting the production, these are to be checked (CLIT activity)
• Dirt, dust, , leakage and damaged part available on the machine
• Lubrication supply found dirty, damaged or deformed
• Oil level indicator also found dirty, damaged or in leakage condition
• Loss Nuts/Bolts
• Washer, Wing Nut, Locknut not available in the required
Example
Dust
Oil leakage
Loss nut/bolt
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6. Abnormality Details
3. Inaccessible/Hard to access Place
• If we can’t access the machine or any area for cleaning, lubrication,
inspection, retightening or regular operation purpose, is called
inaccessible Place or hard to Access Place
• Need to implement Kaizen to eliminate this kind of abnormality
• Can’t clean the m/c due to layout, m/c construction, covers etc.
• Can’t lubricate due to the position of Lubrication Inlet or outlet,
construction, height, space etc.
• Can’t inspect the critical parameters due to Layout, covers,
Instrument position, & orientation
• Can’t tighten nuts/ bolts due to covers, layout, construction,
space etc.
Example
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7. Abnormality Details
4. Sources of Contamination
• Leakage, Spillages, Scattering or overflows of any
material
• This kinds of abnormalities can create bad impacts of
Productivity, Quality & Cost
• This can be eliminated by implementing so Standard
Process Checklists
• Leakage, Spillages, Scattering or overflows of any
material, lubricants or gases
• Scrap material like flashes, cutting chips /burrs,
packaging materials & non-conforming products are also
considered as the source of contamination because they
can contaminate the machine or products
Example
Leakage
chips
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8. Abnormality Details
5. Sources of Quality Defects
• Defect generation sources are called Sources of Quality
Defects
• It can be foreign particles, shocks, vibration, moisture
content, Concentration, Viscosity, etc.
• The sources vary as per the processes & products
• Foreign particles of dust, dirt, powder, chips, moisture,
wire pieces, wood pieces, paper pieces, stone etc. can
create quality defects.
• In machine dropping, collision or vibration also can create
quality defects
• Sometimes inadequate cooling, heating, machining, etc.
can create quality issues
Example
Vibration
FP
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9. Abnormality Details
6. Unnecessary items
• At workplace, if any non-required item is available then it is
called Unnecessary Item
• There may be any spares, machinery, pipes, measuring
instruments, electrical items, tools or any other items that are
not required at a particular place but it is still available
• Pumps, fan, compressors, blowers, pipes, hoses, ducts,
valves, dampers etc.
• Different types of measuring instruments like Pressure
gauges, vacuum gauges, temp. Gauges etc.
• Various spares & electrical equipment's like wire, switches,
plugs, boards etc.
Example
Extra cables
Unwanted item
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10. Abnormality Details
7. Unsafe Places
• The working place having unevenness, crack, holes,
projects, peeling or the slipping surface that can
create any accident
• Unsafe place can create bad impact of humans &
machines
• Working place is too steep, irregular, slipping,
having cracks, holes, etc.
• If the Emergency Stop is not working, that is
also a unsafe place
• Broken or cracked wire or hooks
Example
Unsafe place for work
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11. Abnormality Identification
Five types of abnormality highlighted in the FUGUAI tags must be removed or eliminated by operation personnels. These five types are -
Minor flaws, unfulfilled basic conditions, quality defect sources, unwanted and slow moving objects, unsafe conditions.
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12. Types FUGUAI Tags
1. Red FUGUAI Tags:
They are used to sight those specific machine malfunction/(s)
, that needs special attention from a specialist or a
maintenance personnel or a contractor personnel or
representative of particular machine manufacturer. Production
operator or JH circle members (JH CIRCLE- small group of
people who are associated with a specific machine or line
forms a team do take up improvement projects related to that
machine or line.)
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13. Types FUGUAI Tags
2. White FUGUAI Tags :
They are used to highlight those abnormalities or malfunctions
that can be taken be rectified by the machine operators or the JH
circle members. A white tag may be attached in case of following
abnormalities for example :
1. Loosening of fitting bolts of limit switches, proximity switches
and photoelectric switches.
2. Replacement of worn-off screws, scattering of cut powders
and cutting oils.
3. Dislocation and twisting of movable sections in wiring.
4. Replacement of damaged V-belts, tension springs and
loosened chains.
5. Air and oil leakage due to less tightened bolts, loose joints or
loose tube fittings.
6. Replacement of grease cups due to chipping.
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14. Types FUGUAI Tags
3. Yellow FUGUAI Tags :
Some companies uses yellow FUGUAI tags to sight the
abnormalities or non-conformities related to safe work
performance of the machine. Some unsafe conditions and
potential unsafe situations are highlighted in these tags.
These tags can be mounted by any body (the personnel
related to the machine or not does not matter) on the
machine. These safety tags are preferably to be closed in
consensus with safety officer or a safety expert of the
machine. Operators along with maintenance personnel may
be involved in closing the abnormalities or malfunctions
highlighted in the safety tags (yellow FUGUAI tags).
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15. FUGUAI Tags tree
Fuguai means Abnormality, so Fuguai tree is
used to hanged the abnormality tags on it
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16. Abnormality Listing
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17. Abnormality Removal
Global Industrial Practice
The Red FUGUAI tags are to be removed
(i.e. abnormality is eliminated) with in 7
days from the date of tagging
The White tags are removed with in 48
hours (maximum two days) form the
date of tagging.
The Safety FUGUAI tags are to be
removed only after taking consensus of
Safety personnel or relevant responsible
person.
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18. Abnormality Analysis
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19. How to Use FUGAI Tree, Tags and matrix
1. Fault in machine
(which in not
repairable by
operator)
2. Tagging on
machine (Actual
location)
3. Tag hanged to
FUGAI Tree
4.
Problem/Abnormal
ity Register in
FUGAI matrix
5. Tag Removal
After Abnormality
sort out
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20. Implement plan for FUGUAI
20 % TRANING
30 % EXECUTION
50 % HANDS ON
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21. Thank you for listening !
10/23/2023 By Samsher Singh chahal copyright 2023