This document discusses abnormality tagging to identify issues that can lead to inefficiencies in the workplace. It defines abnormalities as undesirable anomalies that can cause performance variations, damage, quality and production problems. Abnormalities can be detected using the senses and by closely observing equipment. Techniques for tagging abnormalities include using checklists, mapping, and photographing issues. Examples of common low-hanging fruit abnormalities include missing or loose parts, unusual sounds or vibrations, safety hazards, and dirt/grime buildup. The goal of tagging abnormalities is to improve equipment performance, maintenance, and quality.

1. ABNORMALITY TAGGING –
FUGUAI’S
LIBERATING THE THREAT OF WORKPLACE INEFFICIENCIES
RRG

2. CONCEPT OF EQUIPMENT/PROCESS
ABNORMALITY
• Any Abnormality is undesirable
• Abnormalities; anomalies eventually lead to
• Special cause performance variation
• reversible and/or irreversible damage
• Performance deterioration
• Inconsistency of production quality
• OEE losses
• Total Equipment Failure

3. CONCEPT OF EQUIPMENT ABNORMALITY
• Abnormality can be detected by
• SIGHT (Different) – color, shape, size, configuration , foreign
material, contamination
• FEEL (Vibration, Heat, Texture, etc.)
• HEARING (Noise, high frequency pitch)
• SMELL (Burnt; chemical gas leaking)
• TASTE (Acidic vs Basic)
• DISCOMFORT (Ergonomics / Safety issues or violations against
Working Standards)
• COST BURDEN – REPEATED EQUIPMENT REPAIR
• UN-OPTIMIZED SPACE
• TIME – MOTION

4. CONCEPT OF EQUIPMENT ABNORMALITY
• Elimination of Abnormalities will lead to:
• Better equipment performance
• Prolonging of continuous productive time
• More controlled Maintenance
• Reduction of Cost of Ownership
• Prolonging equipment usable life
• Repeatable Quality
• Lesser rejects/defects
• User-friendly equipment
• Operator productivity
• Ergonomic solutions
• Better safety features

5. WHAT IS AN ABNORMALITY?
• Parts wear-out
• Something is Dirty and Disorganized
• Something is performing not right
• Something is broken or about to be broken
• Something is missing
• Looks different ( “Batibot” ) from the rest
• Intermittent or Cyclic error manifestation
• Causes Discomfort
• Not safe
• Not ergonomic

6. HOW TO DETECT ABNORMALITIES
• Use your senses
• Observe closely; “deep dive”
• Uncover barriers (Cabinet doors/shields/filter traps)
• Look underneath with aid of white flashlight
• Use appropriate tools to expose hard to reach areas
• Take photos or videos or samples
• Cross-Compare observations with another equipment
• Compare with observation of others
• Compare against standards/drawing/specs

7. TECHNIQUES OF EQUIPMENT
ABNORMALITY TAGGING
• One common point of reference of observation
• Checklist method
• Equipment mapping and abnormality concentration chart
• Progressive recording (Example: markers on screw nuts or
measurements of noise/vibration levels)
• Take photo; explain abnormality & Data log
• Discuss abnormality findings with equipment owner
• Go back to the same abnormality to verify
countermeasures
• Fan-out (Bright Ideas) and standardize (globalization)

8. EXAMPLES OF LOW “HANGING FRUITS”
ABNORMALITIES
1. Missing screws
2. Loose screws
3. Grime Build-up
4. Squeaky Sound
5. High Frequency Sound
6. Excessive Vibration
7. Unusually hot surface
8. Unusual fumes
9. Narrow passage ways
10. Safety Pinch points
11. Dripping water/oil
12. Evidence of metal scraping/scratches
13. Paint or coating peel-off
14. Corrosion build-up
15. Loose threads

9. EXAMPLES OF LOW “HANGING FRUITS”
ABNORMALITIES
16. Non functioning detectors
17. By-passed safety interlocks
18. Non-aligned equipment
19. Lay-out discrepancy (Actual vs Plan)
20. Exposed conductive wires and cables
21. Unharnessed wires and cables
22. Tripping hazards
23. Sharp corners
24. Non-functioning equipment status tower lamps
25. Tight enclosure leaks (Gases)
26. Dirty /Clogged Filters
27. Discolorations
28. Blurred/ Non Functioning Meters
29. Foreign Objects inside the equipment panels and
cabinets
30. Missing components
31. Crowded working tables or workstations
32. Poor ventillation ; poor lighting

11. ABNORMALITY DETECTION FLOW CHART (PDCA)
Identify Reference
and Common point
Refer to
Abnormality
Checklist
Record Abnormality
observed
Obtain Objective
Evidence (Photo,
Video or Sample)
Place Abnormality
Tag with
Descriptions
Verify and review
Countermeasures