Abnormalities TPM

Abnormalities

The Prime Mover - Towards Excellence 1

Abnormalities TPM

• Anything which is NOT NORMAL

• Deviation from the Standard

• Deviation from the Requirement

The Prime Mover - Towards Excellence 2

 Abnormalities TPM

Abnormalities Examples
Example -1
3-4 threads
at least

Fixing of nut only on 2 – 3 threads Fixing of nut on all threads

Normal
Abnormal

Example -2

Piping hanging & entangled

Piping with routing & support

Normal
Abnormal

The Prime Mover - Towards Excellence 3

 Abnormalities TPM

Abnormalities Examples
Example -3

Belt

Pulley

Belt touching to bottom portion of pulley

Abnormal Normal

The Prime Mover - Towards Excellence 4

Abnormalities TPM

UNFULLFILLED
BASIC
MINOR INACCESSIBLE
CONDITION
FLAWS PLACES

UNSFAE 7 TYPES OF CONTAMINATION

PLACES ABNORMALITIES SOURCES

UNECESSARY
& NON QUALITY
URGENT DEFECT
ITEMS SOURCES

The Prime Mover - Towards Excellence 5

 Abnormalities TPM

1. Minor flaws
ABNORMALITY EXAMPLE
Contamination Dust, dirt, 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 smell, discoloration, incorrect pressure or current
Adhesion Blocking, hardening, accumulation of debris, peeling, malfunction
Image Abnormality Action If Not Done

Dust accumulation on Clean fixture & provide

Defect
fixture auto flushing

Side guard damaged Repairing of guard

Accident

Play in spindle Replace bearing Breakdown

The Prime Mover - Towards Excellence 7

Abnormalities TPM

1. MINOR FLAWS

OVER HEATING CHIPS CAN DAMAGE SLIDES

LOOSE FITTING BROKEN/DAMAGED GUARDS

The Prime Mover - Towards Excellence 8
 Abnormalities TPM

2. Unfulfilled Basic conditions

ABNORMALITY EXAMPLE
Lubrication Insufficient, Dirty, Unidentified , Unsuitable, Leaking lubricant
Lubricants supply Dirty, Damaged, Deformed lubricant inlets, Faulty lubricant pipes
Oil level gauges Dirty, Damaged, Leaking, No indication or Correct level
Nuts & Bolts loose, Missing, Crushed, Corroded, Washers missing, Washers unsuitable, Wing nuts on
Tightening
back side
Image Abnormality Action If Not Done
Leakage from sight glass Replace gasket Breakdown

Oil sight glass dirty Clean sight glass Breakdown

Pump mounting bolt loose Tighten bolts Breakdown

The Prime Mover - Towards Excellence 9

 Abnormalities TPM

2. UNFULLFILLED BASIC CONDITION

CUTTING OIL OVERFLOW NO INDICATIONS OF LOW/HIGH WORN OUT PADS

The Prime Mover - Towards Excellence 10

 Abnormalities TPM

3. Inaccessible places
ABNORMALITY EXAMPLE
Cleaning Covers, layout, machine construction
Checking Instrument position and orientation, operating range display, covers, construction, layout
Lubricating Position of lubricant inlet, height space
Tightening Covers, construction, layout, size, space
Operation Machine layout, position of switches, levers and valves
Adjustment Position of pressure gauges, flow meters, thermometers, vacuum gauges etc.

Image Abnormality Action If Not Done

Difficult to inspect Y-axis Remove guard Breakdown
motor

Difficult to inspect air Reposition gauge Breakdown

pressure

Difficult to clean floor Reposition fume extractor Accident

around hydraulic tank unit

The Prime Mover - Towards Excellence 11

 Abnormalities TPM

3. INACCESSIBLE PLACES

HARD TO CLEAN HARD TO LUBRICATE

HARD TO CHECK BELT

CONDITIONS

The Prime Mover - Towards Excellence 12

 Abnormalities TPM

4. Contamination sources
ABNORMALITY EXAMPLE
Product Scatter, overflow, leaks, spills
Raw material Instrument position and orientation, operating range display, covers, construction, layout
Lubricants Leakage, spillage
Gases Leakage
Scrap Cuttings, packaging material, non-confirming products
Others Contaminants brought in by people, fork lift trucks, material handling equipment etc.

Image Abnormality Action If Not Done

Splashing of dust on side Clean & provide localized Breakdown
walls guard

Splashing of chips on Clean & provide localized Defect

fixture guard

Chips falling on floor Clean floor & Reorient Accident

trolley position

The Prime Mover - Towards Excellence 13

 Abnormalities TPM

4. CONTAMINATION SOURCES
MIXING OF CUTTING OIL & MIXING OF HYDRAULIC &
LUBRICATION OIL CUTTING OIL

The Prime Mover - Towards Excellence 14

 Abnormalities TPM

5. Quality defect source

ABNORMALITY EXAMPLE
Foreign matter Chips, wire scraps, rust, insects, infiltration
Shock Vibration, collision, droppings.
Moisture Mist
Concentration Process chemical concentration
Viscosity Process chemical viscosity

Image Abnormality Action If Not Done

Chip accumulation on tool Clean & provide guard on Defect
taper dummy pocket

Accumulation of chips on Clean & provide auto Defect

rest pad flushing

Dust accumulation in Clean tank & provide Defect

coolant tank paper filtration system

The Prime Mover - Towards Excellence 15

 Abnormalities TPM

5. QUALITY DEFECT SOURCES

FULL OF CHIPS DENTS PROBLEM

The Prime Mover - Towards Excellence 16

 Abnormalities TPM

6. Unnecessary & non-urgent items

ABNORMALITY EXAMPLE
Machinery Pumps, fans, tanks.
Piping Pipes, hoses, ducts, valves.
Measuring instruments Gauges, ammeters, energy meters, voltmeters
Electrical equipment Wires, switches, plugs.
Jigs & tools Jigs/Fixtures, cutting tools, dies, hand tools.
Spare parts Standby spares, auxiliary material.
Make shift repairs Tape, string, wire, metal plates.
Image Abnormality Action If Not Done
Unwanted attachment for Remove attachment Accident
cutter removal

Make shift repairs by Replace & reroute cable Accident

applying insulation tape

Unwanted pneumatic Remove pneumatic Breakdown

clamping system clamping elements

The Prime Mover - Towards Excellence 17

 Abnormalities TPM

6. UNECESSARY & NON URGENT ITEMS

UNWANTED
AIR PIPE

LEAKAGE OF CUTTING OIL

PARTS AFTER
INSPECTION

The Prime Mover - Towards Excellence 18

 Abnormalities TPM

7. Unsafe places
ABNORMALITY EXAMPLE
Floor Uneven projections, pot holes, slippery
Steps Too steep, irregular, missing handrails
Lights Out of position, dirty or broken covers, dim
Rotating machinery Broken covers, no safety
Lifting Parts of cranes and hoist, wires, hooks, breaks
Others Danger sign, insulating material, special solvent, toxic gases

Image Abnormality Action If Not Done

Push button connection Provide cover Accident
box open with live wires

No side railing for ladder Provide side railing Accident

No high voltage indication Provide indication sticker Accident

sign on fume extractor of High voltage & Danger

The Prime Mover - Towards Excellence 19

 Abnormalities TPM

7. UNSFAE PLACES
OPEN UNGUARDED

UNGUARDED

The Prime Mover - Towards Excellence 20

Abnormalities TPM

Checking of
Abnormalities

The Prime Mover - Towards Excellence 21

 Abnormalities TPM

Checking of Abnormalities
Different kind of areas & their checking points related to specific system are mentioned below :

1. Lubrication system

AREA DETAILS CHECK POINTS

Is it clean?
Storage Does it positioned correctly?
Tank
Is there any arrangement to close the oil filling point?

Is the oil type mentioned on tank?

Is the oil level visible?

Is it supplying correct quantity of oil at required frequency?

Piping,
Distributor,
Metering Are the greasing/oiling points or nipples blocked?
valves
Are the lubrication pipes pressed or pinched?

The Prime Mover - Towards Excellence 22

 Abnormalities TPM

2. Transmission system
AREA DETAILS CHECK POINTS
Check belt is not damaged due to coolant, oil or grease
Check the availability of belts
V-belts & Check for correct belt tension
Pulleys Check pulley groove wear
Check for belt is not touching to root diameter of pulley
Check for correct alignment of pulleys
Check for correct chain tension
Check for wear on sprocket teeth
Chain,
Sprocket Check for wear of chain rollers
Check for chain lock clip position
Check for play in pin & bush
Check wear of gear teeth
Gear train Check for no backlash in gear train
Check for no dents on gear teeth
Check for overheating, Vibrations, Abnormal noise
Shaft Check wear of keys
Check for alignment of coupling
Bearing Check wear of seals
Coupling Check tightness of coupling screws
Check for correct alignment of pulleys

The Prime Mover - Towards Excellence 23

 Abnormalities TPM
3. Hydraulic system
AREA DETAILS CHECK POINTS

Check for correct oil level

Check for oil temperature

Hydraulic Oil
Check cleanliness of oil

Check for no discolouration of oil

Check for no foaming of oil

Check correct location of baffle plates

Check for correct location of suction & return lines

Check for no open hole on tank

Storage
Tank Check for no leakage from man hole cover packing

Check cleanliness of filler filter mesh

Check suction strainer cleanliness

Continue
The Prime Mover - Towards Excellence 24
 Abnormalities TPM
3. Hydraulic system
AREA DETAILS CHECK POINTS

Check for no abnormal noise

Pump
Check for no overheating of pump / motor

Check for correct oil pressure

Valves Check for tightness of solenoid coil lock nut

Check for tightens of solenoid coil plug top mounting screw

Check for no leakage from valves

Actuator
Check for no scratch marks on piston rod

Check for cleanliness of fins

Check for no blockage of tubes

Heat exchanger
Check for no leakage from tubes

Check for difference in temperature at inlet & outlet

The Prime Mover - Towards Excellence 25

 Abnormalities TPM
4. Pneumatic system
AREA DETAILS CHECK POINTS
Check for cleanliness of filter element
Check for cleanliness of filter bowl
FRL Unit
Check for correct mounting as per flow direction
Check condition of regulator diaphragm for no leakage
Check for no air leakage from piping
Check for no scratch marks on piston rod
Valve, Actuator
Check for no chattering of valve coil
Check for tightness of sol coil lock nut

5. Nuts & Bolts

AREA DETAILS CHECK POINTS
Check that nuts & bolts are not loose
Check that nuts or bolts are not missing
Check that minimum 2 to 3 threads are projecting out of nut
Nuts & Bolts Check that play washer & spring washer are used wherever vibration are observed.
Check that nuts can be seen from outside
Check that all bolts or screws are of same type
Check that wing nuts are fitted at correct locations
Check that locking devices are used wherever there are chances for nuts to get loose

The Prime Mover - Towards Excellence 26

 Abnormalities TPM
6. Electrical Panel
AREA DETAILS CHECK POINTS

Check that panel door beading is in place

Check that there is no open hole on panel body

Check that panel door is getting locked without gaps

Electrical Panel
Check that all cables are routed through PVC channel with cover

Check that main switch position is easy to operate

Check that earthing end termination is with lug & having sufficient contact area

Check for availability of safety sign stickers on panel

Check that no unwanted switch gears, fuses or material is lying inside panel

The Prime Mover - Towards Excellence 27

 Abnormalities TPM

Explanation of do’s & don’ts during JH

• Use PPE’s (personal protective equipment) while working, such as hand gloves, goggles, helmet etc.

• Lock the ladders, mobile platforms before climbing.

• Switch off the electrical supply before opening the pipes covers.

• Drain accumulator before removing hydraulic pipes, electric cabinet, electric cable covers.

• Shut off air supply valves.

• In case of doubt, ask the maintenance person for safety precautions.

• Do not use compressed air for cleaning.

The Prime Mover - Towards Excellence 28

 Abnormalities TPM
Red tag & White tag
Following tags are used while doing JH activity - Red & White Tags.

RED TAG WHITE TAG

9 19
C CASE 2 C CASE 3
Makino LH Makino RH
12.03.15 14.04.15
Ms. Dipali Sharukh
Oil leakage Out put
from conveyor bolt
lubrication loose
tank
Cost loss Eqmt. failure
20.03.15 22.05.15

Removed with the help of White Tag to be removed

maintenance members by production operator
(External skill / Expertise if
required)

The Prime Mover - Towards Excellence 29

 Abnormalities TPM
Abnormality finding format Shop:
Cell:
Abmormality (FUGAI) Record Sheet : JH Step 1
M/c Name:
M/c No.:
Date:
Audit by:
Leads to

Abnormalities

Total Count
Transmission

Instruments

Equipments
Jigs / Fixt. /
Lubrication

Hydraulic

Pnemutic

Coolent
Type of

System

Breakdown
Sytem
Sytem

Sytem

Sytem

Other
Aux.
Tool
Sr. Abnormality Description

Accident

Defect
1 Contamination (Dust, dirt, oil, grease, rust, paint)

2 Damage (Cracking, crushing, deformation, chipping, bending )

Minor Flaws
Play (Shaking, falling out, tilting, eccentricity, wear, distortion,
1 3
corrosion), Slackness (Belts, chains)
Abnormal phenomenon (Unusual noise, overheating, vibration,
4
strange smell, discoloration, incorrect pressure or current)
Adhesion (Blocking, hardening, accumulation of debris,
5
peeling, malfunction)
Lubrication (Insufficient, Dirty, Unidentified, Unsuitable,
6

Unfulfilled Basic
Leaking lubricant, Oil level)

Condition
Electricals (Loose, hanging, dangling, stretched, insulations,
7
2 etc.)
Tightening (Nuts & Bolts loose, Missing, Crushed, Corroded,
8 Washers missing, Washers unsuitable, Wing nuts on back
side)
9 Cleaning (Covers, layout, machine construction)
Checking (Instrument position and orientation, operating range
10
display, covers, construction, layout)

Hard to Acces
11 Lubricating (Position of lubricant inlet, height space)
3
12 Tightening (Covers, construction, layout, size, space)
Operation (Machine layout, position of switches, levers and
13
valves)
Adjustment (Position of pressure gauges, flow meters,
14
thermometers, vacuum gauges etc.)
15 Raw Materil, WIP, FG (Scatter, overflow, leaks, spills)
Contamination
Source of

16 Lubricants / Gases (Leakage, spillage)

4
17 Scrap (Cuttings, packaging material, non-confirming products)

Others (Contaminants brought in by people, fork lift trucks,

18
material handling equipment etc.)
Defects
Quality

19 Shock (Vibration, collision, droppings.)

5
20 Humidity, Temp., Viscosity, Chemical concentration,
Accessories / Attachements (Pumps, fans, tanks, pipes, hoses,
Unnecessary Items

21 ducts, valves, gauges, instruments, electrical items, etc.)

Spare parts (Standby spares, auxiliary material.)
6
22 Make shift repairs (Tape, string, wire, packings, metal plates.)

23 Jigs & tools (Jigs/Fixtures, cutting tools, dies, hand tools)

Movements - Floor (Uneven projections, pot holes, slippery),
24
Steps (Too steep, irregular, missing handrails),
Unsafe Conditions

Guards - Rotating / Reciprocating parts (Missing / Broken

25
covers)
7 Lights (Out of position, dirty or broken covers, dim, not
26
working)
27 Lifting (Parts of cranes and hoist, wires, hooks, breaks)
Unhealthy & unsafe conditions (Noise, Fumes, Temp,.
28
Ventilation, Illumination, Etc.)
Total Count

Good
Points
(for HD at
Remarks

Urgent
attention
reqd.
Other

The Prime Mover - Towards Excellence 30

Abnormalities TPM

Thank You.

The Prime Mover - Towards Excellence 31