FUGUAI By Samsher Singh.pptx

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. 19/10/2023 by Samsher Singh Copyright 2023 1 FUGUAI Basis, Awareness and I mplementation Samsher Singh Chahal [phone]

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? 19/10/2023 by Samsher Singh Copyright 2023 2

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 19/10/2023 by Samsher Singh Copyright 2023 3

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 19/10/2023 by Samsher Singh Copyright 2023 4

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 19/10/2023 by Samsher Singh Copyright 2023 5

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 19/10/2023 by Samsher Singh Copyright 2023 6

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 19/10/2023 by Samsher Singh Copyright 2023 7

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 19/10/2023 by Samsher Singh Copyright 2023 8

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 19/10/2023 by Samsher Singh Copyright 2023 9

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 19/10/2023 by Samsher Singh Copyright 2023 10

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.  19/10/2023 by Samsher Singh Copyright 2023 11

12. Types FUGUAI Tags 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.) 19/10/2023 by Samsher Singh Copyright 2023 12

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 :  Loosening of fitting bolts of limit switches, proximity switches and photoelectric switches. Replacement of worn-off  screws, scattering of cut powders and cutting oils. Dislocation and twisting of movable sections in wiring. Replacement of damaged V-belts, tension springs and loosened chains.  Air and oil leakage due to less tightened bolts, loose joints or loose tube fittings. Replacement of grease cups due to chipping. 19/10/2023 by Samsher Singh Copyright 2023 13

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).  19/10/2023 by Samsher Singh Copyright 2023 14

15. FUGUAI Tags tree Fuguai means Abnormality, so Fuguai tree is used to hanged the abnormality tags on it 19/10/2023 by Samsher Singh Copyright 2023 15

16. Abnormality Listing 19/10/2023 by Samsher Singh Copyright 2023 16

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. 19/10/2023 by Samsher Singh Copyright 2023 17

18. Abnormality Analysis 19/10/2023 by Samsher Singh Copyright 2023 18

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/Abnormality Register in FUGAI matrix 5. Tag Removal After Abnormality sort out 19/10/2023 by Samsher Singh Copyright 2023 19

20. Implement plan for FUGUAI 20 % TRANING 30 % EXECUTION 50 % HANDS ON 19/10/2023 by Samsher Singh Copyright 2023 20

21. Thank you for listening ! 10/19/2023 By Samsher Singh chahal copyright 2023