TOTAL PRODUCTIVE MAINTENANCE NOTES:

TYPES OF ABNORMALITIES OR FUGUAI AND FUGUAI MAPPING

❖ 7 TYPES OF ABNORMALITIES OR FUGUAI:

1. Minor Flaws
- Abnormal condition that is related to any play, slackness, or damaged part
available in any mechanism
2. Unfulfilled Basic Conditions:
- Abnormal condition that is related to not fulfilling the basic condition of the
machine to operate.
- Example: cleaning, lubricating, tightening, etc.
3. Inaccessible Places:
- If we cannot access the machine or any area for cleaning, lubrication,
inspection, retightening, or regular operation purpose
4. Sources of contamination:
- Any types of leaking, spillage, scattering, or overflows of any material.
5. Sources of Quality Defects:
- Can be foreign particles, shocks, vibrations, moisture, concentration,
viscosity, etc.
6. Unnecessary Items:
- Any non-required item available at the workplace.
- Examples: spare parts, etc
7. Unsafe Places:
- Unevenness of flooring or surfaces, cracks, holes, projections, peeling,
slipping surface that can cause accidents.

❖ FUGUAI MAPPING:
Fuguai mapping is a machine map used to differentiate abnormalities and focus
on an area of a selected machine. To perform fuguai identifications (data collection), f-
tag is used (red or yellow tags). Descriptions of the items on the fuguai tag are as follows:
physical, functions, safety, contents, date, machine. For date collection, an inspection
checklist is used and applied.
Example: Fuguais observed are divided into three categories: safety, physical, and
function. Those categories are considered to clarify the fuguai status. After analyzation
(charts, graphs, etc), results could be useful techniques to know where to focus and things
that need to be done in order to overcome abnormalities.