7 Types of Abnormalities

1. Minor Flaws

Contamination Dust, Dirt, Oil, Grease, Rust

Damage Cracking, Crushing, deformation, chipping, bending

Play Shaking, falling out, tilting, eccentricity, wear, distortion,

corrosion
Slackness Belts, Chains

Abnormal Unusual noise, overheating, vibration, strange smells,

Phenomenon discoloration, incorrect pressure or current
Adhesion Blocking, hardening, accumulation of debris, peeling,
malfunction
 2. Unfulfilled Basic Conditions

Lubrication Insufficient, Dirty, Unidentified, unsuitable, Leaking

Lubrication Supply Dirty, damaged or deformed lubricant inlets, faulty

lubricant pipes
Oil level gauges Dirty, Damaged, leaking, No Indication of correct levels

Tightening Nuts & Bolts slackness, Missing, Cross threaded, Too

Long, Crushed, Corroded, Unsuitable washers
 3. Inaccessible places

Cleaning Machine construction, Covers, Layout, Space shortage

Checking Construction, Covers, Layout, Instrument position &

orientation
Lubricating Position of Lubricant inlet, construction, height,
lubricant outlets, space shortage
Tightening Covers, Layout, Space

Operation Machine layout, Position of valves, Switches & leavers

Adjustment Position of pressure gauges, thermometers, flow

meters, moisture gauges, vacuum gauges
 4. Contamination Sources

Product Leaks, Spills, Scattering, overflow

Raw Materials Leaks, Spills, Scattering, overflow

Lubricants Leaks, Spills, Hydraulic fluids, Fuel Oils

Gases Leaking compressed air, gases, steam, vapors,

exhaust fumes
Liquids Leaking water, Waste water, leaking supply linbes

Scrap Flashes, cuttings, packaging materials and non

conforming products
Others Contaminants by people, forklifts, cracked walls,
broken windows etc
 5. Quality Defect Sources

Foreign Matter Dust, Rust, Chips, Moistures, Wire scraps, wood piece,
paper pieces, stones etc
Moisture Too little or too much

Viscosity Inadequate warming, heating, compounding, mixing,

evaporation, stirring etc
Concentration Inadequate warming, heating, compounding, mixing,
evaporation, stirring etc
Shock Jolting, Collision, vibration
 6. Unnecessary & Non Urgent Items

Machine Pumps, fans, compressors, tanks etc

Piping Equipment Pipes, hoses, ducts, valves, dampers

Measuring Temperatures, pressure gauges, vacuum gauges

Instruments
Electric equipment Wiring, piping, power leads, switches, plugs

Jigs & Tools General tools, cutting tools, jigs, molds, dies, frames
etc
Spare parts Standby equipment, Spares

Makeshift repairs Tape, String, wire, metal plates etc

 7. Unsafe places

Floors Unevenness, cracked, holes, peeling, slipping

Steps Too steep, irregular, slipping, missing handrails

Lights Dim, out of position, dirty or broken covers, no

explosion
Rotating machinery Displaced, Fallen oil or broken covers, not safe for
emergency, Missing emergency stop devices
Lifting devices Wires, hooks, brakes

Others Solvents, toxic gases, missing PPEs

Checkpoints to Identify Abnormalities
 Nuts & Bolts Checkpoints

Slight defects • Loose nuts & bolts, missing Nuts & bolts
Bolt lengths • All bolts should protrude from nuts by 2-3 threads
Washers • Are flat washers used on long holes
• Are tapered washers used on angle bards and
channels
• Are spring washers used for parts subject to
vibration
• Are identical washers used in identical parts
Fixing of nuts & bolts • Are bolts inserted from below, are they visible from
outside
• Are devices such as limit switches fastened atleast
by 2 bolts
• Are wing nut direction clock wise
 Lubrication Checkpoints
Lubricant storage • Are lubricant sores always kept clean, tidy. Are 5S principles
applied
• Are lubricant containers always capped
• Are lubricant type clearly indicated and is proper stock
control practiced
Lubricant inlets • Are Grease nipples, speed reduce lubricant ports and other
lubricant inlets always kept clean
• Are lubricant inlets dust proofed
• Are lubricant inlets labeled with correct type and quantity of
lub
Oil level gauges • Are oil level gauges always kept clean, are oil levels easy to
check
• Is correct oil level marked
• Is equipment free of oil leaks, and oil pipers and breathers
unobstructed
Auto LUB Devices • Are auto lubricating devices operating correctly and
supplying correct quantity of lubricants
Lubricating • Are rotating, sliding parts, and transmissions well
condition lubricated? And are surroundings free of contamination by
excess lubricant
 Transmission System Checkpoints
V Belts & Pulleys • Are any belts cracked, swollen, worn out or
contaminated by lubricants
• Are any belts twisted or missing. Are any belts
stretched or slack
• Are multiple belts under uniform tension and all of
same type
• Are top surfaces of Belts protruding above pulley
rims? Are the bottom of any pulleys groves shiny?
(indicating a worn out belt or pulley)
• Are pulleys correctly aligned
• Roller chains • Are any chains stretched indicating worn out pins or
bushings
• Are any sprocket teeth worn, missing or damaged
• Is lubrication between pins and bushings sufficient
• Are sprockets properly aligned
Shafts, Bearings & • Is there nay overheating, vibration, abnormal noise
Couplings due to excessive play or lack of greasing
• Are any keys or set bolts loose or missing
• Are any couplings misaligned or wobbling
• Are any seals worn out
 Transmission System Checkpoints
Gears • Are gears rightly lubricated with proper amount of
lubricant
• Are any teeth missing, damaged worn out or
jammed
• Is there any unusual noise or vibration
 Hydraulics Checkpoints
Hydraulic check • Is there correct quantity and level indicated for fluid
points in the reservoir
• Is fluid of correct temp. and is min and max for temp
indicated
• Is fluid cloudy (indicating air entrapment)
• Are all fluid inlets and strainers clean, are any
suction filters blocked?
• Are any fluid reservoir breather filters blocked?
• Are fluid pumps operating without any unusual noise
and vibration
• Are hydraulic pressures correct, and are operating
at ranges displayed
Heat Exchangers • Is any fluid or water leaking from fluid cooler or
pipes
• Are temp. differences between fluid and water inlets
and outlets correct? Are any tubes blocked?
 Hydraulics Checkpoints
Piping & Wiring • Are all pipes and hoses fastened tightly
• Are there any fluid leaks
• Are any hoses cracked or damaged
• All all valves operating correctly? Is it easy to see
whether valves are open or closed
• Are any pipes, valves unnecessary?

Hydraulic equipment • Are there any fluid leaks? Are hydraulics properly
fastened
• Are hydraulic devices operating correctly without
speed loss or breathing
• Are hydraulic pressures correct and are all gauges
working
 Pneumatics Checkpoints
FRLs (Filters, • Are FRLs clean? Is it easy to see inside any of them. Are they
Regulators, fitted in right way
Lubricators) • Is there sufficient oil and are drains clear
• Is oil dip rate correct? (Approx. 1 drop for 10 strokes)
• Are FRLs installed not more than 3m from the equipment
• Are pressure adjusted to correct value and operating ranges
correctly indicated
Pneumatic • Is compressed air leaking from pneumatic cylinders or
Equipment solenoids?
• Are all pneumatic cylinders or solenoid valves firmly fastened?
• Are any pistons dirty, worn, damaged?
• Are their speed controllers installed right way
• Is there abnormal sound or overheating of solenoid valves and
any lead wires chafed or trailing?
Piping & Wiring • Are there any places in pneumatic pipes or hoses where fluid
is liable to collect? Are all hoses and pipes clipped firmly in
place
• Are any hoses cracked, damaged or are there any air leaks
• Are valves operating correctly and open and close position
known
 Electrical Checkpoints
Control Panels • Are the interiors of distribution boards, switch boards and
control panels kept clean, tidy and well organized
• Are wires inside discolored or hardened
• Have any objects or flammable materials been left insided
• Is wiring inside control panels in good condition. Are any wires
coiled or trailing
• Are all ammeters and voltmeters working correctly
• Are any switches, bulbs working correctly, broken
• Are panel doors in good condition? Do they open and close
easily?
• Are there any unused holes? Are control panels water proof &
dustproof?
Electrical • Are all motors free of overheating, vibration, unusual smell &
Equipment noise
• Are all motor cooling fans and fins clean
• Are any bolts loose? Are pedestals free of cracks and
damages
 Electrical Checkpoints
Sensors • Are all manual switches clean and free of damages and excessive
play
• Are all switches installed in correct position
• Are all interiors of limit switches is clean
• Are any wires coiled or trailing
• Are any limit switch dogs worn, deformed or of wrong shape
• Are all photoelectric switches and proximity switches clean and
free of excessive play
• Are any sensors out of position? Are correct positions clearly
indicated
• Are all lead wires un chafed, and is insulation intact at entry
points?
Switches • Are all switches installed in correct position
• Are all manual switches clean and free of damages and excessive
play
• Are emergency stop switches installed in appropriate locations and
are they in good working condition
Piping & • Are any pipes, wires or power leads loose or unsecured
wiring • Are any ground wires damaged or disconnected
• Are any pipes damaged or corroded? Are there bare wires with
damaged insulation
• Are any wires coiled on floor or dangling overhead
Cleaning Map Example
Abnormality Examples: Leakages
Abnormality Examples: Loose Fittings
Abnormality Examples: Leakages
Abnormality Examples: Leakages