Balasore Alloys Ltd.www.balasorealloys.com

By : Deepak Kumar SahooManager – TPM,Balasore Alloys Ltd.

July, 2014

7 Type of FUGUAI

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Think of the rocks and boulders as barriers because they slow

down the water flow. Fuguai are the is the first step to eliminate

these barriers.

Index

Fuguai/Abnormality

Types Of Fuguai

1.Minor flaws

2. Unfulfilled basic conditions

3. Inaccessible places

4. Contamination sources

5. Quality defect sources

6. Unnecessary and Non-urgent items

7. Unsafe places

Details about various types of Fuguai

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What is Abnormality / Fuguai ?

Anything which is not Normal.

Deviation from the Standard.

Deviation from the Requirement.

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Types Of Fuguai

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• Minor flaws1

• Unfulfilled basic conditions2

• Inaccessible places3

• Contamination sources4

• Quality defect sources5

• Unnecessary and non-urgent items6

• Unsafe places7

1. Minor Flaws

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Contamination Dust, Dirt, powder, oil, grease, rust, paint

Damage Cracking, crushing, deformation,

Play Falling out, tilting, eccentricity, wear, distortion, corrosion,

Slackness Belts, Chains

Abnormal

Phenomenon

Unusual noise, overheating, Vibration, strange smells,

discoloration, incorrect pressure or current

Adhesion Blocking, hardening, accumulation of debris, Peeling, malfunction

2.Unfulfilled Basic Conditions

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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 level

Tightening Nuts and Bolts slackness, Missing, Cross-threaded, Too long, Crushed,

Corroded, Unsuitable washers, wing nuts on backward

3. Inaccessible places

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Cleaning Machine construction, Covers, Layout, footholds, Space

Checking Construction, Covers, Layout, footholds, Instrument position and

Orientation, Operating – Range display

Lubricating Position of lubricant inlet, construction, height, lubricant outlets, space

Tightening Covers, Construction, Layout size, Space

Operation Machine layout, Position of valves, Switches and leavers, Footholds

Adjustment Position of pressure gauges, thermometers, flow meters, moisture gauges,

vacuum gauges, etc.

4.Contamination sources

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Product Leaks, Spills, Scattering, Overflow

Raw materials Leaks, Spills, Scattering, Overflow

Lubricants Leaking, Spills, Hydraulic fluids, Fuel oils, etc.

Gases Leaking compressed air, gases, steam, vapors, exhaust fumes, etc.

Liquids Leaking water, Hot, Cold, half finished products, Waste water, Leaking

supply lines etc.

Scrap Flashes, cuttings, packaging materials, and non conforming products.

Others Contaminants by people & Forklifts, Infiltration through cracked walls,

broken windows etc.

5. Quality Defect Sources

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Foreign MatterDust, Rust, powder, chips, moisture, wire scraps, wood pieces, paper

pieces, stones etc.

Shock Dropping, Jolting, collision, Vibration etc.

Moisture Too little or Too much, infiltration

Grain SizeAbnormalities in screens, Compressed air separators, centrifugal

separators,

ConcentrationInadequate warming, heating, compounding, mixing, evaporation,

stirring etc.

ViscosityInadequate warming, heating, compounding, mixing, evaporation,

stirring etc.

6. Unnecessary and non-urgent items

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Machinery Pumps, fans, compressors, columns, tanks etc.

Piping equipment Pipes, hoses, ducts, valves, dampers etc.

Measuring

instruments

Temperatures, pressure gauges, vacuum gauges, ammeters etc.

Electrical Wiring, piping, power leads, switches, plugs etc.

Jigs & Tools General tools, cutting tools, jigs, molds, dies, frames etc.

Spare parts Standby equipment, spares, permanent stocks, auxiliary materials, etc.

Repairs Tape. String, wire, metal plates etc.

7. Unsafe places

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Unevenness, cracked, holes, projections, peeling, wear of steel chucker plates,

slipping.

Too steep, irregular, slipping, missing handrails, etc.

Dim, out of position, dirty or broken covers, no explosion proofing, etc.

Displaced, fallen oil or broken covers, not safe for emergency, missing emergency

stop devices

Wires, hooks, brakes and other parts of cranes and hoists etc.

Special substances, solvents, toxic gases, insulating materials, danger signs,

protective clothing etc.

1. Minor Flaws : Details

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1.1 Contamination

DUST RUST

1.2 Damage

CRACKING CHIPPING

1. Minor Flaws : Details

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1.3 PLAY

FALLING OUT CORROSION

1.4 SLACKNESS

BELT CHAIN

1. Minor Flaws : Details

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1.5 Abnormal Phenomenon

DISCOLORATION INCORRECT PRESSURE

1.6 Adhesion

PEELING BLOCKING

2. Unfulfilled basic conditions : Details

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2.1 Lubrication

UNIDENTIFIED LEAKING

2.2 Lubrication Supply

DAMAGED LUBE INLET DIRTY

2. Unfulfilled basic conditions : Details

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2.1 Oil Level Gauges

NO INDICATION DAMAGED

2.2 Tightening

TOO LONG UNSUITABLE WASHERS

3. Inaccessible places : Details

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3.1 Cleaning

M/C CONSTRUCTION SPACE CONSTRAINT

3.2 Inspection

CONSTRUCTION OPERATING DISPLAY

3. Inaccessible places : Details

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3.3 Lubrication

POSITION OF LUBRICATING INLET SPACE

3.4 Tightening

TOO LONG UNSUITABLE WASHERS

3. Inaccessible places : Details

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3.5 Operation

M/C LAY OUT POSITION OF VALVES

3.6 Adjustment

FLOW METER POSITION OF TEMPERATURE GAUGES

4. Contamination sources: Details

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4.1 Product

SPILLAGE OVERFLOW

4.2 Raw Materials

LEAKAGE SCATTERING

4. Contamination sources: Details

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4.3 Lubricants

HYDRAULIC FLUIDS LEAKAGE

4.4 Gases

EXHAUST FUMES VAPORS

4. Contamination sources: Details

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4.5 Liquids

WATER LEAKAGE WASTE WATER

4.6 Scraps

NON CONFORMING PRODUCTS PACKAGING MATERIALS

5. Quality defect sources : Details

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5.1 Foreign Matter

RUST WOOD PIECES

5.2 Shock

DROPPING COLLISION

5. Quality defect sources : Details

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5.3 Moisture

TOO LITTLE TOO MUCH

5.4 Grain Size

ABNORMALITIES IN SCREEN COMPRESSED AI R SEPERATORS

5. Quality defect sources : Details

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5.5 Concentration

INADEQUATE HEATING INADEQUATE MIXING

5.6 Viscosity

INADEQUATE STIRRING INADEQUATE MIXING

6. Unnecessary & Non-Urgent items: Details

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6.1 Machinery

FANS TANKS

6.2 Piping Instruments

PIPES VALVES

6. Unnecessary & Non-Urgent items: Details

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6.3 Measuring Instruments

AMMEMETERS VOLTMETERS

6.4 Electrical Equipments

WIRING PLUGS

6. Unnecessary & Non-Urgent items: Details

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6.5 Jigs & Tools

DIES JIGS

6.6 Spare Parts

SPARES STANDBY EQUIPMENTS

6. Unnecessary & Non-Urgent items: Details

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6.7 Makeshift Repairs

STRING TAPE

7. Unsafe places : Details

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7.1 Floors

CRACKED PEELING

7.2 Steps

TOO STEEP MISSING HANDRAILS

7. Unsafe places : Details

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7.3 Lights

DIM BROKEN COVERs

7.4 Rotating machinery

BROKEN COVERS NOT SAFE FOR EMERGENCY

7. Unsafe places : Details

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7.5 Lifting Devices

HOOKS HOISTS

7.6 Others

INSULATING MATERIALS HANGING WIRES

By : Deepak Kumar SahooManager – TPM,Balasore Alloys Ltd.+91 – 73810 35030