FUGUAI = DEVIATION<->ABNORMALITY

  • Functional Defects
  • Pollution
  • Difficult to Access/Observe
  • Hard to Load/Operate
  • Unsafe
  • Safety, Health, Environment, Quality (SHEQ) “unfriendly”
  • Undesirable Tasks

“F” Tags are used to highlight Deviations, Faults, or Abnormalities.

3 Types of F-Tags

Safety

Everyone writes safety F-Tags for everyone. Mechanics or operators can close these—yellow colour.

Fuguai tag to identify safety, ergonomics or environmental issues

Operator

  • Operator F-Tags are Blue.
  • Operator means anyone non-maintenance (ie. Operators, Supervisors, Cleaners, Sanitation, etc.) to fix the abnormality.
  • F-Tag should be attached to the following malfunctions:
    • Wear, Play, Slackness
    • Leakage
    • Dust, Dirt
    • Corrosion
    • Adherence of raw materials
    • Deformation, Surface damage, Cracking
    • Overheating, Vibration, Noise …
Fuguai tag to identify operational issues

Maintenance

  • Maintenance F-Tags are Red.
  • These F-Tags require Electricians, Mechanics, etc. to fix the abnormality.

F-tag templates in high resolution .pdf files can be downloaded here

F-TAG (Tagging)

  • F-Tag (is a visual work order) is a tag that is used to identify problems with the machines

“Four Lists” are used to track the F-Tags:

  • Abnormality List
  • F-Tag Tally Sheet
  • SOC (Sources of Contamination) List
  • HTA (Hard-to-Access) List
F-Tag ProcessAutonomous Maintenance

Where Are Abnormalities Found? Typical F-Tags

  • Broken Parts
  • Wear, Play, Rattling
  • Dust, Dirt, Corrosion
  • Cracks, drip marks,
  • Deformation, Surface Damage
  • Noisy, Hot, Cold, Odour, etc…

Examples of “Fuguai” – Potential problems

  1. Minor defects
    • Examples:
      • Dirtiness
      • Scratches
      • Play
      • Looseness
      • Abnormality Adhesion
    • Examples of checkpoints:
      • Dust, dirt, powders, oil, rust and paint
      • Cracking, collapsed, deformed, chipping, bends
      • Shake, slip off tilting, eccentricity, wear, distortion, corrosion
      • Bolt, nut, gauge, cover, belt, chain:
        • Looseness, omission, incorrect tightening, excessively long bolt
        • Battered threads, corrosion, Incorrect washer, bolt direction, double nut put in reverse
      • Abnormal sound, heat, vibration, offensive odor, discoloration, pressure
      • Clogging, sticking, deposition, peeling off
  2. Lubrication
    • Examples:
      • Leaking
      • Incorrect conditions
      • Incorrect indicators
    • Examples of checkpoints:
      • Oil depletion, dirty oil, oil type (not known, inadequate), leak
      • Dirty oil support port, clogging, damage, deformation, collapsed pipe, storage condition, inadequate oiling equipment
      • Dirtiness, damage, leak, wrong level indication
  3. Source of contamination
    • Examples:
      • Products
      • Raw Materials
      • Hydraulic oil
      • Liquid Gasses Machining & Processing
      • Other
    • Examples of checkpoints:
      • Leak, spilling, blowing off, scattering, overflow
      • Leak, spilling or permeation of fluid
      • Leak, spilling air, gasses, steam, vapor, exhaust water
      • Burrs, chips, packing, sputters, sparks, smokes, adhesive, paints
      • Dropped parts
  4. Hard-to-reach areas
    • Examples:
      • Cleaning / Inspection
      • Lubrication
      • Operation
    • Examples of checkpoints:
      • Equipment structure, cover, layout, foothold, space, installing height high or low, indicators inadequate
  5. Quality defects
    • Examples:
      • Foreign matters
      • Manufacturing condition
    • Examples of checkpoints:
      • Leaking, overflow
      • Humidity, vibration, collision, temperature
  6. Unnecessary things
    • Examples:
      • Equipment components
      • Products
      • Tools and Jigs
      • Spare parts
      • Pipes
    • Examples of checkpoints:
      • Messy
      • Disordered
  7. Safety concerns
    • Examples:
      • Incorrect conditions
      • Incorrect indicators
    • Examples of checkpoints:
      • Floor, Steps, Stairs:
        • unevenness, cracks, peeling off, wear
      • Lighting:
        • dark Safety devices; broken, worn stoppers, wear

F-tag Log

F-Tag Tracking

  • To track the F-Tags we write as part of AM activities, the team will create an Activity Board called the F-Tag Tracking Centre
  • This board will show the “Three Lists”, and keep track of how many F-Tags are written and how many have been completed

Breakdown evidence tag

3 Comments

    1. Assuming that you are referring to 7 steps of Autonomous Maintenance, f-tag are used through all steps from the moment it would be implemented during step 1.

      Tagging is a process of identifying issues (defects), while doing cleaning and or inspections, as well while running equipment, and not related to a particular step of AM. It is a visual tool, that helps to see if equipment has any issues that needs to be resolved.

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