7 Deadly Defects Training Pack

1. 7 Deadly DefectsTraining Pack

2. Introduction Are these problems familiar? • Equipment breaks down. • Change-overs, setups and adjustments take too long. • Running machines at the rated speeds generates defects. • Machines are plagued by minor stoppages.

3. Minor Flaws Lack of basic Conditions Unsafe Places Unnecessary & Non-Urgent Equipment Hard to reach Places Quality Defect Sources Contamination Sources

4. Contamination Damage • Dust • Dirt • Powder • Oil • Grease • Rust • Paint • Cracking • Crushing • Deformation • Chipping • Bending Slackness Play • Shaking • Falling out • Tilting • Eccentricity • Wear • Distortion • Corrosion • Belts • Chains Minor Flaws Adhesion Abnormal Phenomena • Unusual noise • Overheating • Vibration • Strange smells • Discoloration • Incorrect pressure or current • Blocking • Hardening • Accumulation of debris • Peeling • Malfunction Defect #1 – Minor Flaws

5. Lubrication Lubrication Supply • Dirty • Damaged or Deformed Lubricant Inlets • Faulty Lubricant Pipes • Insufficient • Dirty • Unidentified • Unsuitable • Leaking Lubricant ? X Lack of Basic Conditions Oil Level Gauges Tightening • Dirty • Damaged • Leaking • No indication of correct level • Nuts and bolts • Slackness • Missing • Cross-threaded • Too long • Crushed • Corroded • Washer unsuitable • Wing nut on backward Defect #2 – Lack of Basic Conditions

6. Cleaning Checking • Machine • Construction • Covers • Layout • Footholds • Space • Covers • Construction • Layout • Instrument Position and Orientation • Operating-range Display Lubricating Tightening Hard to Reach Places • Position of lubricant inlet • Construction • Height • Footholds • Lubricant Outlet Space • Covers • Construction • Layout • Size • Footholds • Space Operation Adjustment • Machine Layout • Position of valves • Switches and Levers • Footholds • Position of pressure gauges • Thermometers • Flow-meters • Moisture Gauges • Vacuum Gauges Defect #3 – Hard to Reach Places

7. Lubricants Product/Raw Material • Leaks • Spills • Spurts • Scatter • Overflow • Leaks • Spills • Spurts • Scatter • Overflow Gases Liquids Contamination Sources • Leaking • Spilt and spurting cold water • Hot water • Half-finished products • Cooling water • Waster water • Leaking compressed air • Gases • Steam • Vapors • Exhaust fumes Scrap Other • Flashes • Cuttings • Packaging materials • Nonconforming product • Contaminants brought in by people • Fork-lift trucks, etc. • Infiltrating through cracks in buildings Defect #4 – Contamination Sources

8. Shock Foreign Matter • Inclusion, infiltration, and entrainment of rust • Chip • Wire scraps • Insects • Dropping • Jolting • Collision • Vibration Moisture Grain Size Quality Defect Sources • Too much • Too little • Infiltration • Defective elimination • Abnormalities in screens • Centrifugal separators • Compressed-air separators. Concentration Viscosity • Inadequate warming • Heating • Compounding • Mixing • Evaporation • Stirring • Inadequate warming • Heating • Compounding • Mixing • Evaporation • Stirring Defect # 5 – Quality Defect Sources

9. Machinery Piping equipment • Pipes • Hoses • Ducts • Valves • Dampers • Pumps • Fans • Compressors • Columns • Tanks Measuring instruments Electrical equipment • Temperatures • Pressure gauges • Vacuum gauges • Ammeters • Wiring • Piping • Power leads • Switches • Plugs Unnecessary/Non-Urgent Items Jigs and tools Spare parts Makeshift repairs • Tape • String • Wire • Metal plates. • Standby equipment • Spares • Permanent stocks • Auxiliary materials • General tools • Cutting tools • Jigs • Molds • Dies • Frames Defect #6 – Unnecessary Items

10. Steps Floors • Unevenness • Ramps • Projections • Cracking • Peeling • Wear (steel deck-plates) • Too steep • Irregular • Peeling anti-slip covering • Corrosion • Missing handrails Lights Rotating machinery Unsafe Places • Dim • Out of position • Dirty or broken covers • Not properly explosion-proofed • Displaced • Fallen off or broken covers • No safety or emergency stop devices Lifting gear Other • Wires • Hooks • Brakes • Other parts of cranes and hoists • Special substances • Solvents • Toxic gases • Insulating materials • Danger signs Defect #7 – Unsafe Places

11. 1. Lack of Basic Condition • Lack of SOP, no standardized procedure or up-to-date training, missing settings/centerlines, missing PM Developed C/O SOPs C/O Play Cards

12. 2. Lack of Basic Condition • People - Resources not utilized efficiently Developed Throughput Operating Strategy (TOS) Maintenance CI Team Work-order Backlog – Past Due PMs

13. 3. Contamination Sources • Product leaks, spills, spurts, scatter, overflow Line 4 Packaging Line 4 Sifter Defect: product spillage Fix: ST: w/o 47682 replaced gasket LT: auto filler installation Defect: product spillage Fix: PM @ next c/o – ongoing issue Defect: product spillage Fix: end seals replaced @ next c/o – complete Line 1 Blending

14. 3. Contamination Sources • Product leaks, spills, spurts, scatter, overflow Line 4 PMX Rotary Valve Line 4 BD Rotary Valve Defect: product spillage Fix: w/o #47684 Defect: product spillage Fix: w/o #47685 Defect: product spillage Fix: w/o #47679 – partially completed Line 4 PMX blender

15. 4. Minor Flaws – Dust, dirt, powder, oil, grease, rust, paint Line 4 PMX sifter Line 1 Dust Collector Defect: product leakage Fix: Safety w/o Defect: paint chipping Fix: Sanitation audit prep Defect: Leaking oil from motor Fix: Temporary fix Dust Collector Leak

16. 5. Lack of Basic Condition • Tightening nuts, and bolts, slackness, missing, cross-threaded, too long, crushed, corroded, washer unsuitable Line 4 Surge Bin Line 4 PMX Discharge Gate Defect: broken latch Fix: w/o #47685 Defect: 38 bolts/1missing bolt Fix: replace @ next mthly PM

17. 6. Hard to Reach Places • Wasted motion – clutter, congestion, etc. Line 1 Blending Line 1 Blending Defect: Beating live bottom to release bridged product Fix: review centerline settings Defect: Clutter, congestion in high traffic area Fix: Reinforce 5S standards Line 1 Blending

18. 7. Hard to Reach Places – Operation – machine layout: position of valves, switches, hoses, doors Line 1 Blending Defect: position of air hoses Fix: w/o 42457 to install air line on pole next to sifter for accessibility during c/o Line 1 Blending Defect: Standing on blender to disassemble/assemble LBB Fix: ST: Safety w/o 41840 implemented fall harness LT: w/o 43816 – CAAP to build platform – in process

19. 8. Unsafe Places – Lights dim, out of position, dirty or broken covers Line 3 Blending Defect: No lighting @ blender, bulb out Fix: w/o #47685

20. – foreign matter – inclusion, infiltration, and entrainment of rust, chips, wire scraps, insects, etc. 9.Quality Defect Sources Silo Room Defect: insects found in silo tailings Fix: increase frequency of heat treatment. Isolate silo, contact vendor for flour removal

21. 10. Unnecessary & Non-urgent Equipment, Activity or Process • Electrical equipment – wiring, piping, power leads, switches, plugs, etc. Defect: Excess wiring left from installation Fix: Complete installation, remove left-over wiring Line 4 Packaging Line 4 Packaging • Piping equipment – pipes, hoses, ducts, valves, dampers, etc. Defect: Obsolete vacuum equipment and ducts Fix: Remove equip. during L4 auto filler installment Defect: Dual discharge valves on scales Fix: Currently unknown Line 4 Packaging Line 1, 2, 3 Blending

22. 1 • Contamination • Damage • Play • Slackness • Abnormal phenomena • Adhesion Minor Flaws 2 • Lubrication • Lubricant supply • Gauges • Tightening • Lack of training • Lack of SOP • People Insufficient, dirty, unidentified, unsuitable, or leaking lubricant Dirty, damaged, or deformed lubricant inlets, faulty lubricant pipes Dirty, damaged, leaking: no indication of correct level Nuts and bolts: slackness, missing, cross-threaded, too long, crushed, corroded, washer unsuitable, wing nuts on backward No standardized procedure or up to date training, missing settings/centerlines, missing PM Resources not utilized efficiently Lack of Basic Conditions 3 • Cleaning • Checking • Lubricating • Tightening • Operation • Adjustment • Wasted motion Machine construction, covers, layout, footholds, space Covers, construction, layout, instrument position and orientation, operating-range display Position of lubricant inlet, construction, height, footholds, lubricant outlet space Covers, construction, layout, size, footholds, space Machine layout: position of valves, switches, and levers, footholds Position of pressure gauges, thermometers, flowmeters, moisture gauges, vacuum gauges, etc. A place for everything and everything in its place Hard To Reach Places 4 Leaks, spills, spurts, scatter, overflow Leaks, spills, spurts, scatter, overflow Leaking, spilt, and seeping lubricating oils, hydraulic fluids, fuel oil, etc. Leaking compressed air, gases, steam, vapors, exhaust fumes, etc. Leaking, cold water, hot water, half-finished products, cooling water, waste water, etc. Flashes, cuttings, packaging materials, and nonconforming product Contaminants brought in by people, fork-lift trucks, etc. and infiltrating through cracks in buildings • Product • Raw Materials • Lubricants • Gases • Liquids • Scrap • Other Contamination Sources 7 Deadly Defects List Example Abnormality Dust, dirt, powder, oil, grease, rust, paint Cracking, crushing, deformation, chipping, bending Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion Belts, chains Unusual noise, overheating, vibration, strange smells, discoloration, incorrect pressure or current Blocking, hardening, accumulation of debris, peeling, malfunction

23. 5 • Foreign Matter • Shock • Moisture • Grain Size • Concentration • Viscosity • Spec. Incorrect Inclusion, infiltration, and entrainment of rust, chips, wire scraps, insects, etc. Dropping, jolting, collision, vibration Too much, too little, infiltration, defective elimination Abnormalities in screens, centrifugal separators, compressed-air separators, etc. Inadequate warming, heating, compounding, mixing, evaporation, stirring, etc. Inadequate warming, heating, compounding, mixing, evaporation, stirring, etc. Raw materials instructions or standards Quality Defect Sources 6 • Machinery • Piping equip. • Measuring instrumt. • Electrical equip. • Jigs and tools • Spare parts • Makeshift repairs • Out dated procedure Pumps, fans, compressors, columns, tanks, etc. Pipes, hoses, ducts, valves, dampers, etc. Temperatures, pressure gauges, vacuum gauges, ammeters, etc. Wiring, piping, power leads, switches, plugs, etc. General tools, cutting tools, jigs, molds, dies, frames, etc. Standby equipment, spares, permanent stocks, auxiliary materials, etc. Tape, string, wire, metal plates, etc. Process changed, procedure not standardized, frequency of activity Unnecessary & Non-Urgent Equipment, Activity or Process 7 • Floors • Steps • Lights • Rotating machinery • Lifting gear • Other Unevenness, ramps, projections, cracking, peeling, wear (steel deck-plates) Too steep, irregular, peeling anti-slip covering, corrosion, missing handrails Dim, out of position, dirty or broken covers, not properly explosion-proofed Displaced, fallen off or broken covers, no safety or emergency stop devices Wires, hooks, brakes, and other parts of cranes and hoists Special substances, solvents, toxic gases, insulating materials, danger signs Unsafe Places 7 Deadly Defects List

24. Restore Phase at Haddenham How many Defects do we have in our Process??? • The 7 Deadly Defects are part of the Restore Phase. • This also includes: • Executing PMs • Identifying any TPM activities • Reviewing Best Practises across Operators • SOPs, Training, Audits • Centre-lining