7 types of abnormality poster (TPM tags)

In autonomous maintenance, every fault an operator finds gets a tag, and the tags are sorted into seven types of abnormality: minor flaws, unfulfilled basic conditions, places that are hard to reach, sources of contamination, sources of quality defects, unnecessary items and unsafe places. Sorting them shows where a machine is weakest. This poster lists the seven types with examples and leaves blanks for the tag colours your site uses, since they vary.

Download the poster

The PNG is free to download now. The print-ready vector PDFs open after a short form, once.

Download PNG (300 dpi)2550 x 3300 px, prints at 8.5 x 11 in · 425 KB · no form

Free to print and share with your team. Enter your name and work email once to download.

Seven types of abnormality poster — 24 x 36 in18 x 24 inA2A3LetterA4PNG 300 dpi

The words on the poster

7 types of abnormality

Tag every one you find. The type tells you where the machine is weak.

Minor flaws Dirt, play, slack, wear, noise, heat, vibration.
Basic conditions not met Missing lubrication, low oil, loose bolts.
Hard to reach Places hard to clean, inspect, lubricate or adjust.
Contamination sources Leaks, chips, dust, spilled product.
Quality defect sources Foreign matter, shock, moisture, wrong settings.
Unnecessary items Unused brackets, pipes, wiring, old spares.
Unsafe places Slippery floors, exposed moving parts, poor lighting.

Operator tag colour: ____
Maintenance tag colour: ____

Types after the Japan Institute of Plant Maintenance, Autonomous Maintenance for Operators (1997).

On the floor

How to use it

Putting the 7 types of abnormality poster (TPM tags) poster to work

1
Fill in your tag colours, then post it on the AM activity board or the tag board.
2
When the team raises a tag, ask which of the seven types it is, and write the type on the tag.
3
Each month, count open tags by type: the biggest type tells you what the next kaizen is.
4
Pair it with the free TPM tag log and the cleaning is inspection poster.

Where the poster goes and how to teach with it, in the order to try them.

Which size to print

24 x 36 in or A2: a main wall or team board, read from a few metres away.
18 x 24 in or A3: a station or notice board. The A3 file also fits 11 x 17 in paper.
Letter or A4: a clipboard, binder or handout, on any office printer.

Every PDF is vector, so it stays sharp at full size. Nothing runs to the edge of the page, so no bleed is needed.

Sources and notes

Japan Institute of Plant Maintenance (ed.), Autonomous Maintenance for Operators (Productivity Press, 1997), and TPM for Every Operator (Productivity Press, 1996).