4M

CHANGE
 AGENDA

 What is it purpose? – (इसका उद्देश्य क्या है?)

 What is 4M ? – (4M क्या है?)
 4M Change Communication ? - (4M परिवर्तन का संचार)
 How many types of 4M Change ? – (4M परिवर्तन कितने प्रकार का होता है ?)
 4M Change Process Flow – (4M परिवर्तन - प्रक्रिया प्रवाह)
 Activity to be done when Planned Change? – (योजनाबद्ध परिवर्तन के दौरान क्या कार्य किया जाना
चाहिए?)
 Activity to be done when Unplanned Change? – (अनियोजित परिवर्तन के दौरान क्या कार्य किया जाना
चाहिए?)
 Activity to be done when Abnormal Change? – (असामान्य परिवर्तन के दौरान क्या कार्य किया जाना
चाहिए?)
WHAT IS IT PURPOSE?
 इस का उद्देश्य 4 M (मैन, मटेरियल, मेथोड, मशीन) के बदलने
पर बदलाव को नियंत्रण करने के लिए इस्तेमाल होने वाली
विधियों को परिभाषित करना है, जो उत्पाद की प्राप्ति को प्रभावित
करती हैं।
 WHAT IS 4M?
 Man (मैन) - आदमी
 Material (मटेरियल) - सामग्री
 Method (मेथड) - तरीका
 Machine (मशीन) - मशीन
4M CHANGE COMMUNICATION?
 Operator ->
 Supervisor ->
 Plant Incharge ->
 Quality Incharge ->
 Shop Floor ->
 Customer (if required)
4M CHANGE CATEGORY?
 Planned /Expected Change
 (नियोजित / अपेक्षित परिवर्तन)
 Unplanned / Unexpected Change
 (अनियोजित / अप्रत्याशित परिवर्तन)
 Abnormal Change
 (असामान्य परिवर्तन)
 4M CHANGE PROCESS FLOW
4M Change

Category

Planned / Unplanned /
Abnormal
Expected Unexpected
Change
Change Change
Set-up Set-up Set-up
Approval Approval Approval
Start Start Start
Production Production Production
Retroactive Identify
Checking Suspect Lot
 4M CHANGE CATEGORY - PLANNED
Activities to be done
Planned
Change /
Changed Action
4M Unplanned Set-Up Retroactive Suspected
Description Taken Change / Remarks
Approval Inspection lot check
Abnormality

Operator of same skill No need to fill 4M

deputed (who has been Planned Change Record as
Yes No No
working on the station Change decided by Production
Operator On frequently) Head.
leave with
information
Operator of same skill
deputed (Operator Planned
Yes No No Set-up approval
deputed to work station Change
after long duration)
Man

Operator On
leave without
Operator of same skill Planned
information Yes No No Set-up approval
deputed Change
(during start of
shift)

No need to fill 4M
Operator on Job Operator of same skill Planned Change Record as
Yes No No
rotation deputed Change decided by Production
Head.
 4M CHANGE CATEGORY - PLANNED
Activities to be done
Planned
Change /
Changed Action
4M Unplanned Set-Up Retroactive Suspected
Description Taken Change / Remarks
Approval Inspection lot check
Abnormality

Planned Set-up
New Joining of Operator Operator of same skill deputed Yes No No
Change approval
Man

Production run by same Planned Set-up

Shift Extended Yes No No
operator Change approval

Machine under preventive Production shifted to same Planned Set-up

Yes No No
maintenance capacity m/c Change approval
Machine/Tool

Tool/Mould under Production done with 2nd set Planned Set-up

Yes No No
preventive maintenance of Tool/Mould Change approval

Restart the m/c after changing

Power Source changed Planned Set-up
the machine parameters, if Yes No No
with intimation Change approval
required

Material received from

Material

other approved source Start production after set up Planned Set-up

Yes No No
(usually not being used approval Change approval
regularly)
Process sequence /
etho

Start production after set up Planned Set-up

Additional / New technology Yes No No
d

approval Change approval

 4M CHANGE CATEGORY - UNPLANNED Activities to be done
Planned
Change /
Changed Action
4M Unplanned Set-Up Retroactive Suspected
Description Taken Remarks
Change / Approval Inspection lot check
Abnormality

Check all the parts

Operator suddenly leave work
Operator of same skill Unplanned produced by the
Man

place due to accident/illness Yes Yes No

deputed Change operator since last
(after start of production)
inspection

Check all the parts

Machine/

Production shifted to same Unplanned produced since last

Tool

Machine under break down Yes Yes No

capacity m/c Change inspection before m/c
breakdown

Check all the parts

produced since last
Production done with 2nd Unplanned
Tool/Mould under break down Yes Yes No inspection before
set of Tool/Mould Change
Tool /Mould
breakdown
Check last part
Unplanned
Power Failure Restart the m/c Yes Yes No produced before
Change
power failure
Restart the m/c after
Check last part
Power Source changed after changing the Unplanned
Yes Yes No produced before
power failure machine parameters, if Change
power failure
required

Process sequence / Additional / Check all the parts

thod

Start production under Unplanned

 4M CHANGE CATEGORY - ABNORMAL

Activities to be done
Planned
Change /
Changed Action
4M Unplanned Set-Up Retroactive Suspected
Description Taken Change / Remarks
Approval Inspection lot check
Abnormality

Operator On
Check all the
leave without Operator of under Abnormal
Man

Yes No Yes parts produced

information skill deputed Situation
by the operator
(during start of
shift)
1. Check all the
Operator parts produced by
suddenly leave the operator since
work place due to Operator of under Abnormal last inspection
Yes Yes Yes
accident/illness skill deputed Situation 2. Check all the
(after start of parts produced
production) by the new
operator
Check all the
Operator on Job Operator of under Abnormal
Yes No Yes parts produced
rotation skill deputed Situation
by the operator
[Link] all the
parts produced
New Joining of Operator of under Abnormal by the operator
Yes No Yes
Operator skill deputed Situation 2. Training
provided for skill
improvement
 4M CHANGE CATEGORY - ABNORMAL

Activities to be done
Planned
Change /
Changed Action
4M Unplanned Set-Up Retroactive Suspected
Description Taken Change / Remarks
Approval Inspection lot check
Abnormality

Machine under Production shifted to

Abnormal Check all the parts
preventive higher/ Yes No Yes
Situation produced by the machine
maintenance lower capacity m/c
Production shifted to Check all the parts
Machine under break Abnormal
higher/ Yes Yes Yes produced by the new
down Situation
lower capacity m/c machine
Production done with Check all the parts
Tool/Mould under Abnormal
temporarily repaired Yes Yes Yes produced with the
break down Situation
Die/Tool/Mould Tool/Mould after repair
Machine/Tool

Machine parameters
Machine started after Check all the parts
found out of spec. Abnormal
resetting Yes Yes Yes produced since last check
during routine Situation
the parameters of parameters
checking
[Link] all the parts
produced since last
Machine started after poka Abnormal
Poka Yoke Failure Yes Yes Yes inspection
yoke verified corrected Situation
2. Check all the parts
produced by the machine
Check all the parts
Repeated Power Abnormal
Restart the m/c Yes Yes Yes produced since start of
Failure Situation
power failures
 4M CHANGE CATEGORY - ABNORMAL

Activities to be done
Planned
Change /
Changed Action
4M Unplanned Set-Up Retroactive Suspected
Description Taken Change / Remarks
Approval Inspection lot check
Abnormality

Material used from

Start production with Abnormal
unapproved source Yes Yes Yes Reject all the material
Material

approved source material Situation

without intimation
Different grade Start production with OK Abnormal
Yes Yes Yes Reject all the material
material used material Situation
[Link]-up approval
Method

Inspection Start work after set up Abnormal 2. Check all the parts
Yes Yes Yes
Breakdown approval Situation produced by the operator
since last inspection