4M change

1. 4M Change &
Abnormal Handling
Procedure

2. Agenda
￮ Purpose & Definitions
￮ What is 4M
￮ What is Process
￮ 4M Change Category
￮ 4M Change Process Flow
￮ 4M Change Examples
￮ 4M Change Handling Procedure
￮ 4M Change Monitoring Criteria
￮ 4M Change Communication System
￮ 4M Change & Abnormal Conditions Management System
￮ 4M Change Monitoring Sheet
￮ 4M Change PDCA Cycle
￮ Thanks Note

3. Purpose & Definition
Purpose
The Organization shall monitor
the effect of change in 4M (Man
, Machine, Material , Method )
Condition & Control the
situation which affecting the
finished product
Definition
Any Addition , Updation
or Deletion from pre-
Approved procedure is
called 4M Change.
4M (आदमी, मशीन, सामग्री, विधि) स्थिति में
परिवर्तन के प्रभाव की निगरानी करना और उस
स्थिति को नियंत्रित करना जो तैयार उत्पाद को
प्रभावित कर रहा है !
पूर्व-अनुमोदित प्रक्रिया में कोई भी जोड़,
अद्यतनीकरण या हटाना 4M परिवर्तन
कहलाता है !

4. Objective & Definition
Definition
A Condition that occurs in
a Process system When
an Operating Variable
(Flow , Temperature,
Pressure etc.) ranges
outside of its Normal
Operating Limits.
Objective
The Objective of
Abnormal Situation
Management is to Return
The Process to Normal
before Safety System and
Defects are Engaged
असामान्य स्थिति प्रबंधन का उद्देश्य
सुरक्षा प्रणाली और दोष उत्पन्न होने से
पहले प्रक्रिया को सामान्य स्थिति में
लौटाना है !
एक ऐसी स्थिति जो एक प्रक्रिया
प्रणाली में तब घटित होती
है जब एक ऑपरेटिंग वेरिएबल
(प्रवाह, तापमान, दबाव आदि)
अपनी सामान्य ऑपरेटिंग सीमाओं से
बाहर होता है

5. 01
02
03
04
Man
Who works in a process to manufacture a Use full
Product
Machine
By Which a Product is being manufactured.
Material
Raw Material which is being used for
manufacture the Product
Method
The Method by which A product is being
produced.
What is 4M
These are the resources which is used to convert Input Material into Output Material.

6. What is Process
Process
A process of Activity which converts input material in output
material with the utilization of Available Resources.
These available Resources are called 4M. Man , Machine , Material
, Method
एक प्रक्रिया गतिविधि का एक समूह है जो उपलब्ध संसाधनों के
उपयोग के साथ इनपुट सामग्री को आउटपुट सामग्री में परिवर्तित
करती है।
इन उपलब्ध संसाधनों को 4M कहा जाता है।

7. Process (As per ISO 9001 :2015)

8. Process (GB Enterprises Pvt. Ltd.)
MotherCoil Slitting RollForming
Packing
FG Product
Dispatch
SlittingCoil

9. 4M Change Category - Definition
Planned Change
When We have
information about
any change within
The Organization ,
It is called Planned
Change.
Unplanned
Change
When We do not
have information
about any change
within the
organization , It
is called
Unplanned
Change
Abnormal
Condition
When any
Undesired
condition occurs
against defined
Procedure , It is
called Abnormal
Condition.
असामान्य स्थिति –
जब कोई अवांछित
स्थिति निर्धारित प्रक्रिया
के विपरीत उत्पन्न होती
है तो उसे असामान्य
स्थिति कहा जाता है।
अनियोजित परिवर्तन -
जब हमें किसी परिवर्तन
के बारे में कोई
जानकारी नहीं होती
तो उसे अनियोजित
परिवर्तन कहा जाता है।
नियोजित परिवर्तन –
जब हमारे पास किसी
परिवर्तन की जानकारी
होती है तो उसे नियोजित
परिवर्तन कहा जाता है

10. 4M Change Process Flow
Set Up Approval
Category
Planned Change
Unplanned Planned
Change
Abnormal Change
4M Change
Start Production
Set Up Approval
Start Production
Retro-Active
Checking
Set Up Approval
Start Production
Identify Suspected
Lot

11. Method Material
Man Machine
4M
Example
4M Change Examples
Are the Work Standard Adequate
Is the Work Standard Adequate
Is it a Safe Method
Is it a Method that ensures a Good Product
Is it an efficient method
Is the Sequence of work adequate
Is the set up adequate
Are the temperature and humidity adequate
Are the lighting and ventilation adequate
Is there adequate contact with the previous
and next processes
Does he follow standard.
Is his work efficiency acceptable
Is he problem conscious
Is he responsible / accountable
Is he qualified
Is he experienced
Is he assigned to the right job
Is he willing to improve
Does He maintain Good Human Relations
Is he fit & Healthy
Does it meet production requirements.
Does it meet process capabilities.
Si the lubrication adequate
Is the inspection adequate
Is operation Interrupted due to machine trouble.
Does It meet precision requirements.
Does it make any unusual noises
Is the layout Adequate
Are there enough machines / facilities
Is everything in Good Working order
Are there any mistakes in Volume.
Are there any mistakes in Grade
Are there any mistakes in brand Name
Are there impurities mixed in
Is the Inventory Level Adequate
Is there any waste in material
Is the Storage Layout Adequate
Is the Quality Standard Adequate

12. 4M Change Handling Procedure

13. 4M Change Handling Procedure

14. 4M Change Monitoring Criteria
Set Up Approval to be done
Planned Changes
100% Visual Inspection
Move to Next Operation
Set Up Approval to be done
Unplanned Change
100% Retroactive
Inspection to be done
100%Visual Inspection to
be done of Suspected Lot
Move to next Operation

15. 4M Change Escalation (Information) Flow
Monitoring Criteria
Inform To Concern
Supervisor (Operator)
Planned Change
Concern Supervisor takes
approval from concern
Head
Fill the 4M Change Request
Form
Production Sup. Inform to
QA Head by 4M Change
Req. Form
Verify the change by Set Up
Approval
100% Visual Inspection
Inform To Concern
Supervisor (Operator)
Unplanned Change
Concern Supervisor takes
approval from concern
Head
Fill the 4M Change Request
Form
Production Sup. Inform to
QA Head by 4M Change
Req. Form
Verify the change by Set Up
Approval
100% Visual Inspection of
Suspected Lot
Start of Production
by Quality Sup.
100% Retroactive
Inspection

16. 4M Change & Abnormal Situation Management

17. 4M Change & Abnormal Situation Management

18. 4M Change & Abnormal Situation Management

19. 4M Change & Abnormal Situation Management

20. 4M Change Monitoring Sheet

21. ACT CHECK
PLAN DO
4M
PDCA
Cycle
Plan-Do-Check-Act for 4M Change
Take Preventive
Actions as required
Define the 4M Change
Monitoring Procedure
Implement the 4M
Procedure
Monitor 4M Conditions &
Check Effectiveness

22. Thanks!
Any questions?