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4M Change Management
Overview 4 M – Rollout @ GS in 2015 / 2016
What is 4M Objective of 4M
• 4M is a method for planning and tracking of changes in the • Visualisation and exchange of information about all
production process in accordance with defined responsibilities intentional and incidental changes
• the changes are classified into the 4M´s: • Monitoring of the change control method and result
Man, Machine, Material, Method confirmation
Advantages:
• Regular and systematic information exchange
• All concerned functions are participating in daily routine
• Preventive Approach: Problem avoidance instead of problem solving
Advantages:
• Well-defined procedure for implementation changes in the shop floor No firefighting
• 4M templates are available; plant specific modifications are explicitly allowed
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4M Change Management - Management Briefing
“How to” – Central Theme
4M Change Matrix: Listing of intended and incidental changes with control and documentation method
purpose:
procedure:
Specification of intentional / incidental change point with control method and responsibilities
Restart Checklist
△
Responsibilities
4M Category Change Point control method documentation method Operator Fitter Teamleader Shift Supervisor Supervisor Planner Senior Manager Director QMM TEF
TPM instruction
additional measuring and testing equipment test instruction KEB-Production ● ◎ ○△ ◎
MAE regular maintenance (TPM) TPM instruction TMP check sheet ● ●△ ◎ ○ ◎
relocation of MAE ECR Serial Release ○● ◎ △
exchange of workpiece carrier TPM instruction TMP check sheet ● ○●△◎
intentional
change
exchange of tooling, fixture
Change over
TPM instruction
maintenance and restart
TMP check sheet
maintenance and restart
● ○●△◎
● ○△ ◎
…
check sheet check sheet
Documentation Method
maintenance and restart maintenance and restart
replacement of MAE components (e.g. repair work) ○●△ ◎ ◎ ●
check sheet check sheet
MAE modification ECR Oracle DB (SAP) ● ○△ ◎ ●
Machine
maintenance and restart maintenance and restart
restart ●△ ○ ◎
check sheet check sheet
Restart Checklist
machine breakdown, error without TEF support ●△
check sheet check sheet
incidental machine breakdown, error with TEF support malfunction message SAP △ ●
change maschine stop with andon cord / high scarp rate escalation model Shift book ● △ ◎
…
intentional
change maintenance and restart
Change of maintenance and restart specification KEB-Production ● ◎ ○●△ ◎
Method check sheet
Responsibilities
deviation from production process E-Mail to Planner Outlook ●△ ●△
incidental
change
Grund:
geplanter
Umbau
Reparatur, Tausch
laufende Nummer (optional)
Beschädigung
/ Crash / BA
Störung / Stillstand /
hoher AS
☐ What happened?
☐ Short description of problem / cause
Datum: Uhrzeit: Linie: Station:
IST-Situation: Problem, Ursache
Teil A: Durch Einsteller/Maschinenführer
Ergebnis Rückverlesen:
i.O. n.i.O.
☐ Validation by Supervisor
☐ Validation by different sections if necessary (e.g. MFT, TEF, MOE, Planner, …)
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4M Change Management - Management Briefing
“How to” – Central Theme
4M Change Point Record Sheet: Listing of all effectuated intended and incidental changes
Change Point describtion and implementation change control method result confirmation
1 13.01.2015 Miller machine testing replacement of proximity switch No. 251-A TEF- Arnold 13.01.2015 maintenance and restart check sheet ok Sanders
2 15.01.2015 Buck man visual inspection new operator Buck 20.01.2015 training plan completed ok Miller
3 15.01.2015 Buck material assembly old: holding plate …05 254 new: ..05 257 Buck 15.01.2015 ECR closed, first serial No. with new material ..861 ok Richards
4 19.01.2015 Miller method testing new process specification St3: 25mA --> 19mA Haynes tdb Richards
5 23.01.2015 Miller machine assembly planned maintenance St. 3-6 Miller TPM instructions not followed follow-up Buck
• Personnel Change / Rotation • MAE modification • new component • Process Engineering Change
• Support from other dept. • replacement of measuring and • Design Change according to CDQ
• New Operator testing equipment • subsidiary material change • change of process specification
Intentional
• Change of standardized work • software change / software update • overstay of storage life • change of test specification
• No of operators in the loop • replacement of MAE components • change of TPM specification
• Work after planed holidays • restart
• exchange of tooling, fixture
• incidental absent of operator • machine breakdown • material outside • deviation from production
• incidental support from / to • damage of tooling, fixture specification process
Incidental
Shared Content
Detection of incidental change
Operator skill matrix
Standardized Work
Optional Elements
Operator allocation
Change Point Indication Card
• Daily Management / Shop Floor Routine • MD to describe standard, process and • P5 – Process Parameters
• Link to BPS – System Approach mandatory / optional elements of method • P7 – TPM
• Link to BPS Elements in combination with 14 • Integration in PI for ECR as mandatory • P8 – Tools
Q-Basics Value Stream standard for minor Changes (w/o ECR) • P9 – Restart
manufacturing process. Um die Auswirkungen einer Änderung auf den Fertigungsprozess bewerten zu können, sollten alle Änderungen — auch Änderungen
When required by the customer, the organization shall: bei Lieferanten — einen Produktionsprobelauf zur Veri fizierung der Änderung erforderlich machen (wie zum Beispiel Änderungen an
e) notify the customer of any planned product realization changes atter the most recent product approval; der Auslegung des Produktes, Verlagerung des Produktionsstandortes oder Änderungen am Fertigungsprozess).
f) obtain documented approval, prior to implementation of the change;
g) complete additional veri fication or identification requirements, such as production trial run and new product validation. Wenn vom Kunden gefordert, muss die Organisation:
e) den Kunden über jede beabsichtigte Änderung am Produktrealisierungsprozess nach der letztgültigen Freigabe informieren,
f) eine dokumentierte Freigabe einholen, bevor die Änderung umgesetzt wird,
g) alle Maßnahmen zur Erfüllung zusätzlicher Anforderungen zu Veri fizierung oder Kennzeichnung, wie Produktionsprobelauf oder
erneute Produktvalidierung, abgeschlossen haben.
Changes without formal ECR Process: changes without formal ECR process are process-/ method-related
changes for optimization of processes and flows within the limits specified with the customer and within the
internally specified limits (no change with respect to fit, form, function and reliability of components).
The change is classified on the basis of Attachment 4 "Customer Involvement matrix” footnote 1).
If a change does not have any effect on the product bill of materials (BOM), test specifications, offer
drawings, TCD, drawings (product drawings, tool-drawings with effect on product) or similar, then it can be
handled as change without formal ECR process and in these cases without formal documentation.
Safeguarding against risks must be carried out and documented. The documentation must suffice the basic
principles of traceability. (extract from CDQ0404 Att 5)
The organization shall implement traceability of all product produced while any altemate process control devices or processes are Nach Wiedereinsetzen der ursprünglich geplanten Maßnahmen zur Prozesslenkung sind entsprechende Überprüfungen für einen
being used (e.g., veri fication and retention of first piece and last piece from every shift). festgelegten Zeitraum aufrechtzuerhalten und zu dokumentieren. Für den Überprüfungszeitraum maßgebend sind die Tragweite und die
Bestätigung, dass alle Funktionen/Eigenschaften der ursprünglichen Prüf- und Messmittel oder -prozesse wirksam wiederhergestellt sind.
Die Organisation muss die Rückverfolgbarkeit aller produzierten Produkte sicherstellen, die während des Einsatzes von alternativen Prüf-
und Messmitteln oder -prozessen hergestellt wurden (z. B. Überprüfung und Aufbewahrung der Erststücke und Letztteile jeder Schicht).
Documentation of process that manages the use of alternate methods incl. standard work instructions
Internal approvals prior to implementation defined in 4M Change Matrix e.g. Concession
Daily leadership meeting / LPA and LPC (Process Confirmation)
4M Integration in Daily shop floor routine / Daily management
Restart verification documented and assured that all features of error-proofing device are effectively installed
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© Robert Bosch GmbH 2017. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
4M Change Management - Briefing session
IATF 16949:2016
8.5.1.3 Verifi cation of job set— ups 8.5.1.3 Verifi zierung von Einrichtvorgängen
The organization shall: Die Organisation muss:
a) verify job set-ups when performed, such as an initial run of a job, material changeover, or job change that a) Einrichtvorgänge überprüfen, unter anderem bei einem Erstanlauf der Fertigung, nach Materialwechsel oder
requires a new set-up; nach Anderungen am Fertigungsablauf, die eine Neueinrichtung der Fertigungsanlagen erfordem,
b) maintain documented information for set-up personnel; b) dokumentierte Informationen für die Maschineneinrichter aufrechterhalten,
c) use statistical methods of veri fication, where applicable; c) statistische Verfahren zur Verifizierung einsetzen, sofem möglich, MODIFIED
d) perform first-off/last-off part validation, as applicable; where appropriate, first-off parts should be retained for d) Erst-lLetztteilbewertungen durchführen, soweit anwendbar. Wo angebracht, sollten die Erststücke IATF16949:2016
comparison with the last-off parts; where appropriate, last-off-parts should be retained for comparison with first- zum Vergleich mit den Letztteilen aufbewahrt werden. Wo angebracht, sollten die Letztteile zum
off parts in subsequent runs; Vergleich mit den Erststücken nachfolgender Fertigungsläufe aufbewahrt werden,
e) retain records of process and product approval following set-up and first— off/last-off part e) Aufzeichnungen über die den Einrichtvorgängen und Erststück-Letztteilbewertungen folgenden
Produktionsprozess- und Produktfreigaben aufbewahren.
8.5.1.4 Verifi cation after shutdown 8.5.1.4 Verifi zierung nach Produktionsstillstand
The organization shall define and implement the necessary actions to ensure product compliance with Die Organisation muss notwendige Maßnahmen definieren und einleiten, um sicherzustellen, dass die NEW
requirements after a planned or unplanned production shutdown period. Produkte nach einer geplanten oder ungeplanten Unterbrechung der Fertigung die Anforderungen erfüllen. IATF16949:2016
P7: TPM
All these principles have a strong planning topic and are considered in the IQP Process
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COACHING AND
SUPPORT CONCEPT
Q-Basics (VS) Strategy 2017 / 2018
Coaching and Support Concept based on CRI (IQIS BA10,20,21 – 0 km / 0 mileage)
CRI violating – Q-Basics Planning MRC…”Not planned”
IQP – Integrated
Quality Planning ** CRI violating – Q-Basics Execution MRC…“Not fulfilled”
Prepare Series *
Production
Working according to
Standards
Coaching / Support Concept
BPS PGL * LPC / Daily routine
IQP Q-Basics
4M Change - Management • Maturity Evaluation for IQP • Maturity Evaluation for 14 Q-Basics (VS)
SE – Team / ISEC * • Briefing Sessions for IQP • Training / Coaching in CIP (e.g. KPI)
• FMEA and CP • LPC – Process Confirmation
Mindset / Leadership
• SPC, Capabilities, … • Learn to See
• Inspection Strategy Product <-> Process • 4M Change management
8D, PS, LL + IPN LL / 8 D / Problem Solving
Transfer ** (Lead plant)
* Preventive Approach – Before SOP; ** Preventive – Before SOP + Event-driven Reviews – After SOP e.g. 8D, ECR, LL in IPN, …
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© Robert Bosch GmbH 2017. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Q-Basics (VS) Strategy 2017 / 2018
Coaching Concept
• CRI (Customer Related Incidents) • IQP (Integrated Quality Planning) • Preventive Approach in SE Teams
• Deviations (Audit, iDC, …) • Capability and SPC • Mature Products and Processes
• LPC (Layered Process Confirmation) • 14 Q-Basics (VS) + BPS PGL • Safe Launch and high productivity
• Maturity Evaluation • 4M Change Mgmt.
• Improvement Work – PDCA • Mini - Training e.g. Restart • True North: Zero defects
RODEZ: RESTART
CUSTOMER (RENAULT) REQUIREMENT FOR
PROCEDURE AFTER MAINTENANCE
Mini – Training: 14 Q-Basics (VS) Principle 9 – Restart
WS 4M Change Management / Restart after TPM – RzP (DS)
• 4M Matrix – Template 4M
• Restart form – AdP
• Q-”Wiederfreigabe” – WaP
• Restart Flow Chart – RzP
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Mini – Training: 14 Q-Basics (VS) Principle 9 – Restart
Listing of interventions on the machine
FMEA as important input
FMEA
for Priorisation / criticality
for product quality!
Machine
Dressing of tool
Tool change
Maintenance
Preventive
Deep dive into details
‒ Shop floor
Which elements?
‒ TEF
‒ Set-up mechanic
Who is responsible?
Test performed after intervention?
Curative
‒ TEF What kind / how many parts?
‒ Set-up mechanic Where are is it documented?
Adjustment …
Changes in process
Changes in personnel, …
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© Robert Bosch GmbH 2017. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Mini – Training: 14 Q-Basics (VS) Principle 9 – Restart
Results after WS – Matrix and Release form
4M Change Matrix Release from for Restart
Matrice du changement 4M Fiche de validation de redémarrage
Est-ce que ce cas est pris en compte dans la matrice 4M : OUI / NON
Est-ce que ce cas influence la qualité : OUI / NON
Atelier: MSN At 970 Ligne: Rectification aiguille HTT Si le cas influence la qualité et qu'il n'est pas pris en compte dans la matrice 4M alors prévenir le N+1
Objectif: Désignation des modifications planifiées et non planifiées des critères de vérification Situation actuelle: Problème, Raison
OT validé (SAP)
Besoin de créer un doc de validation de
Maintenance préventive faite par TEF SAP X oui △ ◎
redémarrage pour les différents niveaux
d'intervention
Fiche de
Action / Modification réussie?
Maintenance 1er Niveau Listing SAP - - ●△ ◎
maintenance Oui Non Pas encore confirmée
Redémarrage fait:
Date: Heure: Régleur / Chef d'équipe
ECR OK Non OK
Nouveau fournisseur de pièces achetées (EZRS) Mode Op chez MSI non
Nomenclature
artie C:
OK Non OK
plant
1.
produ
ct
Use existing
tools
Analog
Visualization
Digital
Visualization
WaP 4M Procedure:
Änderungsverfolgung
Visualisierung über Monitor
4M Change Matrix: