WORK INSTRUCTION FOR 4M CHANGE

Activities To be Done
Planned change /
4M Change Description Action Taken Unplanned change / Retroactive Containment
Set Approval
Abnormality Inspection Action Remarks
(A)
(B) (C)
Operator of same skill level
Planned change Yes No No A. Take setup approval
deputed
Operator on leave with A. Take setup approval
information Operator of under skill level C. Check all parts 100% visually. Check parts
Abnormality Yes No Yes
deputed dimensionally as per control plan & keep 5 parts
record
Operator of same skill level
Planned change Yes No No A. Take setup approval
Operator on leave without deputed
information C. Check all parts 100% visually. Check parts
(during start of shift) Operator of under skill level
Abnormal change Yes No Yes dimensionally as per control plan & keep 5 parts
deputed
record
A. Take setup approval
Providde training as per C. Check all parts 100% visually. Check parts
New operator Planned change Yes No Yes
Operation standard dimensionally as per control plan & keep 5 parts
record
Operator of same skill level
Job rotation Planned change Yes No No A. Take setup approval
deputed
A. Prepare poison test report
New PDI inspector Conduct poison test Planned change Yes No Yes C. If not qualify, provide training and reconduct the
Man poison test before deputing
A. Take setup approval
Considered as a new operator
Operator on long leave (More C. Check all parts 100% visually. Check parts
(provide training as per Planned change Yes No Yes
than 15 days) dimensionally as per control plan & keep 5 parts
operation standard)
record
Provide separate bins for parts C. Check all parts 100% visually. Check parts
Extended shift (More than 8
produced during extwended Abnormality No No Yes dimensionally as per control plan & keep 5 parts
hours)
shift record
 Man

Activities To be Done
Planned change /
4M Change Description Action Taken Unplanned change / Retroactive Containment
Set Approval
Abnormality Inspection Action Remarks
(A)
(B) (C)
A. Take setup approval
Operator suddenly leave work
Operator of same skill level B. Check all parts 100% visually since last
place due to accident (after Unplanned change Yes Yes No
deputed inspection. Check parts dimensionally as per
start of production)
control plan & keep 5 parts record
A. Take setup approval
Operator of same skill level B. Check all parts 100% visually since last
Unplanned change Yes Yes No
deputed inspection. Check parts dimensionally as per
Operator suddenly leave work control plan & keep 5 parts record
place due to illness (after start A. Take setup approval
of production) B. Take retroactive inspection
Operator of under skill level
Abnormality Yes Yes Yes C. Check all parts 100% visually. Check parts
deputed
dimensionally as per control plan & keep 5 parts
record

Working on same machine after

Planned change Yes No No A. Take setup approval
preventive maintenance
Machine under preventive
maintenance
Production shifted to same
Planned change Yes No No A. Take setup approval
capacity machine

A. Take setup approval

Working on same machime B&C. Check all parts 100% visually since last
Unplanned change Yes Yes Yes
after repair inspection. Check parts dimensionally as per
control plan & keep 5 parts record
Machine under breakdown
A. Take setup approval
Production shifted to same B. Check all parts 100% visually since last
Unplanned change Yes Yes No
capacity machine inspection. Check parts dimensionally as per
control plan & keep 5 parts record
New machine Working with new machine Planned change Yes No No A. Take setup approval
A. Take setup approval
Machine B. Check all parts 100% visually since last
Tool / insert broken Working with new tool / insert Unplanned change Yes Yes No
inspection. Check parts dimensionally as per
control plan & keep 5 parts record
Poka yoke Addition of poka yoke Planned change Yes No No A. Take setup approval
 Activities To be Done
Machine Planned change /
4M Change Description Action Taken Unplanned change / Retroactive Containment
Set Approval
Abnormality Inspection Action Remarks
(A)
(B) (C)
A. Take setup approval
Working on machine after poka B. Check all parts 100% visually since last
Unplanned change Yes Yes No
yoke repair inspection. Check parts dimensionally as per
control plan & keep 5 parts record
Poka yoke not working or under
A. Take setup approval
breakdown
B. Take retroactive inspection
Poka yoke bypassed Abnormal change Yes Yes Yes C. Check all parts 100% visually. Check parts
dimensionally as per control plan & keep 5 parts
record
A. Take setup approval
C. Check all parts 100% visually since last
Power failure Re-start the machine Unplanned change Yes No Yes
inspection. Check parts dimensionally as per
control plan & keep 5 parts record

Material received from other Start production after setup

Planned change Yes No No A. Take setup approval
approved source approval

A. Take setup approval

B. Take retroactive inspection
Material Same grade material used Unplanned change Yes Yes Yes
C. Check the received material MTC, if found ok
Material used from other release for production
unapproved source A. Take setup approval
B. Take retroactive inspection
Different grade material used Abnormal change Yes Yes Yes
C. Release to production after getting approval
from customer
A. Take setup approval
Start production after getting
C. Check all parts 100% visually. Check parts
approval from Quality & Planned change Yes No Yes
dimensionally as per control plan & keep 5 parts
Customer
record
Any change in process
A. Take setup approval
parameter
B. Take retroactive inspection
Machine parameter found out
Abnormal change Yes Yes Yes C. Check all parts 100% visually. Check parts
of spec. during routine checking
dimensionally as per control plan & keep 5 parts
Method record

Start of production after setup A. Take setup approval

Any change in process method
approval from quality & Planned change Yes No Yes C. Update related documents after parts are ok as
(ECN/PCN)
customer per drawing
Method Activities To be Done
Planned change /
4M Change Description Action Taken Unplanned change / Retroactive Containment
Set Approval
Abnormality Inspection Action Remarks
(A)
(B) (C)

Start of production after setup A. Take setup approval

Any change in process sequence approval from quality & Planned change Yes No Yes C. Update related documents after parts are ok as
customer per drawing

During retroactive inspection check all parts 100% visually since last inspection, check the parts dimwnsionally as per control plan
Note During containment action check all the parts 100% visually produced during shift, check the parts dimwnsionally as per control plan
Link all retroactive inspected parts with invoice for traceability