SL 4M Change Management Briefing en

4M CHANGE MANAGEMENT
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
• 4M is used in the shop floor • Systematic tracking of changes
• the changes are classified into the 4M´s: • Monitoring of the change control method and result
Man, Machine, Material, Method confirmation
Procedure and status Schedule
Plants group I: BaP; BhP; BuP1; EhP; FeP-Ru;

MuP; NuP1; RBCB; RBEF; TbP; WaP
Plants group II: AdP; CaP; ChP; DaeP; AmaP;

UAES; HcP; TlP; SlpP; BljP; GanP
2 Internal | GS/QMM2 - Steffl | 04.07.2017

170072
© 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.
Big Picture
Situation: Incidents, sorting actions , recursions
• Instructions not followed
• Changes not validated / not sufficiently validated
• Responsibilities not clear / not clearly defined
Action: 4M is structuring specifications

• Focus: minor changes (changes w/o formal ECR process) and implementation of ECR
• Strength: Communication and Visualization
• Clearly defined responsibilities
• Integrations in existing process landscape and tools
Result: standardized, validated procedure

 what, how, who, when
• No “wild” changes in the shop floor
• Validation of effectiveness
• Traceability

170072
4M as part of daily management / daily routine
Change / Software-
Change of Change of
Maintenance change
gauges process
Implementation of St. 130 St. 10
Daily routine 4M: ECR on shop floor parameters
Review Process Confirmation of last /

shortly implemented changes
Actual Which changes are running / New New PQI /
planned for today employee Instruction
Preview Which (additional) changes are
planned for the upcoming days
Participants: Team leader, QMM, supporting function e.g. TEF, MOE-Planner
Advantages:
• Regular and systematic information exchange
• All concerned functions are participating in daily routine
• Preventive Approach: Problem avoidance instead of problem solving

170072
4M as part of daily management / shop floor routine
Daily Management 4M Change Management
• Focus: Deviation Management • Focus: Change Management
Strength: Strength:
• Detect deviations • Avoid deviations
• Measures to return to standard • Method to implement changes w/o negative
impact on the production porcess
5 Internal | GS/QMM2-Steffl | 04.07.2017

170072
Supporting Documents
Rules and Standards: 4M Change Matrix
• Overview (existing) specification for implementing and validation of changes
• Clear responsibilities
• …
Outlook: 4M Intentional Change Management Schedule

• Visualization: Which changes are planned?
• Communication: One document instead of loads of e-mails, verbal information, …
• Common understanding (shift overlapping)
Systematic implementation: 4M Change Point Record Sheet

• Documentation of actual changes
• What is changing / has changed
• Who is therefore responsible
• Effectiveness validation
Advantages:
• Well-defined procedure for implementation changes in the shop floor  No firefighting
• 4M templates are available; plant specific modifications are explicitly allowed
6 Internal | GS/QMM2 - Steff | 04.07.2017
170072
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
see the following matrix

Control Method
 Quality release form
legend: ○ preparation --> planning of the change
◎ approval --> approval for implementation
● implementation --> Implementation of the change
confirmation --> result confirmation
 Restart Checklist
△
Responsibilities
4M Category Change Point control method documentation method Operator Fitter Teamleader Shift Supervisor Supervisor Planner Senior Manager Director QMM TEF
 Test instruction / SPC

planned maintenance (additional to TPM) SAP SAP △ ◎ ○●
inspection of measuring and
replacement of measuring and testing equipment PM-Info ●*3 △ ○◎*2
testing equipment
 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) ○●△ ◎ ◎ ●
MAE modification ECR Oracle DB (SAP) ● ○△ ◎ ●
Machine
restart ●△ ○ ◎
damage of workpiece carrier

damage of tooling, fixture
TPM instruction
TPM instruction
E-Mail to Planner
E-Mail to Planner
●△
●△
 SAP / Shop floor documentation
 Restart Checklist
machine breakdown, error without TEF support ●△
incidental machine breakdown, error with TEF support malfunction message SAP △ ●
change maschine stop with andon cord / high scarp rate escalation model Shift book ● △ ◎
restart after breakdown / andon cord Quality release form

Quality release form / Change
Point record sheet
●△ ◎
 Change Point record sheet
Change of tool after tool break / crash Quality release form SPC mesurement ● ○●△ ◎
Process Engineering Change according to CDQ

Change of process specification
ECR
process data sheet
SAP
KEB-Production ● ◎
○●△
○●△
◎
◎
◎  TPM check sheet
Change of test specification test instruction KEB-Production ● ◎ ○●△ ◎
 …
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

170072
 Example for Quality Release form:
Werkstatt
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
☐ Planned action or breakdown / high scrap rate etc.

Beurteilung Auswirkung auf bereits gefertigte Teile: (auch Vorgängerfertigung)
(bei "Ja" und "möglich" müssen Teile gesperrt
☐ What do we have to do with the already produces parts?
Auswirkung auf gefertigte Teile? Nein Ja Möglich
☐ Block / sorting / scarp / rework?

und rückverlesen werden)
Begründung bei NEIN:

Teile gesperrt? Nein Ja Typ: Anzahl:
Teile rückverlesen? Nein Ja Typ: Anzahl:
☐ How many parts blocked / sorted and result of sorting

Rückverlesen nach: (z.B. 100% Sichtprüfung auf Beschädigung)
Ergebnis Rückverlesen:
☐ Action / Change Point

Aktion / Änderung (z.B. Reparatur, Tausch, Justierung, ...)
☐ Short description of action or change effectuated

Teil B: Durch Einsteller/Maschinenführer
Aktion / Änderung erfolgreich?
☐ Validation of action / change by responsible for action / change

Ja Nein Noch nicht abschätzbar
Weiteres Vorgehen:
Bei Unterstützung Service-MA Name und Abteilung für Rückfragen angeben:
☐ Validation of quality of the produced parts after change

Q-Wiederfreigabeprüfung nach Neustart Fertigung:
Beurteilung der nach Aktion / Änderung gefertigten Teile durch:
Prüfung nach PA Dummyprüfung Zusatzprüfung
Art der Zusatzprüfung:
☐ Additional test / serial test including results and quantity

(z.B. Abzugskraft, Schliff, ...)
Typ: Anzahl: Ergebnis:

Wiederfreigabe erfolgt am:
Datum: Uhrzeit: Einsteller / Anlagenführer
i.O. n.i.O.
☐ Validation by Supervisor latest in morning meeting

Kenntnisnahme (spätestens am Folgetag):
Datum: Uhrzeit: W.-Meister oder Meister oder Planer:
Meister oder Pl.
Teil C:
i.O. n.i.O.
☐ Transfer in 4M Matrix / Input for LL / Input for CIP projects

Aufnahme in Teilelebenslauf: Ja Nein Bei ja Info an Planer zum Eintrag in Lebenslauf
Prüfen ob Vorgang LL relevant: Ja Nein Bei ja Info an WaP LL Koordinator über Planer

170072
 Example for Restart / Machine Release from:
☐ Definition of interventions on the machine / stations
☐ Maintenance actions / Regular Maintenance
☐ Repairs and Replacement of different organs of the machine / station
☐ Adjustment on the machine / stations
☐ Process parameters / high adjustment / …
☐ Definition of which inspections / test have to be done after intervention
☐ Allocation of test numbers from table below
☐ Definition of different inspections / test to be done

☐ Definition of what, how, how many
☐ Definition of responsibility for inspection / test (e.g. Technician, MFE)
☐ Numeration for allocation the interventions in table above
☐ Validation by Supervisor
☐ Validation by different sections if necessary (e.g. MFT, TEF, MOE, Planner, …)
170072
 4M Change Point Record Sheet: Listing of all effectuated intended and incidental changes
Change Point describtion and implementation change control method result confirmation
consecutive responsible for

start date added by 4M station Change Point describtion end date describtion of the change control method result name
NO implementation
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
Change Point Decryption Control Method Confirmation

 Classified in the 4M – Man, Machine, Material, Method  Quality release form  Shop floor Mgmt.
 Concerned station / machine / area  Restart Checklist  Supervisor
 Who added that point and when?  Test instruction / SPC
 Who is responsible for the implementation  TPM instruction
Goal: Traceability and information of all changes over all shifts

170072
Case Examples for 4M change points
Men Machine Material Method
• 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
others • blackout of medium supply (air, • material defect

cooling water) • lot change
• transport damage
11 Internal | GS/QMM C/MPE | 04.07.2017

170072
4M Change Management - Briefing session
Overview Content (details see PNMD-505 4M Change Management)
Mandatory Elements
 Change Matrix
 Intentional Change Management Schedule
 Change Point record Sheet
Shared Content
 Detection of incidental change
 Operator skill matrix
 Standardized Work
Optional Elements
 Operator allocation
 Change Point Indication Card

170072
Sustainable implementation in rules and standards
QMS Powertrain:
 PNMD-505 4M | Change Management
 PNPI-312.01 – Manage Product and Process changes for ECR (Engineering Change request)
 PNMD-522 14 Q – Basics Value Stream (Maturity Evaluation for e.g. P9 – Restart)
BPS Guidelines:
 Link to Daily Management / “Daily Shop Floor Routine”
 Link to BPS – System Approach and BPS elements
BPS QMS 14 Q-Basics
System approach MD + PI Maturity evaluation
• 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
13 Internal | PS/QMM21-Steffl | 24.08.2018

170072
QMS Powertrain documentation (PNPI-312.01 + PNMD-505)

170072
PS BGN page 14 Q-Basics and 4M Change Management

170072
IATF16949 AND 4M
CHANGE MANAGEMENT
IATF 16949:2016
8.5.6.1 Control of changes — supplemental 8.5.6.1 Überwachung von Änderungen — Ergänzung
The organization shall have a documented process to control and react to changes that impact product realization. Die Organisation muss über einen dokumentierten Prozess zur Lenkung von und Reaktion auf Änderungen verfügen, welche die
The effects of any change, including those changes caused by the organization, the customer, or any supplier, shall be Produktrealisierung beeinflussen. Die Auswirkungen jeder Änderung müssen bewertet werden, gleichgültig, ob sie durch die
assessed. Organisation, den Kunden oder einen Lieferanten veranlasst werden.
The organization shall: Die Organisation muss:
a) define verification and validation activities to ensure compliance with customer requirements; a) Maßnahmen zu Veri fizierung und Validierung festlegen, um sicherzustellen, dass die Anforderungen der Kunden weiterhin erfüllt
b) validate changes before implementation; werden,
c) document the evidence of related risk analysis; b) Änderungen validieren, bevor sie umgesetzt werden,
d) retain records of veri fication and validation. c) Nachweise für eftsprechend durchgeführte Risikoanalysen erbringen,
Changes, including those made at suppliers, should require a production trial run for veri fication of changes (such as d) Aufzeichnungen über Veri fizierungen und Validierungen aufbewahren.
changes to part design, manufacturing location, or manufacturing process) to validate the impact of any changes on the MODIFIED
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.
 First level: ECR (Engineering Change request)

 Documented Process 
 Second level: Changes w/o formal ECR process (Acc. CDQ0404)
 Documented process (4M Matrix, Change Management Schedule, Change Point Record Sheet) 

170072
CDQ0404 – Attachment 4: Customer involvement matrix
Links:
CDQ0404
CDQ0404-Att 4
CDQ0404-Att 5
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)

170072
IATF 16949:2016
8.5.6.1.1 Temporary change of process controls 8.5.6.1.1 Zeitlich begrenzte Änderungen in der Produktionsprozesslenkung
The organization shall identify, document, and maintain a list of the process controls, including inspection, measuring, test, and error- Die Organisation muss eine Liste der Produktionsprozesslenkungsmaßnahmen — einschließlich der Prüf- und Messmittel — erstellen,
proofing devices, that includes the primary process control and the approved back-up or alternate methods. dokumentieren und pflegen, die sowohl die ursprünglich geplanten Methoden zur Prozesslenkung enthält als auch die freigegebenen
„Backup“- oder Alternativmethoden.
The organization shall document the process that manages the use of alternate control methods. The organization shall include in
this process, based on risk analysis (such as FMEA), severity, and the internal approvals to be obtained prior to production Die Organisation muss den Prozess dokumentieren, mit dem der Einsatz alternativer Steuerungs- und Überwachungsmethoden geregelt
implementation of the alternate control method. wird. Die Organisation muss in diesem Prozess festlegen, dass — auf Risikoanalysen (wie FMEA) und der Tragweite basierend — zunächst
interne Freigaben erfolgen müssen, bevor die alternativen Steuerungs- und Überwachungsmethoden in der Produktion umgesetzt werden.
Before shipping product that was inspected or tested using the alternate method, if required, the organization shall obtain approval
from the customer(s). The organization shall maintain and periodically review a list of approved alternate process control methods Bevor das mit alternativen Steuerungs- und Überwachungsmethoden geprüfte Produkt ausgeliefert wird, muss die Organisation eine
that are referenced in the control plan. entsprechende Freigabe des (der) Kunden einholen, sofern gefordert. Die Organisation muss eine Liste der freigegebenen und im PLP
referenzierten alternativen Methoden zur Produktionsprozesslenkung führen und in regelmäßigen Abständen überprüfen.
Standard work instructions shall be available for each alternate process control method. The organization shall review the operation
NEW
of alternate process controls on a daily basis, at a minimum, to verify implementation of standard work with the goal to retum to the Für alle alternativen Produktionsprozesslenkungsmaßnahmen müssen entsprechende Arbeitsanweisungen (standard work) vorliegen. Die
IATF16949:2016
standard process as defined by the control plan as soon as possible. Example methods include but are not limited to the following: Organisation muss die Anwendung der alternativen ProduktionsprozessIenkungsmaßnahmen mindestens einmal täglich überprüfen, um
a) daily quality focused audits (e.g., layered process audits, as applicable); sicherzustellen, dass die Anweisungen auch tatsächlich befolgt werden. Ziel ist es, so bald wie möglich zu den ursprünglichen, im
b) daily leadership meetings. Produktionslenkungsplan geplanten Methoden zur Prozesslenkung zurückzukehren. Beispielhafte Überprüfungen sind Folgende und
Weitere:
Restart verification is documented for a defined period based on severity and confirmation that all features of the error-proofing device a) tägliche qualitätsbezogene Audits (z. B. LPA — Layered Process Audits, wenn anwendbar),
or process are effectively reinstated. b) tägliche Treffen auf Leitungsebene.
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
170072
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
Direct Link to IQP (Integrated Quality Planning) and 14 Q-Basics (VS)

 P6: Check the Checker
 P9: Restart (8.5.1.2 Verification of job set-ups…requires new set-up  definition with 4M Change Matrix)
 P7: TPM
 All these principles have a strong planning topic and are considered in the IQP Process
170072
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, …
170072
Q-Basics (VS) Strategy 2017 / 2018
Coaching Concept
Event driven Support Coaching / Enabling Mature

Organization
• 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

170072
WS EXAMPLES FOR 4M
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
170072
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, …
170072
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
Atelier le numéro de série (en option)

Est-ce que ce cas est pris en compte dans la matrice 4M : OUI / NON Usure / Cassé / Défaut Arrêt / Problème sur machine/
Reparation,
Est-ce que ce cas influence la qualité : OUI / NON Raison: Modif planifié
Changement
X provenant du process
amont
Augmentation du taux de rebut en vert: non planifié
Si le cas influence la qualité et qu'il n'est pas pris en compte dans la matrice 4M alors prévenir le N+1
Date: Heure: Ligne: Station:
Objectif: Désignation des modifications planifiées et non planifiées des critères de vérification Situation actuelle: Problème, Raison
Procédure: Réalisation conformément Tableau
Légende: ○ Défini --> défini la méthode de redémarrage
Partie A: réglageur / opérateur

◎ Autorise --> Autorise la réalisation du changement
● Réalise --> Réalise le changement
△ Valide --> Valide le changement
Méthode de Emettre une Carte de

Documentation Validation
4M Modification / Changement surveillance /
pour la validation du chagement Q
Feuile de modif sur la
OP Régleur CEq.
contrôle validation machine Evaluation sur les pièces déjà réalisées: (production également précédent)
(Si "oui" et "possible" bloquer et trier les
Matrice de Impact sur les pièces fabriquées? Non Oui Possible pièces)
Objectif de cette partie:
Nouveau personnel sur le processus Fiche de formation au poste TEF6 ● ◎
compétence Raison du non : Qu'est ce qu'on fait avec les pièces
Pièces bloquées? Non Oui Type: Nombre: Réflexion à mener avant de faire un tri
Main d'œuvre
Pièces triées? Non Oui Type: Nombre:

Tri : (par exempl. 100% visuel des pièces défectueuses) Procédure: PM-25-01a_Rapport_tris
Matrice de Résultat tri:

Absence non planifiée (par exemple. La maladie, ...) Matrice d'affectation ●◎
polyvalence
Action / Modification (par exemple. Réparation, Changement, Réglage, ...)
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
Partie B: régleur / opérateur

Redémarrage après arrêt long FC AP de redémarrage SPC + PV non ●△ ◎ Exemple: voir SPC, équipe suivante, à surveiller pendant 3 jours, refaier un
Procédure suivante : courant de foucault
Redémarrage après arrêt court FC AP de redémarrage SPC non ●△ ◎
Machine
Préciser le nom et service de la personne qui est intervenue:

Changement Molette et turbine selon FR FC AP de redémarrage X oui ●△ ◎
Validation après redémarrage:
Changement des rouleaux d'entrainement FC AP de redémarrage (feuille de validation) X oui ●△ ◎
Validation sur pièces fabriquées après action ou modification:
Capabilité sur tous les critères de la FC
Changement de broche porte meule FC X oui
(Q Stat) CTR suivant AP redémarrage CTR avec pièces test (check
(feuille américaine) the checker) Test supplémentaire Capabilité
Changement de meule FC aucun SPC non ◎ ●△
AP de redémarrage (dans lequel est défini

Intervention sur axe porte pièce ou axe meule FC X non Test supplémentaire A remplir que si on coche test supplémentaire
d'uil faut OE et capa)
(par expl. force d'arrchement, Métallo...)
Type: Nombre: Résultat:
Redémarrage fait:
Date: Heure: Régleur / Chef d'équipe
ECR OK Non OK
Nouveau fournisseur de pièces achetées (EZRS) Mode Op chez MSI non
Nomenclature
ECR Confirmation (au plutard le lendemain):

Changement de pièces achetées (EZRS) Mode Op chez MSI non
Nomenclature
ster oder Pl.

Date: Heure: Contremaitre ou Responsable qualité du secteur
érial
artie C:
OK Non OK

170072
Results after WS – Restart Checklist with validation actions
 Clear responsibilities documented in 4M Change Matrix

 Clear definition of documentation and control method for each change (intentional / incidental)
 Clear definition of which validation has to be done after each intervention  Restart Checklist
 Release form for Restart incl. decision of parts handling
 Validation with 4-eye-principle and cross-check in daily management

170072
Example for restart standard – AdP machine release verification

170072
Implementation
Workshop Concept
Lead: PS/QMM21 Lead: plant   Support concept acc. to
Workshop: No. 1 + 2
No. 3 + 4
(optional)
Release by plant
management
PNPI301.03 Support Q-Methods
Start: June July Sep
General approach 4M:

Change Matrix Try Go live:
 1st step skype clarification
Current tools out in roll-out
 2nd step briefing via skype
for change Tracking of changes the along other
 3rd step Workshop onsite or
implement- shop products +
workshop support via skype
ation Operator allocation floor IPN plants
- Survey of existing - Creation by plant team

documents - Review by workshop team
IPN
plant
1.
produ
ct
Use existing
tools
Internal | PS/QMM21-Steffl | 24.08.2018

30 170072
IMPLEMENTATION
EXAMPLES FROM
PLANTS WW
Examples for implementation in value stream
Analog
Visualization
Digital
Visualization
5 Intern | QMS Powertrain | GS/QMM C/MPE | 15.01.2017

© Robert Bosch GmbH 2017. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Example WaP
Change point record sheet
(Standard template)
4M Change Matrix
Terminierung von
Änderungen
(Standard Vorlage)
WaP 4M Procedure:
Existing plant specific

document for
validation of changes
Visualization on board
33 Internal | GS/QMM2 | 04.07.2017

170072
Example EhP
34 Internal | GS/QMM2 | 04.07.2017

170072
Example NuP1
1. Softwareänderungen: 2. Erprobung von Werkzeugen:
35 Internal | GS/QMM2 | 04.07.2017

170072
Example NuP1
36 Internal | GS/QMM2 | 04.07.2017

170072
Example BuP1
Each 4M change is followed up by a change card.

Activities and responsibilities as defined in the
change matrix.
The communication about the change process is

supported by the 4M Schedule Board.
37 Internal | GS/QMM2 | 04.07.2017
170072
Example BaP
Änderungsverfolgung
Visualisierung über Monitor
Mitarbeiterzuordnung über Monitor Änderungsmatrix

38 Internal | GS/QMM2 | 04.07.2017
170072
Good practice plants (w/o workshop support)
Definition and Scope
ChP - GS SAP Work Order Sheet HcP - GS
Example Change Points Change Matrix
Visualization with board
 All good practice examples will be listed on the QMS

platform similar to the 14 Q-Basics (VS) E2016
 MD in QMS format for further distribution.
170072
Example AdP
4M Display board
40 Internal | GS/QMM2 | 04.07.2017

170072
Example BljP Visualization with board
4M Change Point Indication Card:
4M Change Management Schedule:
4M Change Matrix:
4M Change Point Record Sheet:
41 Internal | GS/QMM2 | 04.07.2017

170072
Example CaP
42 Internal | GS/QMM2 | 04.07.2017

170072

SL 4M Change Management Briefing en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SL 4M Change Management Briefing en

Uploaded by

Copyright:

Available Formats

4M CHANGE MANAGEMENT

• 4M is used in the shop floor • Systematic tracking of changes

Procedure and status Schedule

Plants group I: BaP; BhP; BuP1; EhP; FeP-Ru;

Plants group II: AdP; CaP; ChP; DaeP; AmaP;

2 Internal | GS/QMM2 - Steffl | 04.07.2017

Action: 4M is structuring specifications

Result: standardized, validated procedure

3 Internal | GS/QMM2 - Steffl | 04.07.2017

Review Process Confirmation of last /

Participants: Team leader, QMM, supporting function e.g. TEF, MOE-Planner

4 Internal | GS/QMM2 - Steffl | 04.07.2017

5 Internal | GS/QMM2-Steffl | 04.07.2017

Outlook: 4M Intentional Change Management Schedule

Systematic implementation: 4M Change Point Record Sheet

see the following matrix

 Test instruction / SPC

damage of workpiece carrier

restart after breakdown / andon cord Quality release form

Process Engineering Change according to CDQ

7 Internal | GS/QMM2-Steffl | 04.07.2017

☐ Planned action or breakdown / high scrap rate etc.

☐ Block / sorting / scarp / rework?

Begründung bei NEIN:

☐ How many parts blocked / sorted and result of sorting

☐ Action / Change Point

☐ Short description of action or change effectuated

Aktion / Änderung erfolgreich?

☐ Validation of action / change by responsible for action / change

Bei Unterstützung Service-MA Name und Abteilung für Rückfragen angeben:

☐ Validation of quality of the produced parts after change

Art der Zusatzprüfung:

☐ Additional test / serial test including results and quantity

Typ: Anzahl: Ergebnis:

☐ Validation by Supervisor latest in morning meeting

☐ Transfer in 4M Matrix / Input for LL / Input for CIP projects

8 Internal | GS/QMM2-Steffl | 04.07.2017

☐ Definition of different inspections / test to be done

consecutive responsible for

Change Point Decryption Control Method Confirmation

Goal: Traceability and information of all changes over all shifts

others • blackout of medium supply (air, • material defect

11 Internal | GS/QMM C/MPE | 04.07.2017

12 Internal | GS/QMM2-Steffl | 04.07.2017

13 Internal | PS/QMM21-Steffl | 24.08.2018

14 Internal | PS/QMM21-Steffl | 24.08.2018

15 Internal | PS/QMM21-Steffl | 24.08.2018

 First level: ECR (Engineering Change request)

17 Internal | GS/QMM2-Steffl | 04.07.2017

18 Internal | GS/QMM2-Steffl | 04.07.2017

Direct Link to IQP (Integrated Quality Planning) and 14 Q-Basics (VS)

Event driven Support Coaching / Enabling Mature

23 Internal | GS/QMM2-Steffl | 04.07.2017

Atelier le numéro de série (en option)

Procédure: Réalisation conformément Tableau

Légende: ○ Défini --> défini la méthode de redémarrage

Partie A: réglageur / opérateur

Méthode de Emettre une Carte de

Pièces triées? Non Oui Type: Nombre:

Matrice de Résultat tri:

Action / Modification (par exemple. Réparation, Changement, Réglage, ...)

Partie B: régleur / opérateur

Préciser le nom et service de la personne qui est intervenue: