変更 点

HENKATEN
 What does Henkaten means?

変更 = Henkoo = Changing

点 = Tem = Point
 What does Henkaten means?

Henkaten is an expression,

formed by joining two

Japanese words creating a third word with

specific meaning.
 What does Henkaten means?

Henkaten therefore means changing point. Henkaten

management is a methodology used to record and track

changes in the process that may cause deviations, failures and

problems, and may also affect the product or result of this

process.
 Process Definition

According to ISO 9001 - 2008, the process is: An

activity or set of activities using resources, and

managed in order to enable the transformation

of inputs into outputs.

Examples of Processes

Changing a flat tire;

Sharpen a pencil;

Inject plastic part;

Inspect a component;

Shopping.
 Characteristics of a Henkaten
A Henkaten occurs when a
process undergoes for
a modification, planned or sudden,
temporary or permanent, of
that was originally planned as
the final process directly affecting one
of variables of the process.
 Characteristics of a Henkaten
Planned changes
Preventive Maintenance ;
A new employee is starting on the
organization under training;
Change the provider of raw material
Update a work instruction;
Layout changes.
 Characteristics of a Henkaten
Sudden changes
Corrective maintenance;
An employee which is absent is replaced
by colleague;
Using a component under a deviation;
A new activity is inserted into the
process.
 Characteristics of a Henkaten
Temporary changes and permanent changes
Usually a not planned change is temporary, a
condition to work until the previous and
official condition can be restored, but in
some cases, a temporary change can become
permanent.
 Characteristics of a Henkaten
Thus a Henkaten will impact one or more
process variables, namely the change will
always occur in one or more than one of the
variables in the process. People, Machine,
Method and or Materials.
MANPOWER MATERIAL METHOD

Sub-cause Sub-cause Sub-cause

PROBLEM

Sub-cause
Sub-cause

MEASUREMENT /
MACHINE
ENVIRONMENT
 Characteristics of a Henkaten
What about Measurement and Environment?
Any changing in these two variables, will affect
directly the another variable, for example a new
instrument for measurement will be recorded in
Method and if there is a very cold day, it will affect
directly the people, material or even the machine.
Why to manage and control changes?
In every change inside a process there is a
learning period, Hence which more the
process is executed, less time it takes and
higher is its efficiency, until the process
becomes stable.
 Why to manage and control changes?
Known process / Stable
INPUT PROCESS OUTPUT INPUT PROCESS OUTPUT INPUT PROCESS OUTPUT

New process / Unstable

? ? ? ? ? ? INPUT PROCESS OUTPUT

 Why to manage and control changes?

Every time that a known process or

a stable process, undergoes a
changing it becomes once again a
new process, or unstable, because
is quite hard do predict accurately
how that modification is going to
affect the result of the process, this
results will take time to evaluate
and judge.
 Henkaten Management

This material was made thinking in a small

organization for didactic purpose, how bigger is the
organization also the Henkaten management should
be divided accordingly to make easy for the station
leader to manage without doing it because if
organization politics or his boss has given the order,
the station or substation leader must see the
Henkaten management as a key tool of management
and control or it will be useless, becoming just an
ordinary task and a waste of time.
 Henkaten Management

Man
Machine
Method
Material
 Henkaten Management

Man
First activity is to create all the necessary documents, in case if they are
not available in the organization, most of the documents are required by
best practices and also by ISO standards, the management of Man
Henkaten requires a lot of activities by the leadership, and is the most
hard to be managed appropriately, because it includes a key point in the
changing process management, due the reason is simple, Man will
operate the Machine, transforming and handling the Material following a
Method and getting information from it. So it is required a good
management on that variable. Also because people are not the same
(physicaly, behavioral, etc) It requires need for individual training for
leveling the operational capacity.
 Henkaten Management

Man
For the management of Man Henkaten, are
necessary the following documents:

Board for Henkaten Management;

Employees skill map;
Workstation layout;
Record sheet;
 Manpower Management

Employees skill map, is a document which

must be updated EVERY TIME that a new task
is added or planned for employee or for a new
employee, this document, gives to the
leadership the ability of fast judgement in case
of member absence and the replacement
strategy for absent positions in the work
station.
 Employee’s name and photos
Manpower Management
EMPLOYEE SKILL MAP
ACTVIVITY / NAME ANDRZEJ ARMAND BORYS CLEITON ELKA FRANCISKA NIKOLAI PATRYK TEODOR

INJECTION LINE 01

PRESS LINE 01
Activities / job positions

MACHINING LINE 01

ASSEMBLE LINE 01

INJECTION LINE 02

PRESS LINE 02

MACHINING LINE 02

ASSEMBLE LINE 02

TR
NO SKILL ON THE ACTIVITY TRAINED IS PLANNED

LEGEND
CAN PERFORM THE ACTIVITY CAN PERFORM THE ACTIVITY NO CAN TRAIN OTHER MEMBER
SUPERVISION IS REQUIRED SUPERVISION REQUIRED ON THE ACTIVITY
 Manpower Management

Workstation Layout, is a simple

diagram showing all the workstations
on the shop floor, a scaled drawing of
the production lines localization,
machines, work stand, and if possible
employee’s position on the line or at
the machine.
 Manpower Management
INJECTION PRESS

1 1 2

2
Employee’s photos should
Employee’s photos be placed by using
magnets, making it easy to
MACHINNING ASSEMBLE change positions when
necessary.

1 2

WORKSTATION LAYOUT
 Manpower Management

Record Sheet, is a sheet where the

leader can make all the necessary
registers for keep the changing
under control, plan the necessary
activities and to make historical data
from every changing in his area.
 Manpower Management
RECORDING SHEET OF MANPOWER CHANGING This example
sheet was
PLANNED OR PERMANENT OR
DATE CHANGING REASON LOCATION
SUDDEN TEMPORARY
ITENS TO CHECK HOW LONG APPROVED
created based
Elka is taking Armand Armand is absent due
June 06th 2016
position sickness
Injection Line 01 Sudden Temporary
Only key itens from PIS first
and last part of the batch
June 06th 2016 TEODOR on 5W2H, but
June 07th 2016
Nikolai is training with
Borys
Nikolai was assigned for
a new position
Press Line 01 Planned Permanent
All PIS itens first and last
part of the batch
Until August 07th 2016 TEODOR it could and
June 08th 2016
Cleiton is taking Andrzej Line must product during
position the lunch time
Machining Line 01 Planned Temporary
Only key itens from PIS first
and last part of the batch
June 10th 2016 TEODOR should
June 08th 2016
Patryk is trainning Franciska is going to take
Assemble Line 01 Planned Temporary N/A Until August 08th 2016 TEODOR
modified
Franciszka position vacations
according
with the
organization
necessities, its
culture and
internal best
practices
 Henkaten Management

Machine
First activity is to create all the necessary
documents, in case if they are not available in the
organization, most of the documents are required
by best practices and also by ISO standards.
Machine management if quite simple if comparing
with manpower. This monitoring requires
knowledge of the main wearing parts and their life.
 Henkaten Management

Machine
For the management of Machine Henkaten, are
necessary the following documents:

Board for Henkaten Management;

Preventive maintenance plan;
Workstation layout;
Record sheet;
 Machine Management

Preventive maintenance plan, is a document in

which every maintenance programed in advanced for every
machine on the shop floor is listed, and this document should
contain at least the machine name, position, date for the
maintenance and person in charge for the maintenance. It should
be most clear that every maintenance, planned in advanced as
well the sudden, is a machine Henkaten. Most important on this
activity, maintenance department and manufacturing department
must act together, but the Henkaten management must be of
manufacturing department, because in this relationship,
manufacturing department is a customer from maintenance
department.
 Machine Management
INJECTION PRESS

1 1 2

2
Machine’s position on the
shop floor.

MACHINNING ASSEMBLE

1 2

WORKSTATION LAYOUT
 Machine Management

Record Sheet, is a sheet quite similar

with the sheet used to control
manpower Henkaten, there are
although additional fields on that sheet:

 Part produced after changing;

 Quantity produced after changing;
 Machine Management
RECORDING SHEET OF MACHINE CHANGING This example
sheet was
PLANNED OR PERMANENT PN PRODUCED AFTER
DATE WHO CHANGING LOCATION
SUDDEN
OR
CHANGING
QTY PRODUCED AFTER
CHANGING
ITENS TO CHECK APPROVED created based
TEMPORARY

June 06th 2016 FRANCISKA Die changing Injection Line 01 Planned Permanent PART 12345-123 2000 SHOTS
All PIS itens first and last
APPROVED
on 5W2H, but it
part of the batch
could and
June 07th 2016 ANDRZEJ Changing the guide pin Press Line 01 Sudden Permanent PART-12345-124 1000 PARTS Holes position and size APPROVED
should modified
Changing the cutting oil for 10.000 PARTS / NEXT
June 08th 2016 TEODOR a substitute, due missing of Machining Line 01 Sudden Temporary PART-12345-125 CHANGING COME BACK TO
Burrs and surface
appearance
APPROVED according with
correct oil USE THE CORRECT OIL

June 08th 2016 CLEITON

Changing of welding
electrodes due the wore out Assemble Line 01 Planned Temporary PART-12345-126 3000 PARTS
Weld cut check test in the
APPROVED
the organization
first and last of the batch
before the expected time
necessities, its
culture and
internal best
practices
 Henkaten Management

Method
First activity is to create the only 2 necessary
documents, in case if they are not available in
the organization, one of its of the documents is
also requested by best practices and also by
ISO standards. Method management is even
more easy than Machine.
 Henkaten Management

Method
For the management of Method Henkaten,
are necessary the following documents:

Board for Henkaten Management;

Record sheet;
Correlation documents list;
 Method Management

Record Sheet, is exactly the same of Machine, but

the contents of records will be different, once the
changing in Method will be on documents,
process parameters such as velocity, temperature
or quantity. what is important to handle
parameters as Method Henkaten, not machine,
the reason of that is simple, machine
modifications are done when mechanical
modifications are performed.
 Machine Management
RECORDING SHEET OF METHOD CHANGING This example
sheet was
PLANNED OR PERMANENT PN PRODUCED AFTER QTY PRODUCED AFTER
DATE WHO CHANGING LOCATION
SUDDEN
OR
TEMPORARY
CHANGING CHANGING
ITENS TO CHECK APPROVED
created based
June 06th 2016 CLEITON
Increase of temperare of
injection
Injection Line 1 Sudden Temporary 12345-127 500 shots
All PIS itens first and last
part of the batch
TEODOR on 5W2H, but it
June 07th 2016 ANDRZEJ
Modification of work
Press Line 1 Planned Permanent 12345-128 1000 parts
All PIS itens first and last
TEODOR
could and
instruction part of the batch
should modified
according with
the organization
necessities, its
culture and
internal best
practices
 Method Management

Correlation document list, is a list

required by QMS or the ISO standards, in
this list there is a correlation between
documents, the purpose of this list is to
know or to remember what documents
are necessary to modify when a new
information is added or remove from one
document.
 Method Management
DOCUMENTS CORRELATION LIST EXAMPLE The only reason
of that list exists
DOCUMENT
CHANGED /
PFMEA
PROCESS WORK
PIS
MACHINE
PARAMETERS
CHECK LIST OF SETUP PACKING COSTUMER is to remind
DOCUMENT TO CONTROL PLAN INSTRUCTION MACHINE INSTRUCTION INSTRUCTION DOCUMENTS
CHECK
SHEET
people all
PFMEA
o o o o documents that
one changing is
PROCESS
CONTROL PLAN o o o o applied, if the
WORK
INSTRUCTION o o o o organization
PIS
X X X X have another
mechanism for
MACHINE
PARAMETERS SHEET o this activity so it
CHECKLIST OF
MACHINE can be used.
SETUP
INSTRUCTION o o X X o o
PACKING
INSTRUCTION X X X o X X X
COSTUMER
DOCUMENTS o o o o o o o o
 Henkaten Management

Material
First activity is to create the record sheet,
because is the only document necessary, in
case if they are not available in the
organization, and this document is quite similar
to all the other record sheets.
 Material Management
RECORDING SHEET OF METHOD CHANGING This example
sheet was
PLANNED OR PERMANENT PN PRODUCED AFTER
DATE WHO CHANGING LOCATION
SUDDEN
OR
CHANGING
QTY PRODUCED AFTER
CHANGING
ITENS TO CHECK APPROVED created based
TEMPORARY

June 06th 2016 BORYS

Master Batch supplier
Injection Line 1 Sudden Temporary 12345-129 100 shots
All visual itens of PIS 5
TEODOR
on 5W2H, but it
changing parts every 30 minutes
All PIS itens first and last
could and
June 07th 2016 FRANCISKA Thickness of coil Press Line 1 Planned Permanent 12345-130 1000 parts TEODOR
part of the batch should modified
according with
the organization
necessities, its
culture and
internal best
practices
 Henkaten Management

Visual aid
The visual aid, it simple to apply any visual
detection forms to help in fast identification of
some information, this way you can also apply the
selected color for each 4Ms, to all relevant
documents and controls, thus creating a
distinction and visualization fast each change that
is occuring in the shop floor, this could be trigger
to top management to get involved if necessary.
 Henkaten Management

Man - Red
Machine - Yellow
Method – Green
Material - Blue
 Thanks for your attention!

Cleiton Morais de Melo

cleiton.Moraes@gmail.com
+55 11 99958-8639