Doc.

No- F/PRD/48
4M CHANGE MATRIX
Rev-02
Reference
Set up approval Retroactive Containment
S.N Unexpec Abnormal

Machine
Change point detail

Material
Expected Action (√ / X) Check (√ / X) Action (√ / X) Resp.

Method
o. ted situation
(Sample size-3) (Sample size-3) (Sample size-3)

Man
New Operator(as fresher, & depute as per skill level) 1. Operator observation for 3 days (F/MR/34A) F/MR/34A
1 √ O √ X √ Line incharge
2. Reinforce inspection of produced lot for 3 days (F/HRD/29) F/HRD/29
New Operator(having experience in similar field& depute as per skill level) 1. Operator observation for 3 days (F/MR/34A) (F/MR/34A)
2 √ √ 2. Reinforce inspection of produced lot for 3 days (F/HRD/29) O √ X √ Line incharge

1. Operator observation for 3 days (F/MR/34A) (F/MR/34A)

3 √ Operator working after long time 2. Reinforce inspection of produced lot for 3 days (F/HRD/29) O √ X √ Line incharge

4 Operator on leave with information Skill matrix (F/HRD/03)

√ Depute same skilled operator on line O √ X √ Line incharge

5 Operator on leave without information Skill matrix (F/HRD/03)

√ Depute same skilled operator on line
6 √
7 √
O √ X √ Line incharge
Operator leave sudden work place due to illness/emergency Skill matrix (F/HRD/03)
Depute same skilled operator on line O √ √ √ Line incharge
 Assy Area 1-Part check as per setup approval rule before & after break down IPC
 Machine's A TYPE Break Down 2-Result of part checking shall be mentioned in set-up approval check
(Type A which does effect part quality) sheet.
1. M/c Back support cylinder block suddenly broken.
2. Reviting Punch wearout or damage.
3. Tool and spare parts damage. O √ √ √ Prod. & QA Line incharge
4. Clamping Force on parts not adequate.
5. M/c Push Button not working completely.
6. Cylinder Fixture mounting bolt broken.
7. Fuse of secondary light(illumination).

 Assy Area IPC

8 √
 Machine's B TYPE Break Down
(Type B which doesn't effect part quality)
1. M/C motor not working.
2. Sensor not working.
3.M/c interlocking poka-yoke not working. Automatic M/C shut down / Lock O √ X X Prod. Line incharge / QA
4. Riviting m/c Break down.
5. M/c Air Pipe leakage.
6. Cylinder Fixture mounting bolt loosen.
7. M/c stop and unoperatable
8. M/c push button working partially.

 WELD SHOP IPC

 Machine's A TYPE Break Down
 (Type A which does effect part quality)
1. Air pressure low & Air leakage
2. Power failure
3. Water flow low
4. Poka yoke not working.
5.Cooling system not adequatly working 1-Part check as per setup approval rule before & after break down (5
6. Gas flow not proper. No.)
9 √ O √ √ √ Prod. Line incharge
7. Air Pipe busted. 2-Result of part checking shall be mentioned in set-up approval check
8. tip desser cutter wear out. Nozzel claning tool wear out. sheet.
9. Controller cureent variation.
10. Straight shank bend and wear out.
11. Problem in engraving machine.
12. Pnuematic cylinder not working.
13. Transformer and Thristor not working.
14. Nut feeder and Manager not working.

 WELD SHOP IPC

 Machine's B TYPE Break Down
 (Type B which doesn't effect part quality)
1. M/C motor not working & part no weld
2. water level maintain w.r.t Poka-yoke working, than No impact
3. Clamping Cylinder not working.
10 √ Before & after part check - 1 No. O √ X X Prod. Line incharge
4. Proximity or Beam sensor not working.
5. Safety sensor not working.
6. Linear block.
7. Read switch not working.
8. Push Button not working.

 PRESS SHOP IPC

 Machine's A TYPE Break Down
 (Type A which does effect part quality)
1. Slide automatic up during running operation.
1-Part check as per setup approval rule before & after break down
2. Balancer pressure & clutch pressure low.
11 √ 2-Result of part checking shall be mentioned in set-up approval check O √ √ √ Prod. Line incharge
3. shut height not maintain.
sheet.
4. Coil Feeder not working properly. 5.double storke by RAM.
6. Accessories not use during die loading.
7. M/c Push button not working fully.

 PRESS SHOP IPC

 Machine's B TYPE Break Down
 (Type B which doesn't effect part quality)
1. M/C motor not working & machine stop.
12 √ 2. Sensor not working Before & after part check - 1 No. O √ X X Prod. Line incharge
3. set-up mode during coil setting
4.Abnormal sound from Pulley & other moving parts

 Plating Area IPC

 Machine's A TYPE Break Down
(Type A which does effect part quality)
1. M/c Transpoter not working.
2. Malfunctioning of SCADA system.
3. Less/ higher Temperature as per specification. 1-Part check as per setup approval rule before & after break down (5
4. Oil Skimmer not working. No.)
13 √ O √ √ √ Prod. & QA Line incharge
5. Machine emergency button not working. 2-Result of part checking shall be mentioned in set-up approval check
6. Hanger falls down in the tank. sheet.
7. Water supply leakage.
8. Temperature controller not working.
9. Temperature sensor not working.
10. Auto Dozzer not working.

 Plating Area IPC

 Machine's B TYPE Break Down
(Type B which doesn't effect part quality)
1. Dip Tray not operatable.
14 √ 2. SCADA working on manual controls. 3.M/c alarm stop working. Automatic M/C shut down / Lock O √ X X Prod. Line incharge / QA
4. M/c Break down.
5. M/c Air Pipe leakage.

Operational control standard

24 √ After Machine Preventive Maintenance 1 part spec. check O √ X X QA Line incharge

Operational control standard

25 √ Interchange the machine 1 part spec. check O √ X √ QA Line incharge

Operational control standard

26 √ Machine Parameter Change 1 part spec. check O √ √ √ QA Line incharge

Operational control standard

27 √ Machine location change (Lay out change) 1 part spec. check O √ X √ QA Line incharge

Tool / Fixture / Gauge Maintenance ( Repair or modify ) Operational control standard

28 √ 1 part spec. check O √ √ √ QA Line incharge

Operational control standard

29 √ Tool break down 1 part spec. check O √ √ X QA Line incharge

As per packing std.

30 √ Process Change 5 part Spec.check (Customer approve ) O √ X √ QA Line incharge

Operational control standard

31 √ Packing Change/Logistics 5 part Spec.check O X X √ Prod. Line incharge

IPC
32 √ Inspection method change 5 part Spec.check O X X √ QA Engineer

5 part check & 01 day production monitoring Operational control standard

33 √ Child part supplier change O √ X √ BOP QA Engineer

5 part check & 01 day production monitoring Operational control standard

34 √ Child part design change O √ X √ BOP QA Engineer

5 part check & 01 day production monitoring Operational control standard

35 √ Child part material change O X X √ BOP QA Engineer

5 part check & 01 day production monitoring As per Operational control standard
36 √ ECN √ X √ QA Engineer
requirement
As per Operational control standard
37 √ In Plant Trail parts 01 day production monitoring √ X √ QA Engineer
requirement
Note :- 1- If any abnormal situation happen due to unplaned changes, operator shall be follow the stop call wait rule
2. 4M Change data shall be collect on half-yearly basis and updated in the 4M change matrix.

REVISION NO REVISION DETAIL REVISION DATE APPROVED BY

1 New 4M changes are incorporate and Plating plant 4M changes define. 29.10.2020 Mahesh Kumar

2 Control for reinforce inspection in case of new operator added 16.06.2021 Sanjeev