Document no.

DOC/QA/4M-01
5M+1E CHANGE CONDITIONS & ACTIONS MATRIX Rev.No. 6
Rev Date : 13.01.2022
Category Activities to be done

Sr. Containmen
4M Category Changed Description Action Taken Information Flow Retroactive
No. Planned/ t Action Cust.
Abnormal OJT F.P.I. Inspection Remarks
Unplanned (Proactive) Approval
(A)
(B)

Operator On leave with information

Operator of same skill deputed Planned x x  x x x

Operator of under skill deputed Planned x   x  x

New Joined (after Completed training till required level
process wise)
Start production after First Piece Inspection
Production to QA
Planned x x  x  x

New Joined (Before training completion till req. level) Start production after First Piece Inspection Planned Yes   x  x B) Whole shift material to be checked

Operator Came after Long leave

(>21 DAY)
Start production after First Piece Inspection Planned x x  x  x B) 10 parts to be check during containment

1 Man
Extra working(Operator work more than 12 hour) -
Operator Fatigue
Start production after First Piece Inspection Planned x x  x  x B) Whole lot /shift to be checked

Operator suddenly leave work place due to

Operator of same skill deputed Unplanned x x  x x x
accident/illness
Operator of under skill deputed Unplanned Yes   x  x B) Whole lot /shift to be checked

Operator On leave without information

Operator of same skill deputed Production to QA Unplanned x x  x x x

Operator of under skill deputed Unplanned Yes   x  x B) Whole lot /shift to be checked

A) Min. 3 No's to be checked before & after Change - if NG found then

Defective PARTS Produced by negligence of operator Start production after First Piece Inspection Unplanned Yes     x check all parts up to last QA periodic check

Production shifted to same capacity m/c Planned x x  x x x

Customer approval required & after customer approval trial will be
Production shifted to Higher capacity m/c* Production to QA Planned x x  x x  conducted with A)
Customer approval required & after customer approval trial will be

Preventive maintenance - M/C

Production shifted to lower capacity m/c* Planned Yes x  x   conducted with A) & B)

Machine PM Delayed Planned Yes x x x  x B) Min. 3 Parts to be checked in every 2 hour till PM completion

Maintenance to
Production resumed after PM & correction
Production to QA
Planned x x  x x x

Production resumed after temporary repair Planned Yes x  x  x B) All Parts to be checked up to permanent repair

Production done with approved 2nd set of

Die/Tool/Mould
Planned x x  x  x B) Min. 3 No's to be checked visually after Change

Preventive maintenance - Die/Tool/Mould

Die PM Delayed
Maintenance to
Planned Yes x x x  x B) Min. 3 Parts to be checked in every 2 hour till Die PM completion

Production to QA
Production resumed after PM & correction Planned x x  x x x

Production resumed after temporary repair Planned Yes x  x  x B) All Parts to be checked up to permanent repair

A & B) All Parts to be checked from last QA inspection - UP to Poka

Poka Yoke Bypass Start production after First Piece Inspection
Production to QA and
Maintenance
Planned Yes x    x Yoke Resumes
1. New Machine Added*
2. Machine -major modification*
Customer approval required & relevant documents to be submitted as
3. New Die/Jig /fixture added*
4. Existing Die/Jig/fixture modified*
Stop production Production to QA Planned x x  x x  per MSIL requirements.

5. Location of machine changed*

Machine - Breakdown
Production shifted to same capacity m/c Production to QA Unplanned x x  x x x
(As per Machine breakdown matrix F/QA/4M-01-
A & B) Min. 3 No's to be checked before & after rectification - if NG
Annexture A)
Production resumed after correction Unplanned Yes x    x found then check all parts up to last QA periodic check
Maintenance to A) Min. 3 No's to be checked before & after rectification - if NG found
Machine/ Production to QA then check all parts up to last QA periodic check
2
Die/Tool Production resumed after temporary repair Unplanned Yes x    x B) All Parts to be checked up to permanent repair

A) Min.3 No's to be checked before & after Change - if NG found then

Production done with approved 2nd set of
Die/Tool/Mould
Production to QA Unplanned x x   x x check all parts up to last QA periodic check

A & B) Min. 3 No's to be checked before & after rectification - if NG

Die/Tool/Jig/Mould - Break down
(As per Die breakdown matrix F/QA/4M-01-Annexture
Production resumed after correction Unplanned Yes x    x found then check all parts up to last QA periodic check
A) Maintenance to
Production to QA A) Min. 3 No's to be checked before & after rectification - if NG found
Production resumed after temporary repair Unplanned Yes x    x then check all parts up to last QA periodic check
B) All Parts to be checked up to permanent repair

Production to QA Parts will be rejected which available in Die.

Poka Yoke Failure (Auto cut off) Start production after First Piece Inspection
and Maintenance
Unplanned x x  x  x B) Min. 3 No's to be checked visually after Change

Parts will be rejected which available in Die.

Production to QA
Poka Yoke Failure ( No Cut off, only identification) Start production after First Piece Inspection
and Maintenance
Unplanned Yes x    x A & B) Min. 3 No's to be checked before & after rectification - if NG
found then check all parts up to last QA periodic check

Power Failure Restart the m/c - Unplanned x x x x x x UPS System run in case of power failure

A) Min.3 No's to be checked before rectification - if NG found then

Breakdown- Measuring equipment Use similar calibrated equipment after approval Unplanned x x   x x check all parts up to last QA periodic check

A & B) Min.10 No's to be checked before & after rectification - if NG

Machine is not in good condition (Repeated Break
Downs)
Start production after First Piece Inspection Unplanned Yes x    x found then check all parts up to last QA periodic check
Production to QA
A & B) Min.3 No's to be checked before & after rectification - if NG
Continuous rejection (more than 10 Parts/shot)
Correct the process & check the Process parameter as
per PQCS
Unplanned Yes x    x found then check all parts up to last QA periodic check

A & B) Min. 3 No's to be checked before & after rectification - if NG

Machine parameters found out of spec. during routine
checking
Machine started after resetting
the parameters
Unplanned Yes     x found then check all parts up to last QA periodic check

Material received from other approved source Start production after First Piece Inspection
SCM to QA
Planned x x  x x x
Not allowed & Customer approval required. All material to be
Material received from other unapproved source* Stop production Planned Yes x x x x  rejected.

3 Material Wrong material/grade used Stop production & start with specified material Production to QA Unplanned Yes x   x x A) Hold the suspected lot & Reject all parts

Unidentified material on shop floor Put the Tag of Hold & kept in suspected area Production to QA Unplanned Yes x x  x x A) All Parts to be verified 100%

Parts Bin/Trolley fallen down All parts are to be checked Production to QA Unplanned Yes x x x  x B) Check all parts available in Bin/Trolley

1. Process Change/ Location Change*

Customer approval required & relevant documents to be submitted as
2. Change in flow of process*
3. Sub Supplier Process Change *
Stop production Production to QA Planned x x  x x  per MSIL requirements.
4. Layout Modification or change*
1.New Pokeyoke Added
2.Existing Pokeyoke is modified
3. New inspection instrument / gauge
Start production after First Piece Inspection Production to QA Planned x x  x x x
4. Storage method change
4 Method
Customer approval required & relevant documents to be submitted as
Process parameter/ specification changed* Start production after First Piece Inspection Production to QA Planned x x  x x  per MSIL requirements.

Customer approval required & relevant documents to be submitted as

Inspection Method Change* Start production after First Piece Inspection QA to production Planned x x  x x  per MSIL requirements.

QA to Production to B) Not allowed & Customer approval required. All material to be

Change in packing std* Discussed with Customer for approval
Dispatch
Planned x x x x   rejected.
 A) All Parts to be verified 100% which checked by concerned inspector
Poison test failure
Immediately training required to concerned & conduct
Poison test again
Quality Unplanned Yes  x   x in a shift. B) After passing in Poison test after failure Min. 10 parts to
be verified during running inspection

Customer approval required & relevant documents to be submitted as

1. Gauge, Check jig, Measuring instrument not
calibrated
Inform QA to take up for calibration, use alternative
equipment.
Quality Unplanned Yes x   x  per MSIL requirements.
5 Measurement
A) Min. 3 No's to be checked before Damaged - if NG found then
1.Gauge, Check jig, Measuring instrument damaged
while using.
Inform QA to take up for replace or repair Quality Unplanned x x   x x check all parts up to last QA periodic check

A) All Parts to be verified from the last lux level verification on same
Lux Level low in Inspection area Inform Maintenance to increase Lux level Quality Unplanned x x   x x stage
6 Environment
A) Min. 3 No's to be checked before & after rectification - if NG found
Process parameter/ specification changed Start production after First Piece Inspection Production to QA Unplanned Yes x   x x then check all parts up to last QA periodic check

Check By :- Supervisor / QA Person / skilled operator

Suspected Check- Whole Material which made in case of unplanned/abnormal condition after last QA Inspection
Retroactive Check (Min. 3 Parts and if NG found all suspected parts to be checked ) - OLD parts inspection up to QA periodic check
Containment Check (Min. 3 Parts Visual Check) - in known condition - production run with extra care

LEGENDS Applicable -  Not Applicable - x

Prepared By :- Girdhar Sahu Approved By :- Chain Singh