MANA 2 ey, Oo o By 1 MARUTI CENTER FOR EXCELLENCE MACE] héS Sozur @ACE Change Management Clause No. 3 Of The T2 VSA Check Sheet Clause No. 3 is also crtical clausehé$ Suzuki ; Main Clauses (Category) eee en aml She [clause (Caen) Prien Preprtn eguaton fr ill poducton conto ‘Change management Slandarés management Education and vaiing ‘Qunity Av and Process Veriton Supplier Contol Handling anomaly in quay ‘9 management 10 [ Eauipmentinepecion equpments management 11__[ ptorentson of standards 72 | Products Management 13 _| Honing Management 74 [Cast Parts Menaperent (ars A Pas) 35 [Adequate Testing Faciiy 76 [Process Aust hé$ SuzuKi . Main Clauses (Category) Cee ne Emel No | Gause Cateoon) 17 Seat and Top Wanaponen brawn =| sy 7 | egal Conplace and EnverContents Section 2:- b Section Change Management Procatect at Charge Marapaner Sapiens Rae eee | “ates 4 Change Cane Sanaa Initial Part % Wsisinsipat ‘Abnotmal Situations Fleet 3 checkpoints Last 2 checkpoints of Cause No.3 => ‘Checkpoint No.1 3 2 Dipper sete of Cause No 8 2 Sietieeinae mest . ‘ MS Saat MACE Clause No. 3 (Change Management) craven 30 you define unexpected change (onus ns pefation ana Ronen management + frames charge cen? oyu define procedures apple tor shag 2 ffomaton ores cotton) a chnge a Peyaurecard rove quaty check rest to nig voceabiy? Ie each chads 2 oyu define and conti part dey? hod forint pat 0 you ono intl pas Sparel and make 2 faty score about temo rer na source process rence] In clause no. 3, total check points are S, First 3 check points are related to change ‘management. Second 2 points are related to initial production part.WARUTT a héS Succ 3. Change Management AACE SE TT h. 4M change procede dering owing I> eaion of change Deta spr Arner) 1 ategansaton of enngs into panned/unplenned canes carmion ses | enum fe Rates to etn at hae it implemention | |{urasallinpanses) DvD ofetntonofchngesinshop Noo i tedeocced chat [F Recrnas a chnge manger mane te rmmeenet | | ius Paracas Record of changes (2M change recor) (Checrecar of par prouzed sar change [> Revascve eck econ case of unplanned (anerpeced hanges MARUTT = hé® Suzuns 3. Change Management RACE Se eee at facto te ten in ce of cans 8 ante pace) sttian and esfcopied tom” Ansenes of oes bout 4 chants 1 [ioeneesse | | stannginrmatonts dt scion tobe gure by hom otcanee ‘aeons ctnseenare overran pewert otmpomatn facts at ioe Dep of changes in AM change managementMARUTT wal hes suzuc 3. Change Management AACE el befntionnd | |ooyeuracod padi quality Chek eco of pas prosiced er change | loimemaon | | eck ruts tera ofcnnge ‘waceaity? tractive check record incase of urslannes management cksatmactchecks Jurerpecied) anges we Se a SUZ ges as per IATE 16949:201682 ACF ees 1. 8.5.6.1.1 : Temporary Change of process control: >The organization shall document the process that manages the use of alternate control methods.Section 1 :- Change Management we SE —— SUZUKI ethodology of 4M Change System MACE Define changes and its related documents . Action - 4M Change system Flow . Record of 4M Change Inspection Reports 4. Analysis of Changes and action Planmanunt MS SUZUKI What Is the use What is Change What is Action, What is Report. What is analysis Train the supervisors to note the changes, eS Soeur ACE UK! Vethodology of 4M Change System SéAcky ES 1. Define changes and its related documents Define change management / 4M change management Procedure of 4M Change Management ‘4M Change control standard Visual Display of 4M change at individual station and central board 4M Change Hold Tag 4M Change summary monthly sheet 4M Change & abnormality record Report formatsWARUTT CE Mé$ Suzuki ~~ Change Management &gACE i What is chang ‘Any day-today change made in process 4M when the part is under ‘supply. 2.Something become different from standard in process 4M > Example : Change in Man, Machine, Material and Method, What is Change management- >If any change happens in process 4M, how it is managed. > Criteria to be defined for change, actions required against each change, responsibility, recording of material produced during change, summary sheet. 6 '$ SUZUKI 4M Change Management ean -D ‘Something become diferent from standard | fo Manage the situations Management AaWARUTT GH MS Suzuna 4M Change Management SEACH SS Machine Method Itis a systematic approach to th chi Material 4M Change Management is systematic approach to deal the changes in Man, Material, Machine and Method 7 THAROTT c NAS SUZUKI oct of Poor Change Management 8@ACE So Assy. at oem 1-10-100 Rule Assy at Child Part Ter d_ =~ Process Tier2__ == j Wy Nv 10xparts | | 100x Vehicles || (x] ———> swooxvenes | Dissatisfied customer share the experience with others.M$ Sait RACE Categorization of Changes:- Planned Changes & Unplanned Changes MARUTT —— hé$ Suzuki Type of changes &éACE) “Ll (oe | > Aetaned Planned Changes Unplanned Changes ‘Defrition: Any change with prior informations] [ Defition : Any change without prior information i termed as planned change or expected change. |_| termed as unplanned change or unexpected change. [Gest che cre rar prin ofa Man = or aes freee tance B | Mec Foayote be ew Rf arade 0° Spe. & | meena invoke falen down 10WARUTT M$ Suzuia Change Standardization Process Brainstorming In-house & customer session standards I) = Inputs as in-house defects, customer defects, breakdown and customer requirements, vill be considered to develop 4M change control standard, Format of 4M Change Control StandardhéS SUK [ am Change Control Standard | S@ACE ey $ Suzuxt | 4m Change Control Standard | S@ACE| Forreteence oy 12eS Stzunt For eeronco ony 4M Change Control Standard S@ACE| hes Sozia Foereterence only 4M Change Control StandardForreterence only héS SGziKi a Change Control Standard S$ SuzuKi ‘4M Change Control Standard | 8@ACE| a [> incase of 4M change, put 4M hold card on material and send) done on able avaiable in hold are in hold area. Do quay checks to be 2Visual Management ? 1, Management by eyes 2. Highlighting the abnormal condition 3. Clarity and transparency Benefit 1. Allows you to see the normal state (Standard) 2. Allows you to quickly see a deviator from the standard. Visual Management of 4M AACE) Rotten Apple 4M CHANGE SIGN PLATE (at each m/c. / station) DATE :- a = X a (MACHINE) X at Foren =) t ‘t: X ¥ (METHOD) X LEGENDS: ‘CHANGE:-V NO CHANGE x 15es Sar SS] en Example of Change Management AACE Display change card clearly on machine/ area where change occurs ” “4M CHANGE CENTRAL BOARD Date Machine [MAN MACHINE [MATERIAL [METHOD | Name /No. 1 @ ® @ @ 2 @ @ @ @ Legends | No Ghange : Green Responsiilly = Shop Supervisor ‘Change : Red 5; 16Ms Sozit S@ACE 4M Change Hold-Tag Customer Name :- Date :- Shift Lot No.:- Prepared By:- ‘Approved By:~MS Sozuet Methodology of 4M Change System 2. Action — 4M Change System Flow :- aACE a Reap the mara separate of 4M change =>MARUTT hé$ Suzuxi Methodology of 4M Change System es 2. Action — 4M Change System Flow := fcrange contol esponsile person shall identify changes / abnormal ion mentioned in AM change control standard, i Tange contra esparsile peON wi pate VeuaT Oapay oF aN éhange at Indkidual machine / station and central board as smertloned in 4M change cnt! sana ‘change contol sponsible person will use the 4M change hold tag forthe material produced under 4X condtion. “change approval authority willarange forthe material produced separated fom raining lt. (change approval authority wil arrange inepecton of parts forthe material produced under 4M condltion. WARUTT M$ Suzuct Methodology of 4M Change System [eseseemecasecnesnanea al 3, Records : Making of 4M Change Inspection Reports & other documents :- 2. Updation of ant ‘Summary Monthly ‘Sheet 8 19WAROT! M$ SUZUKI Methodology of 4M Change System ee 3. Records: Making of 4M Change inspection Reports & other documents = (C= 1. Mating of (Qn Enginear wil arrange to make inspection reparsfor Setup Inspection Reports |_| approval, Retroactive inspection and Suspected tot as per requirement given in the 4M Change Control standard 2, Updation of a4 Summary Monthy | | Qn cngncerwiupdate A Summary Monthy shee. 3. Updation of ant ‘change & Abnormality | | QA Engineer wil update of AM change & Abnormality Record sheet. Record @ ue ER Methodology of 4M Change System na 4, Analysis of Changes and action Plan a. Trend of number of 4M change monthly monitoring, b. Pareto of Monthly 4M change individual data. 20MS Soa Hold-card Tag Monthly Monitoring Hold card data, Month wise F¥-19-20 ie : “ i$ SuzuKt ACE am change Analysis Data MACE (semen Toxl Hola carg ty g* He a EF . @ 21hé$ SUZUKI Section 2 :- Initial Part WABUTT a hé$ Suzuci éACE| —— — [SS Procedure of Initial Part PURPOSE > To establish a control system for initial parts which results in better control at change points and zero customer complaints SCOPE > New parts or parts produced after change in product / process which are manufactured for frst time. RESPONSIBILITY > Prime responsibilty for control of Initial part les with QA Head, DEFINITION > Initial part controls the first piece, part or lot or samples from the frst lot produced during production tria(T0,T1 and T2),mass production tril & ater start of mass production under following conditions: 22MARUTI a MS Suet! | intial Production Part _ oe en = A design or engineering change Anew part Raw material change Method change Start of production after long layoff(1 year) Process layout or process control parameters change Machinery change/new machinery. Supplier change Plant location change VV VVVVVVY + Such a first lot when produced is called an initial parts(IPP) aACE WARUTT M$ Suzukt L Initial Production Part Procedure S.No. DESCRIPTION Responsisiuty | DocuMENT {st of al initial Pars are recorded in Initial Initial Part log bs Partlog book ee book Identify machine where Initial Part is being . 2 produced, see Initial Production Parts are identified with supervisor | Initial part ty 3 nel eee (A Supe ital part tag Layout inspection report shall be made and visor | IPP Layout a record shall be maintained for same, oN Inspection ‘Material test certification from tied party 5. | iskept for each initial pat lot f required. (0A Head « 23héS suzuK’ Initial Production Part Procedure inka par lot produced by sub vendor, 6. | inspection test records tobe collected bysub- | QA Head [one endorsSrecords tobe mantained, “The fal part to be kept away rom production ie in lock and key condition in IPP area. Onteed i samples/pars rejected by the customer then Non 2, | thenon-conformity procedure willbe ppicatle | GAHead | conformity ered parswilbe capped. | procedute 7 WARUTT =a hé$ SUzuKt RACE EN IPP Tag Customer name: Date= Part name = Shift - Part No. Lot No.:- Lot Qty. = Reason for IPP :- Prepared By: “Approved By:- 24ws Sa a peli Initial Production Part Log Book A@ACE a = | omer|ro | coes] wom | all ns ee S| Saeaes foe | as) ee | se nen re as | | | es : 2 3 if 5 Prepared Approved By: MAROTI "Wo hes Soeur SéACE| Section 3 :- Abnormal SituationAds SGEuR CE ET Handling abnormality in Quality Clause No. 8 Of The T2 VSA Check Sheet Clause No. 8 is also critical clause Mes SUZUKI nding abnormal situation in quant @ACE ———<—* ama te poe he ne youve ete to estimate the cone of arp ot or 3 finarmal stuston) When sbormslstuston oes >You face suspected lot bated pon he crea? aang cause jton rst sch 955 "Supple fare eck point no. 1 & In clause no. 8, total check points are 6. In handling abnormal situa 3is briefed further @ 26hMé$ Sazux i 8. Handling Abnormality in Quality smo | subciouse | sno check Pit Regurement Deion of abrac stustions {Geta pe Arment] zal ete soir station and. Dp of bnorma stunt inshop one, | 2 | mate opecsorsinowine { foor ‘etoiton? fel wear a SUZ dling Abnormality in Qualit@AC pa a eS sho | swwoase [sino heck Pon egutemert oyounave erento rt nesta suspected quart tstnate he scope of roveed during abt stutos and Handing when furpected letter abnormal fysem to vace suspected lt produces a. | "Sinormat™” | 3 |stomion?wnenaboormat sed upon me crtera stoiton seas | [suntan ces, you wace Suspected lot bsed upon te check recor of pats produced dung tera? bnarmal tuson for Wacehé$ SUzbKt AACE} Handling when common abnormal situation occurs =e Abnormal Situations :- ‘What is Abnormal Situation Common Abnormal Situations Criteria to estimate suspected lot. Methodology of Abnormal Situations System Inspection of suspected lot Recording in 4M Change summary monthly sheet ‘4M Change & abnormality record os “MAROTT = Ne SUZUKI Fa ormalsituation in Quality &éACE Definition :- > Deviating from what is normal or usual or specification, typically in a way that is undesirable or worrying or unacceptable. Any resource going out of normal working. > Example » Machine / Tool ~ Break down, machine producing defective parts 66 28Ms Size ‘SUZUKI nas Common Abnormal Situations ST ‘Any resource going out of normal working, E.G Deployment of under siled operator Die /tool wear out Machine Producing Defective Parts continuously 'Machine/equiement found having abnormal condition (proces parameters beyond spectiod fits) Operator produced defective parts continously (operator careessness/mistake) Operator detects defect produced by previous process (Operator leaves workplace without dsposng off detective or semi frished pats during breaks or atthe end of shit Pars fallen own by operator (operator unable to wark as per workinstrucion operation standard oka Yoke not working Poka Voke by passed Power fare —— Mes Sozun Criteria to estimate suspected lot MACE 7 [Berga oun saesepwar Fas aed nde sleeper 2 | Machi roducng dls par coinucuny | Osos are roamed masa raeaiprt dang anal oan Pas assed argon pararoEeend (erocesparancareteyendsosczntoinis | prctiosin 7 | Oper rast lcte pars conrunaly | Pos raised ewe nora roar, (chaarsnrlesenesn me) © | Orstrceoas dfs proszedty rovaur | Pedaion alm wich@asve para ave Foon deeded 7 | Sesser wn pewam raid | Pee eRe pana nae waka WaWAROTT M$ SUZUKI : Sy ‘Methodology of Abnormal Situations System. Action :- Abnormal Situations Process Aativity (Gperator Prodveton Superior shallidentiy abnormal situation as mentioned in Common Abnormal Stations sheet. "Abnormal suation- Operator folow stop call wait ‘rneple &lnfrm to Production Supervisor / Line Leader / Quality Engineer Production Superisr will update visual display f 4M change individual machine / station and cenrl boar. ‘Gi enaneer Tpracton supervisor wil enti the sspected Tot as Aefned in Cetera for suspected lot sheet. ‘Tee QA shall ae ations for inspection of parts for suspected ot and ‘update n 4 change & Abnormality record. MS Soeur , 4M Change & Abnormality RecordExercise Sheet T ot MAROTT = peau Glossary of key term fAC* Visual Management : + Management by eyes. + Displaying the status of an activity so every employee can see it and take appropriate action. Retroactive check : + Itis applicable / effective from since last o.k. check to problem happened now. Abnormal Situation in Quality : + Deviating from what is normal or usual or specification, typically in a way that is undesirable or worrying or unacceptable. + Any resource going out of normal working. Change / 4M Change : + Any day-today change made in process 4M when the part is under supply. + Something become different from standard in process 4M = > Example : Change in Man, Machine, Material and Method, 31vvvvvvY v vy WAROTT hé$ Suzuxi Initial Part : + Initial partis the part or lot or samples from the first lot produced during production trial(T0,T1 and T2),mass production trial & after start of mass production under following conditions:- Glossary of key term ae Anew part A design or engineering change Raw material change Method change Start of production after long layoff(1 year) Process control parameters change Machinery change/new machinery. Supplier change Plant location change MS SoEn THANK YOU 32