Classification of 4M Change

Planned Change
Planned/ Activities to be done
4M Change Description Actions Taken Unplan/ Suspected lot
Abnormal Change Set up Approval Retroactive Inspection check

Operator of same skill

deputed (who has been
Planned Change Yes No No
working on the station
frequently)
Operator on leave with
information
Operator of same skill
deputed (Operator
Planned Change Yes No No
deputed to work station
after long duration)

Operator On
Man

leave without Operator of same skill

Planned Change Yes No No
information (during deputed
start of shift)

Operator on Job Operator of same skill

Planned Change Yes No NO
rotation deputed

Operator of same skill

New Joining of Operator Planned Change Yes No No
deputed
Production run by same
Shift Extended Planned Change Yes NO NO
operator
Machine under Production shifted to
Planned Change Yes No No
preventive maintenance same capacity m/c
Machine

Tool under Production done with

Planned Change Yes No No
preventive maintenance 2nd set of Tool
Restart the m/c after
Power Source changed
changing the machine Planned Change Yes No No
with intimation
parameters, if required
Material received from
Material

other approved source Start production after set

Planned Change Yes No No
(usually not being used up approval
regularly)

Process sequence /
Method

Start production after set

Additional / New Planned Change Yes No No
up approval
technology Change
 Unplanned Change
Planned/ Activities to be done
4M Change Description Actions Taken Unplan/ Suspected lot
Abnormal Change Set up Approval Retroactive Inspection check

Operator suddenly leave Operator of same skill

work place due to deputed (who has been Unplanned
Man

Yes Yes No
accident/illness (after working on the station Change
start of production) frequently)

Production shifted to Unplanned

Machine under break Yes Yes No
same capacity m/c Change
down

Production done with Unplanned

Machine

Tool under break down Yes Yes No

2nd set of Tool Change

Unplanned
Power Failure Restart the m/c Yes Yes No
Change
Restart the m/c after
Power Source changed Unplanned
changing the machine Yes Yes No
after power failure Change
parameters, if required
Process sequence /
Method

Start production under Unplanned

Additional /New Yes Yes No
temporary deviation Change
technology Change
 Abnormal Situation
Planned/ Activities to be done
4M Change Description Actions Taken Unplan/ Suspected lot
Abnormal Change Set up Approval Retroactive Inspection check

Operator On
leave without Operator of under Abnormal
Yes No Yes
information (during skill deputed Situation
start of shift)

Operator
suddenly leave
Man

Operator of under skill Abnormal

work place due to Yes Yes Yes
deputed Situation
accident/illness (after
start of production)

Operator on Job Operator of under skill Anormal

Yes No Yes
rotation deputed situation

Operator of under skill Abnormal

New Joining of Operator Yes No Yes
deputed Situation
Production shifted to
Machine under Abnormal
higher/ lower capacity Yes No Yes
preventive maintenance Situation
m/c
Production shifted to
Machine under break Abnormal
higher/ lower capacity Yes Yes Yes
down Situation
m/c
Production done with
Tool under Abnormal
temporarily repaired Yes Yes Yes
break down Situation
Die/Tool
Machine

Machine parameters
Machine started after Abnormal
found out of spec. Yes Yes Yes
resetting the parameters Situation
during routine checking

Machine started after

Abnormal
Poka Yoke Failure poka yoke verified Yes Yes Yes
Situation
corrected

Repeated Power Abnormal

Restart the m/c Yes Yes Yes
Failure Situation
Material used from
Start production with Abnormal
unapproved source Yes Yes Yes
Material

approved source material Situation

without intimation
Different grade Start production with OK Abnormal
Yes Yes Yes
material used material Situation
Method

Inspection Start work after set up Abnormal

Yes Yes Yes
Breakdown approval Situation