4M Change Management | Change Management Business Process

WHAT IS 4M CHANGE MANAGEMENT?

The 4M change management is a systematic approach to managing changes to:

• MAN
• MACHINE
• METHOD
• MATERIAL

It helps to ensure that changes are correctly implemented and efficiently, with minimal disruption to operations.

DEFINITION: 4M CHANGE

A situation that affects quality in any way may lead to customer complaints or internal rejection.

The term “change” to a process or product is defined as a situation where the “man, material, machine, and method used for” are not in accordance with the work standard, control plan, work instructions, and customer requirements.

SCOPE: 4M CHANGE

It is applicable to all temporary or permanent changes related to Man, Machine, Method & Material (4M), and engineering standards/specifications change during development and normal production including the supplier production process.

RESPONSIBILITY: 4M CHANGE

ACTIVITY	RESPONSIBILITY
Change Point Control Board	Shift  In-charge/Supervisor
Change Approval	Quality Head/Plant Head

4Ms  OF CHANGE MANAGEMENT

The  4Ms of change management are:

Man: Any change in people such as operators, inspectors, engineers involved in the process/work/task.

Machine: Any change of machine/equipment/ tools/gauges used in the process.

Method: Any change in the method/way the process/work is carried out.

Material: Any change in the raw materials or other inputs used in the work/process.

 

TYPES OF 4M CHANGE

There are three types of 4M changes:

• PLANNED CHANGE – EXPECTED CHANGE
• UNPLANNED CHANGE – UNEXPECTED CHANGE
• ABNORMAL CHANGE

PLANNED CHANGE

When we have the information about change in advance then we call it as planned change.

UNPLANNED CHANGE

When we do not have any information about the change in advance then we call it Unplanned change.

ABNORMAL CHANGE

Which is different from normal and not as per specification, and opposite from normal.

4M CHANGE CATEGORIES

All changes for every M are categories as:

• PLANNED CHANGE
• UNPLANNED CHANGE
• ABNORMAL CHANGE

ABNORMAL CHANGE | EXAMPLES

CATEGORY	CHANGE DESCRIPTION
MAN	Operator sickness or Injury/accident
	The operator produces defective parts continuously
	Manpower deputed after a long break due to natural disasters/Curfew/ Lockdown
MACHINE	Power failure
	Continuous rejection produced by machine
	Machine accident, tool/fixture broken
	Low tonnage machine used for production
	Machine run after long duration due to natural disasters / sudden lockdown/curfew
METHOD	Process parameters found out of spec during routine checking
	Poke yoke failure observed during routine checking
	Unidentified material/components
	The operator not working as per the WI
	Sudden stoppage of production due to natural disasters/sudden lockdown/curfew
	Start of production after a long duration due to due to natural disasters/curfew/lockdown
MATERIAL	Wrong material/grade used
	Shortage of material
	Material bin or trolley fell down on shop floor
	Start of production after a long duration due to natural disasters/curfew/lockdown

PLANNED CHANGE | EXAMPLES

CATEGORY	CHANGE DESCRIPTION
MAN	Working after a long time i.e.> 30 DAYS
	Working after 12 Hrs.
	Operator on leave with information
MACHINE	After preventive maintenance  of the machine /die /fixture
	New machine/die /fixture used
METHOD	Process sequence change
	Machine location change
	Packing method change
	Checking method change
MATERIAL	Material/source change

UNPLANNED CHANGE | EXAMPLES

CATEGORY	CHANGE DESCRIPTION
MAN	Operator on leave without information
MACHINE	Machine under breakdown
	Tool/Die/Fixture under breakdown
METHOD	Measuring equipment/gauge fallen on the floor
MATERIAL	Unapproved material sources used

4M CHANGE MANAGEMENT PURPOSE

The purpose or importance of 4M change management is to: 

• To control and react to changes that impact product realization processes, including those changes caused by the organization, the customer, or any supplier.
• Changes can have a significant impact on operations
• 4M change management helps to reduce the risks associated with change.
• Helps to ensure that changes are implemented in a way that reduces disruption to manufacturing processes or operations.

CHANGE MANAGEMENT BUSINESS PROCESS

The 4M change management business process is:

• First to identify the need for change or change occurred.
• Evaluate the impact of the change.
• Make a change plan & communicate the change plan to the affected parties.
• Implement the change plan
• Monitor the change, and make necessary adjustments if required.

4M CHANGE MANAGEMENT BENEFITS

• Smoother and more effective change implementation.
• Risk of operations disruption reduced.
• Improved success rate of change efforts.
• Employee satisfaction levels increased
• Customer satisfaction increased.
• Improved product or service quality.
• Increased efficiency by eliminating waste
• Improved workplace safety
• Reduced costs by improving efficiency & waste reduction