Henkaten-introductionenglish-160630200536 4j5t6j

変更 点 HENKATEN

What does Henkaten means?

変更 = Henkoo = Changing 点 = Tem = Point

What does Henkaten means? Henkaten is an expression,

formed by ing two Japanese words creating a third word with specific meaning.

What does Henkaten means? Henkaten therefore means changing point. Henkaten management is a methodology used to record and track changes in the process that may cause deviations, failures and problems, and may also affect the product or result of this process.

Process Definition According to ISO 9001 - 2008, the process is: An

activity or set of activities using resources, and managed in order to enable the transformation of inputs into outputs.

Examples of Processes Changing a flat tire;

Sharpen a pencil; Inject plastic part; Inspect a component;

Shopping.

Characteristics of a Henkaten A Henkaten occurs when a process undergoes for a modification, planned or sudden, temporary or permanent, of that was originally planned as the final process directly affecting one of variables of the process.

Characteristics of a Henkaten Planned changes Preventive Maintenance ; A new employee is starting on the organization under training; Change the provider of raw material Update a work instruction; Layout changes.

Characteristics of a Henkaten Sudden changes Corrective maintenance; An employee which is absent is replaced by colleague; Using a component under a deviation; A new activity is inserted into the process.

Characteristics of a Henkaten Temporary changes and permanent changes Usually a not planned change is temporary, a condition to work until the previous and

official condition can be restored, but in some cases, a temporary change can become permanent.

Characteristics of a Henkaten Thus a Henkaten will impact one or more process variables, namely the change will always occur in one or more than one of the

variables in the process. People, Machine, Method and or Materials.

MANPOWER

MATERIAL

METHOD

Sub-cause

Sub-cause

Sub-cause

PROBLEM

Sub-cause Sub-cause

MACHINE

MEASUREMENT / ENVIRONMENT

Characteristics of a Henkaten What about Measurement and Environment? Any changing in these two variables, will affect directly the another variable, for example a new instrument for measurement will be recorded in

Method and if there is a very cold day, it will affect directly the people, material or even the machine.

Why to manage and control changes? In every change inside a process there is a learning period, Hence which more the

process is executed, less time it takes and higher is its efficiency, until the process

becomes stable.

Why to manage and control changes? Known process / Stable INPUT

PROCESS

OUTPUT

INPUT

PROCESS

OUTPUT

INPUT

PROCESS

OUTPUT

?

?

INPUT

PROCESS

OUTPUT

New process / Unstable ?

?

?

?

Why to manage and control changes? Every time that a known process or a stable process, undergoes a changing it becomes once again a new process, or unstable, because is quite hard do predict accurately how that modification is going to affect the result of the process, this results will take time to evaluate and judge.

Henkaten Management This material was made thinking in a small organization for didactic purpose, how bigger is the organization also the Henkaten management should be divided accordingly to make easy for the station leader to manage without doing it because if organization politics or his boss has given the order, the station or substation leader must see the Henkaten management as a key tool of management and control or it will be useless, becoming just an ordinary task and a waste of time.

Henkaten Management

Man Machine Method Material

Henkaten Management

Man First activity is to create all the necessary documents, in case if they are not available in the organization, most of the documents are required by best practices and also by ISO standards, the management of Man Henkaten requires a lot of activities by the leadership, and is the most hard to be managed appropriately, because it includes a key point in the changing process management, due the reason is simple, Man will operate the Machine, transforming and handling the Material following a Method and getting information from it. So it is required a good management on that variable. Also because people are not the same (physicaly, behavioral, etc) It requires need for individual training for leveling the operational capacity.

Henkaten Management

Man For the management of Man Henkaten, are necessary the following documents: Board for Henkaten Management; Employees skill map; Workstation layout; Record sheet;

Manpower Management Employees skill map, is a document which must be updated EVERY TIME that a new task is added or planned for employee or for a new employee, this document, gives to the leadership the ability of fast judgement in case of member absence and the replacement strategy for absent positions in the work station.

EMPLOYEE SKILL MAP ACTVIVITY / NAME

ANDRZEJ

ARMAND

BORYS

CLEITON

ELKA

FRANCISKA

NIKOLAI

PATRYK

TEODOR

Activities / job positions

INJECTION LINE 01

PRESS LINE 01

MACHINING LINE 01

ASSEMBLE LINE 01

INJECTION LINE 02

PRESS LINE 02

MACHINING LINE 02

ASSEMBLE LINE 02

LEGEND

NO SKILL ON THE ACTIVITY

TRAINED IS PLANNED

CAN PERFORM THE ACTIVITY SUPERVISION IS REQUIRED

CAN PERFORM THE ACTIVITY NO SUPERVISION REQUIRED

TR

CAN TRAIN OTHER MEMBER ON THE ACTIVITY

Employee’s name and photos

Manpower Management

Manpower Management

Workstation Layout, is a simple diagram showing all the workstations on the shop floor, a scaled drawing of the production lines localization, machines, work stand, and if possible employee’s position on the line or at the machine.

Manpower Management PRESS

INJECTION 1

1

2

Employee’s photos

MACHINNING

ASSEMBLE

2

Employee’s photos should be placed by using magnets, making it easy to change positions when necessary.

1 1

2

2

WORKSTATION LAYOUT

Manpower Management

Record Sheet, is a sheet where the leader can make all the necessary s for keep the changing under control, plan the necessary activities and to make historical data from every changing in his area.

Manpower Management RECORDING SHEET OF MANPOWER CHANGING DATE

CHANGING

REASON

LOCATION

PLANNED OR SUDDEN

PERMANENT OR TEMPORARY

ITENS TO CHECK

HOW LONG

APPROVED

June 06th 2016

Elka is taking Armand position

Armand is absent due sickness

Injection Line 01

Sudden

Temporary

Only key itens from PIS first and last part of the batch

June 06th 2016

TEODOR

June 07th 2016

Nikolai is training with Borys

Nikolai was assigned for a new position

Press Line 01

Planned

Permanent

All PIS itens first and last part of the batch

Until August 07th 2016

TEODOR

Machining Line 01

Planned

Temporary

Only key itens from PIS first and last part of the batch

June 10th 2016

TEODOR

Assemble Line 01

Planned

Temporary

N/A

Until August 08th 2016

TEODOR

June 08th 2016 June 08th 2016

Cleiton is taking Andrzej Line must product during position the lunch time Patryk is trainning Franciszka position

Franciska is going to take vacations

This example sheet was created based on 5W2H, but it could and should modified according with the organization necessities, its culture and internal best practices

Henkaten Management

Machine First activity is to create all the necessary documents, in case if they are not available in the organization, most of the documents are required by best practices and also by ISO standards. Machine management if quite simple if comparing with manpower. This monitoring requires knowledge of the main wearing parts and their life.

Henkaten Management

Machine For the management of Machine Henkaten, are necessary the following documents:

Board for Henkaten Management; Preventive maintenance plan; Workstation layout; Record sheet;

Machine Management Preventive maintenance plan, is a document in which every maintenance programed in advanced for every machine on the shop floor is listed, and this document should contain at least the machine name, position, date for the maintenance and person in charge for the maintenance. It should be most clear that every maintenance, planned in advanced as well the sudden, is a machine Henkaten. Most important on this activity, maintenance department and manufacturing department must act together, but the Henkaten management must be of manufacturing department, because in this relationship, manufacturing department is a customer from maintenance department.

Machine Management PRESS

INJECTION 1

1

2

2

Machine’s position on the shop floor.

MACHINNING

ASSEMBLE

1 1

2

2

WORKSTATION LAYOUT

Machine Management

Record Sheet, is a sheet quite similar with the sheet used to control manpower Henkaten, there are although additional fields on that sheet:  Part produced after changing;  Quantity produced after changing;

Machine Management RECORDING SHEET OF MACHINE CHANGING PLANNED OR PERMANENT PN PRODUCED AFTER OR CHANGING SUDDEN TEMPORARY

QTY PRODUCED AFTER CHANGING

DATE

WHO

CHANGING

LOCATION

June 06th 2016

FRANCISKA

Die changing

Injection Line 01

Planned

Permanent

PART 12345-123

2000 SHOTS

June 07th 2016

ANDRZEJ

Changing the guide pin

Press Line 01

Sudden

Permanent

PART-12345-124

1000 PARTS

Holes position and size

APPROVED

June 08th 2016

TEODOR

Machining Line 01

Sudden

Temporary

PART-12345-125

10.000 PARTS / NEXT CHANGING COME BACK TO USE THE CORRECT OIL

Burrs and surface appearance

APPROVED

June 08th 2016

CLEITON

Assemble Line 01

Planned

Temporary

PART-12345-126

3000 PARTS

Weld cut check test in the first and last of the batch

APPROVED

Changing the cutting oil for a substitute, due missing of correct oil Changing of welding electrodes due the wore out before the expected time

ITENS TO CHECK

APPROVED

All PIS itens first and last APPROVED part of the batch

This example sheet was created based on 5W2H, but it could and should modified according with the organization necessities, its culture and internal best practices

Henkaten Management

Method First activity is to create the only 2 necessary documents, in case if they are not available in the organization, one of its of the documents is also requested by best practices and also by ISO standards. Method management is even more easy than Machine.

Henkaten Management

Method For the management of Method Henkaten, are necessary the following documents: Board for Henkaten Management; Record sheet; Correlation documents list;

Method Management Record Sheet, is exactly the same of Machine, but the contents of records will be different, once the changing in Method will be on documents, process parameters such as velocity, temperature or quantity. what is important to handle parameters as Method Henkaten, not machine, the reason of that is simple, machine modifications are done when mechanical modifications are performed.

Machine Management RECORDING SHEET OF METHOD CHANGING PLANNED OR PERMANENT PN PRODUCED AFTER OR CHANGING SUDDEN TEMPORARY

DATE

WHO

CHANGING

LOCATION

June 06th 2016

CLEITON

Increase of temperare of injection

Injection Line 1

Sudden

Temporary

June 07th 2016

ANDRZEJ

Modification of work instruction

Press Line 1

Planned

Permanent

QTY PRODUCED AFTER CHANGING

ITENS TO CHECK

APPROVED

12345-127

500 shots

All PIS itens first and last part of the batch

TEODOR

12345-128

1000 parts

All PIS itens first and last part of the batch

TEODOR

This example sheet was created based on 5W2H, but it could and should modified according with the organization necessities, its culture and internal best practices

Method Management Correlation document list, is a list required by QMS or the ISO standards, in this list there is a correlation between documents, the purpose of this list is to know or to what documents are necessary to modify when a new information is added or remove from one document.

Method Management DOCUMENTS CORRELATION LIST EXAMPLE DOCUMENT CHANGED / DOCUMENT TO CHECK

PFMEA

PFMEA PROCESS CONTROL PLAN WORK INSTRUCTION PIS

o o X

PROCESS CONTROL PLAN

WORK INSTRUCTION

o

o o

o X

PIS

o o o

X

MACHINE PARAMETERS SHEET

CHECK LIST OF MACHINE

SETUP INSTRUCTION

PACKING INSTRUCTION

X o

o

o o o X o

MACHINE PARAMETERS SHEET

CHECKLIST OF MACHINE SETUP INSTRUCTION PACKING INSTRUCTION COSTUMER DOCUMENTS

o X o

o X o

X X o

X o o

o X o

o X o

COSTUMER DOCUMENTS

The only reason of that list exists is to remind people all documents that one changing is applied, if the organization have another mechanism for this activity so it can be used.

Henkaten Management

Material First activity is to create the record sheet, because is the only document necessary, in case if they are not available in the organization, and this document is quite similar to all the other record sheets.

Material Management RECORDING SHEET OF METHOD CHANGING PLANNED OR PERMANENT PN PRODUCED AFTER OR CHANGING SUDDEN TEMPORARY

DATE

WHO

CHANGING

LOCATION

June 06th 2016

BORYS

Master Batch supplier changing

Injection Line 1

Sudden

Temporary

June 07th 2016

FRANCISKA

Thickness of coil

Press Line 1

Planned

Permanent

QTY PRODUCED AFTER CHANGING

ITENS TO CHECK

APPROVED

12345-129

100 shots

All visual itens of PIS 5 parts every 30 minutes

TEODOR

12345-130

1000 parts

All PIS itens first and last part of the batch

TEODOR

This example sheet was created based on 5W2H, but it could and should modified according with the organization necessities, its culture and internal best practices

Henkaten Management Visual aid The visual aid, it simple to apply any visual detection forms to help in fast identification of some information, this way you can also apply the selected color for each 4Ms, to all relevant documents and controls, thus creating a distinction and visualization fast each change that is occuring in the shop floor, this could be trigger to top management to get involved if necessary.

Henkaten Management

Man - Red Machine - Yellow Method – Green Material - Blue

Thanks for your attention!

Cleiton Morais de Melo [email protected] +55 11 99958-8639