変更 点 HENKATEN
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 joining 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 HenkatenA 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 HenkatenPlanned 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 HenkatenSudden 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.
PROBLEM
METHOD
MEASUREMENT / ENVIRONMENT
MATERIALMANPOWER
MACHINE
Sub-cause Sub-cause Sub-cause
Sub-cause
Sub-cause
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?
INPUT OUTPUTPROCESS
Known process / Stable
INPUT OUTPUTPROCESS INPUT OUTPUTPROCESS
New process / Unstable
? ?? ? ?? INPUT OUTPUTPROCESS
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
ManMachineMethodMaterial
Henkaten Management
ManFirst 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.
ManFor the management of Man Henkaten, are necessary the following documents:
Board for Henkaten Management;Employees skill map;Workstation layout;Record sheet;
Henkaten 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.
Manpower Management
Manpower ManagementEm
plo
yee’sn
ame
and
ph
oto
s
Act
ivit
ies
/ jo
bp
osi
tio
ns
TR
EMPLOYEE SKILL MAP
MACHINING LINE 02
CAN TRAIN OTHER MEMBER
ON THE ACTIVITY
NO SKILL ON THE ACTIVITY
CAN PERFORM THE ACTIVITY
SUPERVISION IS REQUIRED
TRAINED IS PLANNED
CAN PERFORM THE ACTIVITY NO
SUPERVISION REQUIRED
NIKOLAI PATRYK TEODORCLEITON FRANCISKAARMAND
LEGEND
ASSEMBLE LINE 02
PRESS LINE 02
INJECTION LINE 02
ASSEMBLE LINE 01
MACHINING LINE 01
PRESS LINE 01
INJECTION LINE 01
ACTVIVITY / NAME ANDRZEJ BORYS ELKA
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
WORKSTATION LAYOUT
1
2
1
INJECTION PRESS
MACHINNING ASSEMBLE
2
1 2
1
2
Manpower Management
Employee’s photos Employee’s photos should be placed by using magnets, making it easy to change positions when necessary.
Record Sheet, is a sheet where the leader can make all the necessary registers for keep the changing under control, plan the necessary activities and to make historical data from every changing in his area.
Manpower Management
Manpower ManagementThis example sheet was created based on 5W2H, but it could and should modified according with the organization necessities, its culture and internal best practices
RECORDING SHEET OF MANPOWER CHANGING
HOW LONG APPROVED
June 06th 2016 TEODOR
Until August 07th 2016 TEODOR
June 10th 2016 TEODOR
Until August 08th 2016 TEODOR
Line must product during
the lunch timeMachining Line 01 Planned Temporary
Only key itens from PIS first
and last part of the batch
DATE CHANGING REASON LOCATIONPLANNED OR
SUDDEN
PERMANENT OR
TEMPORARYITENS TO CHECK
June 06th 2016Elka is taking Armand
position
Armand is absent due
sicknessInjection Line 01 Sudden Temporary
Only key itens from PIS first
and last part of the batch
Nikolai was assigned for
a new positionPress Line 01June 07th 2016
Nikolai is training with
BorysPlanned Permanent
All PIS itens first and last
part of the batch
June 08th 2016Cleiton is taking Andrzej
position
Franciska is going to take
vacationsAssemble Line 01 Planned Temporary N/AJune 08th 2016
Patryk is trainning
Franciszka position
Henkaten Management
MachineFirst 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.
Machine For the management of Machine Henkaten, are necessary the following documents:
Board for Henkaten Management;Preventive maintenance plan;Workstation layout;Record sheet;
Henkaten 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
WORKSTATION LAYOUT
1
2
1
INJECTION PRESS
MACHINNING ASSEMBLE
2
1 2
1
2
Machine Management
Machine’s position on the shop floor.
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
Machine ManagementThis example sheet was created based on 5W2H, but it could and should modified according with the organization necessities, its culture and internal best practices
RECORDING SHEET OF MACHINE CHANGING
APPROVED
APPROVED
APPROVED
APPROVED
APPROVEDITENS TO CHECK
All PIS itens first and last
part of the batch
Holes position and size
Burrs and surface
appearance
Weld cut check test in the
first and last of the batch
10.000 PARTS / NEXT
CHANGING COME BACK TO
USE THE CORRECT OIL
June 08th 2016 CLEITONChanging of welding
electrodes due the wore out
before the expected time
Assemble Line 01 Planned Temporary PART-12345-126 3000 PARTS
PART-12345-124 1000 PARTS
June 08th 2016 TEODORChanging the cutting oil for
a substitute, due missing of
correct oil
Machining Line 01 Sudden Temporary PART-12345-125
June 07th 2016 ANDRZEJ Changing the guide pin Press Line 01 Sudden Permanent
June 06th 2016 FRANCISKA Die changing Injection Line 01 Planned Permanent PART 12345-123 2000 SHOTS
DATE WHO CHANGING LOCATIONPLANNED OR
SUDDEN
PERMANENT
OR
TEMPORARY
PN PRODUCED AFTER
CHANGING
QTY PRODUCED AFTER
CHANGING
Henkaten Management
MethodFirst 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.
MethodFor the management of Method Henkaten, are necessary the following documents:
Board for Henkaten Management;Record sheet;Correlation documents list;
Henkaten 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.
Method Management
Machine ManagementThis example sheet was created based on 5W2H, but it could and should modified according with the organization necessities, its culture and internal best practices
All PIS itens first and last
part of the batchTEODOR
All PIS itens first and last
part of the batchTEODOR
June 07th 2016 ANDRZEJModification of work
instructionPress Line 1 Planned Permanent 12345-128 1000 parts
ITENS TO CHECK APPROVED
June 06th 2016 CLEITONIncrease of temperare of
injectionInjection Line 1 Sudden Temporary 12345-127 500 shots
RECORDING SHEET OF METHOD CHANGING
DATE WHO CHANGING LOCATIONPLANNED OR
SUDDEN
PERMANENT
OR
TEMPORARY
PN PRODUCED AFTER
CHANGING
QTY PRODUCED AFTER
CHANGING
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 remember what documents are necessary to modify when a new information is added or remove from one document.
Method Management
Method Management
PACKING
INSTRUCTION
PFMEA o o o o
DOCUMENT
CHANGED /
DOCUMENT TO
CHECK
PFMEAPROCESS
CONTROL PLAN
WORK
INSTRUCTIONPIS
MACHINE
PARAMETERS
SHEET
CHECK LIST OF
MACHINE
SETUP
INSTRUCTION
PROCESS
CONTROL PLAN o o o oWORK
INSTRUCTION o o o oPIS X X X X
MACHINE
PARAMETERS SHEET oCHECKLIST OF
MACHINE
SETUP
INSTRUCTION o o X X o oPACKING
INSTRUCTION X X X o X X XCOSTUMER
DOCUMENTS o o o o o o o o
DOCUMENTS CORRELATION LIST EXAMPLE
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
MaterialFirst 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
All PIS itens first and last
part of the batchTEODOR
All visual itens of PIS 5
parts every 30 minutesTEODOR
June 07th 2016 FRANCISKA Thickness of coil Press Line 1 Planned Permanent 12345-130 1000 parts
ITENS TO CHECK APPROVED
June 06th 2016 BORYSMaster Batch supplier
changingInjection Line 1 Sudden Temporary 12345-129 100 shots
RECORDING SHEET OF METHOD CHANGING
DATE WHO CHANGING LOCATIONPLANNED OR
SUDDEN
PERMANENT
OR
TEMPORARY
PN PRODUCED AFTER
CHANGING
QTY PRODUCED AFTER
CHANGING
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 aidThe 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 - RedMachine - YellowMethod – GreenMaterial - Blue
Thanks for your attention!
Cleiton Morais de Melo [email protected]+55 11 99958-8639