Henkaten - Introduction English

変更点

HENKATEN

What does Henkaten means?

変更 = Henkoo = Changing

点 = Tem = Point


Henkaten is an expression,

formed by joining two

Japanese words creating a third word with

specific meaning.


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.


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


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.


INPUT OUTPUTPROCESS

Known process / Stable

INPUT OUTPUTPROCESS INPUT OUTPUTPROCESS

New process / Unstable

? ?? ? ?? INPUT OUTPUTPROCESS


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


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


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


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 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


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

mailto:[email protected]

Leadership & Management

Henkaten - Introduction English