Henkaten Fundamentals - English.pdf

Short presentation to present the fundamentals of changing management of Japonese culture - Henkaten

1. 変更点
HENKATEN

2. What does Henkatenmeans?
変更= Henkoo= Changing
点= Tem = Point

3. What does Henkatenmeans?
Henkatenis an expression,
formed by joining two
Japanese words creating a third word with
specific meaning.

4. What does Henkatenmeans?
Henkatentherefore 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.

5. Process Definition
According to ISO 9001-2015, the process
is: Any activity or set of activities that
use resources to transform inputs into
outputs

6. ExamplesofProcesses
Changing a flat tire;
Sharpen a pencil;
Inject plastic part;
Inspect a component;
Shopping.

7. Characteristics of aHenkaten
AHenkatenoccurswhena
processundergoes for
amodification,plannedorsudden,
temporary or permanent,of
thatwasoriginally plannedas
thefinalprocessdirectly affectingone
ofvariables of the process.

8. Characteristics of aHenkaten
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.

9. Characteristics of aHenkaten
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.

10. Characteristics of aHenkaten
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.

11. Characteristics of aHenkaten
Thus a Henkatenwill impact one or more
process variables, namely the change will
always occur in one or more than one of the
variables in the process, according to the
Ishikawa Diagram Man, Machine, Method
and or Materials.

13. Characteristics of aHenkaten
What about Measurementand Environment?
Any changing in these two variables, will affect
directly another variable, for example a new
instrument for measurement will be recorded in,
or Method and if there is a very cold day, it will
affect directly the people, material or even the
machine.

14. 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.

15. Why to manage and control changes?
INPUT OUTPUTPROCESS
Known process / Stable
INPUT OUTPUTPROCESS INPUT OUTPUTPROCESS
New process / Unstable
? ?? ? ?? INPUT OUTPUTPROCESS

16. 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.

17. HenkatenManagement
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.

18. HenkatenManagement
Man
Machine
Method
Material

19. HenkatenManagement
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, Manwill
operate the Machine, transforming and handling the Materialfollowing a
Methodand 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.

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

21. 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
workstation.
Manpower Management

22. Manpower Management
Employee’s name and photos
Activities / job positionsTR
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 / NAMEANDRZEJ BORYS ELKA

23. 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

24. 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.

25. 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

26. Manpower Management
This example
sheet was
created based
on 5W2H, but
it could and
should
modified
according
with the
organization
necessities, its
culture and
internal best
practicesRECORDING SHEET OF MANPOWER CHANGING
HOW LONG APPROVED
June 06th 2016 TEODOR
Until August 07th 2016TEODOR
June 10th 2016 TEODOR
Until August 08th 2016TEODOR
Line must product during
the lunch time
Machining Line 01 Planned Temporary
Only key itens from PIS first
and last part of the batch
DATE CHANGING REASON LOCATION
PLANNED OR
SUDDEN
PERMANENT OR
TEMPORARY
ITENS TO CHECK
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
Nikolai was assigned for
a new position
Press Line 01June 07th 2016
Nikolai is training with
Borys
Planned Permanent
All PIS itens first and last
part of the batch
June 08th 2016
Cleiton is taking Andrzej
position
Franciska is going to take
vacations
Assemble Line 01 Planned Temporary N/AJune 08th 2016
Patryk is trainning
Franciszka position

27. HenkatenManagement
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.

28. Machine
For the management of Machine Henkaten, are
necessary the following documents:
Board for Henkaten Management;
Preventive maintenance plan;
Workstation layout;
Record sheet;
HenkatenManagement

29. 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

30. WORKSTATION LAYOUT
1
2
1
INJECTION PRESS
MACHINNING ASSEMBLE
2
1 2
1
2
Machine Management
Machine’s position on the
shop floor.

31. 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

32. Machine Management
This example
sheet was
created based
on 5W2H, but it
could and
should modified
according with
the organization
necessities, its
culture and
internal best
practicesRECORDING 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 2016CLEITON
Changing of welding
electrodes due the wore out
before the expected time
Assemble Line 01PlannedTemporaryPART-12345-126 3000 PARTS
PART-12345-124 1000 PARTS
June 08th 2016TEODOR
Changing the cutting oil for
a substitute, due missing of
correct oil
Machining Line 01Sudden TemporaryPART-12345-125
June 07th 2016ANDRZEJ Changing the guide pinPress Line 01 Sudden Permanent
June 06th 2016FRANCISKA Die changing Injection Line 01PlannedPermanentPART 12345-123 2000 SHOTS
DATE WHO CHANGING LOCATION
PLANNED OR
SUDDEN
PERMANENT
OR
TEMPORARY
PN PRODUCED AFTER
CHANGING
QTY PRODUCED AFTER
CHANGING

33. HenkatenManagement
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.

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

35. 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

36. Machine Management
This example
sheet was
created based
on 5W2H, but it
could and
should modified
according with
the organization
necessities, its
culture and
internal best
practicesAll PIS itens first and last
part of the batch
TEODOR
All PIS itens first and last
part of the batch
TEODOR
June 07th 2016ANDRZEJ
Modification of work
instruction
Press Line 1 Planned Permanent 12345-128 1000 parts
ITENS TO CHECK APPROVED
June 06th 2016CLEITON
Increase of temperare of
injection
Injection Line 1Sudden Temporary 12345-127 500 shots
RECORDING SHEET OF METHOD CHANGING
DATE WHO CHANGING LOCATION
PLANNED OR
SUDDEN
PERMANENT
OR
TEMPORARY
PN PRODUCED AFTER
CHANGING
QTY PRODUCED AFTER
CHANGING

37. 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

38. Method ManagementPACKING
INSTRUCTION
PFMEA
oooo
DOCUMENT
CHANGED /
DOCUMENT TO
CHECK
PFMEA
PROCESS
CONTROL PLAN
WORK
INSTRUCTION
PIS
MACHINE
PARAMETERS
SHEET
CHECK LIST OF
MACHINE
SETUP
INSTRUCTION
PROCESS
CONTROL PLANo ooo
WORK
INSTRUCTIONoo oo
PIS
XXX X
MACHINE
PARAMETERS SHEET o
CHECKLIST OF
MACHINE
SETUP
INSTRUCTIONooXXoo
PACKING
INSTRUCTIONXXXoXXX
COSTUMER
DOCUMENTSoooooooo
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.

39. HenkatenManagement
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.

40. Material ManagementAll PIS itens first and last
part of the batch
TEODOR
All visual itens of PIS 5
parts every 30 minutes
TEODOR
June 07th 2016FRANCISKA Thickness of coil Press Line 1 Planned Permanent 12345-130 1000 parts
ITENS TO CHECK APPROVED
June 06th 2016 BORYS
Master Batch supplier
changing
Injection Line 1Sudden Temporary 12345-129 100 shots
RECORDING SHEET OF METHOD CHANGING
DATE WHO CHANGING LOCATION
PLANNED 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

41. HenkatenManagement
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.

42. HenkatenManagement
Man -Red
Machine -Yellow
Method –Green
Material -Blue

43. Thanks for your attention!
Cleiton Morais de Melo
[email protected]
[phone]