Free training deck
Updated · About 45 minutes
4M change management training presentation
4M change management, also called change point management, is the practice of logging every change to the people, machines, materials and methods a process depends on, and checking the product more closely until the change is proven. This free deck teaches it in about 45 minutes. Its 19 editable slides cover what 4M change management is, the four Ms, why changes cause defects, planned and unplanned changes, the change point board, a five-step routine, rating the risk, extra checks and how they end, what IATF 16949 asks, supplier changes, people changes, an illustrative worked example, the common mistakes, a 15-minute activity and four check questions with answers. Every slide has speaker notes.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
The title 4M change management, control every change point, on a navy background with the LeanSuite logo.A look inside
What is in the 19 slides
For team leaders, supervisors, production, quality, maintenance and engineering staff. Widescreen, in plain language, with speaker notes on every slide.
Slide 4: The four Ms 
Slide 14: Example: a new torque gun and a new housing lot 
Slide 16: Try it: find this week's change points
- 14M change management: control every change pointCover
- 2AgendaWhat 4M change management is and the four Ms · Why changes cause defects, planned and unplanned · The routine: log, rate, check, display, close · What the standards and customers expect · Example, common mistakes and activity
- 3What 4M change management isLog every change to the process, and check the product more closely until the change is proven.
- 4The four MsTypical change points under each M.
- 5Why changes cause defectsA stable process makes good parts. The first parts after a change are the least proven.
- 6Planned and unplanned changesLog both. The unplanned ones are the ones that slip through.
- 7Making changes visible: the change point boardA board at the line shows what has changed and where to look.
- 8The routine in five stepsEvery change, every time.
- 9Rating the riskThe levels are yours to set with quality. These are common questions.
- 10Extra checks, and when they endExtra checks need a number and a time, or they fade out on their own.
- 11What IATF 16949 and customers ask forIATF 16949 clause 8.5.6.1 asks for a documented process to control and react to changes that affect product realization, with the effects of a change assessed.
- 12Changes at suppliersA change at a supplier is a change to your process, even if you did not make it.
- 13People changesThe M that is most often missed.
- 14Example: a new torque gun and a new housing lotAn illustrative example of two change points on one line in one week. Your own plant will differ.
- 15Common mistakesLogging only planned changes, so repairs and relief operators are missed.
- 16Try it: find this week's change pointsA 15-minute team activity
- 17Check your understanding4 check questions
- 18AnswersThe answers, to discuss
- 19Key points and next stepsNext: put the change point board up in one area and review it in tomorrow's huddle.
The 45-minute session, slide by slide
- Slides, about: 30 minutes
- Activity (slide 16): 15 minutes
Present · 15 slides
- 14M change management: control every change point
- 2Agenda
- 3What 4M change management is
- 4The four Ms
- 5Why changes cause defects
- 6Planned and unplanned changes
- 7Making changes visible: the change point board
- 8The routine in five steps
- 9Rating the risk
- 10Extra checks, and when they end
- 11What IATF 16949 and customers ask for
- 12Changes at suppliers
- 13People changes
- 14Example: a new torque gun and a new housing lot
- 15Common mistakes
Do the activity · 1 slide
- 16Try it: find this week's change points
Check and follow up · 3 slides
- 17Check your understanding
- 18Answers
- 19Key points and next steps
About 30 minutes of slides and 15 minutes of activity. Present: slides 1 to 15 (4M change management: control every change point; Agenda; What 4M change management is; The four Ms; Why changes cause defects; Planned and unplanned changes; Making changes visible: the change point board; The routine in five steps; Rating the risk; Extra checks, and when they end; What IATF 16949 and customers ask for; Changes at suppliers; People changes; Example: a new torque gun and a new housing lot; Common mistakes). Do the activity: slide 16 (Try it: find this week's change points). Check and follow up: slides 17 to 19 (Check your understanding; Answers; Key points and next steps).
How to run it
Running the session
- 1
Prepare
Read the speaker notes once and swap the illustrative example for one from your own area if you have it. Print the PDF if people like a handout.
- 2
Present
The slides take about 30 minutes. Every slide has notes, so you can talk from them rather than read the slide.
- 3
Do the activity
List every change on the line in the last seven days. Use the maintenance log, shift notes, goods-in records and document changes. The activity slide takes the team through it step by step; allow 15 minutes.
- 4
Check and follow up
Ask the check questions before showing the answers, then agree one next step with an owner and a date before people leave.
The check questions
- 1. What are the four Ms?
- Man, Machine, Material and Method. Some plants add Design, and some add Measurement and Environment.
- 2. Why are unplanned changes the riskiest?
- Nobody planned the extra checks, and a repair or a relief operator is easy to forget to log.
- 3. What do extra checks need so they do not fade out?
- A number of parts to check and a time to have them done, and a recorded time when normal checks resume.
- 4. When can normal checks resume?
- Only when the extra checks are done and passed. A defect keeps the change open.
Templates and guides to go with it
- 4M change management sheet (change point)A shift log of every change to Man, Machine, Material, Method or Design, the extra checks after it and when normal checks resume, with a change point board.
- Shift handover templateSafety, production against plan, holds, downtime events, materials and people, and the open actions the next shift takes over.
- First article inspection report template (AS9102 forms)The three forms in the AS9102 layout (part number, product and characteristic accountability), 22 review checks, the full and partial FAI triggers, and a worked example with one failed characteristic.
- Changeover checklist25 checks for every changeover, a record of planned and actual times, and a log of changeover time against target.
- Topic: Quality managementEvery guide we have on the subject, sorted.
After the session
Put it on the wall
Free printable poster on the same subject, so the team sees it every day: a PNG to download now, and print-ready PDFs from Letter to 24 x 36 in.
FAQ
4M change management training presentation: common questions
It is the practice of logging every change to Man, Machine, Material and Method, and checking the product more closely until the change is proven. It is also called change point management, and Toyota-style plants call a change point a henkaten.
About 45 minutes: roughly 25 minutes of slides, a 15-minute activity and the check questions.
4M1D adds Design to the four Ms, so a drawing or specification change is logged the same way. Some plants use 6M and add Measurement and Environment. Use the set that matches your customers and your process.
IATF 16949 clause 8.5.6.1 requires a documented process to control and react to changes that affect product realization, and clause 8.5.6.1.1 covers temporary changes to process controls. It does not call the method 4M, so check the standard and your customer's requirements.
Yes. The PowerPoint file is fully editable, including the speaker notes. Many teams replace the illustrative example with changes from their own line and add their own check levels.
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