4M Change Management

The Problem

Manufacturing changes are often recorded manually or scattered across spreadsheets, emails, and registers. When a customer raises an issue, teams struggle to identify:

• What changed on the production line
• Who made the change
• Whether the change caused the defect

This leads to delayed responses, weak root cause analysis, and poor customer confidence.

DOPOMAC Solution

DOPOMAC digitizes the complete Japanese 4M Change Management system so that every change is logged, traceable, and analyzable in real time.

• Centralized 4M change recording
• ISO, IATF & MACE aligned structure
• Instant traceability for customer issues

Structured 4M Change Recording

Each production change is recorded in a standardized digital format, ensuring zero data loss and complete audit transparency.

4M Change Analytics & Dashboards

Recorded data is transformed into actionable insights through intuitive dashboards and analytics.

• Distribution of changes across Man, Machine, Material & Method
• Planned vs Unplanned change analysis
• Trend of changes vs rejection or complaint rate
• Identification of abnormal and high-risk change patterns

🤖 AI-Based Root Cause Analysis

When a customer complaint arises, DOPOMAC uses AI to backtrace affected production batches to their corresponding 4M changes.

• Identifies all changes active during production
• Highlights suspicious change combinations
• Generates data-backed explanations for customers

🔍 AI Gap & Weak Link Identification

The system continuously analyzes historical 4M data to identify weaknesses in processes and operations.

• Machines linked with frequent abnormalities
• Materials or methods causing repeated issues
• Skill and training gaps in manpower

The 4M Framework