4M Analysis Process

 

The purpose of this procedure is to define the steps to do a 4M Analysis of a system or subsystem. The goal of this 4M Analysis Procedure is to reduce losses in the factory by using the Equipment Attributes as a guideline to achieve this end.

4M Analysis Steps

• Define Improvement Statement

• List Issues into Categories

• Resolve Issues

Define Improvement Statement

4M Fishbone Diagram

• Select a process system or item that can be replaced by another type of system if necessary.

• Each attribute contains a definition and a set of details that define its purpose

Define Statement for Fishbone

• “Improve”

• Select Process

• Select Attribute

• Statement:

1. Improve
2. COB Unloading Area
3. General & Operator Maintainability

List Issues Into Categories

• Put a category on each branch of the fishbone and fill in the attributes of each category on the branch

4M Fishbone Diagram

List Issues Into Categories

• Man
  • Skill
  • Technology
  • Organization
  • Resources
  • Communications
• Machine
  • Design
  • Installation
  • Supplier
• Methods
  • Schedule
  • Procedure
• Material
  • Design
  • Quality
• Other
  • Budget
  • Demand

• Now the team asked the questions of each category: (Evaluating “Man & Skill”) How does “a person’s skill affect the process we are trying to improve”.
• After each question, all of the issues that arise are listed under that subcategory of the 4M

Capture & List Issues into Categories

Machine

Design

Visual access limited

Easy access limited

Maintainability limited (bearings)

Installation

Mounting brackets not clean design

Conveyors stacked on top of one another

Supplier

Too much string

Too many damaged cases

4M Analysis Resolution of Issues

• Select Condition from list of Issues on the fishbone
  • Example: “Design – Visual access limited”
• Select Proper Problem Solving Methodology
  • Problem Solving Methodologies
  • Autonomous Maintenance Process
  • Standards
  • Inspection, Cleaning & Lubrication
  • Root Cause Analysis
  • Cap Do Process
  • 5S Checklist
  • One Point Lesson Plans
  • Re-engineering (MP Data)
  • Project Safety Checklist

• Select Owner of Countermeasures
  • Create work order to schedule work for trades
• Schedule Countermeasure Completion

• 30 days after completion, evaluate countermeasure to ensure that all of the expectations, of the owners, have been met. If not, re-do cause and analysis.

https://tinyurl.com/33mtsu8a

Summary:

The 4M analysis process, primarily used in manufacturing and quality management, helps identify potential causes of problems by categorizing them into four key areas: Man, Machine, Material, and Method. This structured approach allows for a more systematic and efficient root cause analysis, leading to improved processes and reduced defects.

Here's a breakdown of the 4M categories: 

Man (People):

• This encompasses the human factors involved in the process, including skills, training, experience, work habits, and even physical and mental well-being. For example, a lack of training or improper handling of equipment could be categorized under "Man".
• Machine (Equipment):

  This category focuses on the machinery, tools, and technology used in the process. Considerations include maintenance schedules, reliability, performance, and suitability for the task. A faulty machine or one that isn't properly calibrated could be a contributing factor.
• Material:

  This refers to the raw materials, components, and supplies used in the process. Quality, consistency, and proper storage are key aspects to examine within this category. Defective materials, improper handling, or inconsistent supply could be issues.
• Method:

  This category covers the processes, procedures, and instructions used to complete a task. It includes workflows, standard operating procedures, and quality control measures. Outdated or poorly designed methods, lack of clarity in instructions, or non-standardized procedures could be problematic.

By systematically analyzing each of these four Ms, businesses can pinpoint the root causes of problems, implement corrective actions, and ultimately improve overall efficiency and product quality. The 4M analysis is a foundational tool for continuous improvement methodologies like Kaizen and Six Sigma. 

Ishikawa Diagram / Fishbone Chart

These diagrams are named after Kaoru Ishikawa, a Japanese professor and influential quality management expert. They were first started to be used in the 1940s, and are considered to be one of the seven important tools in quality management. They are alternatively referred to as Ishikawa diagrams, fishbone charts, cause and effect charts, or root cause diagrams. They are most frequently used in product design and manufacturing, analyzing defects or deviations and trying to identify the root causes.

The problem is stated in a box to the right of the diagram, and each major branch is devoted to some of the key issues that could have caused the problem. Major issues are generally grouped by people, materials, machinery, processes, measurements and external factors. But there is a whole art to grouping these major branches, and people have come up with standard groupings such as the 8 Ms, the 8 Ps, or the 4 Ss.

The 8 Ms (used in manufacturing)

• Machine (technology)
• Method (process)
• Material (Includes Raw Material, Consumables and Information.)
• Man Power (physical work)/Mind Power (brain work): Kaizens, Suggestions
• Measurement (Inspection)
• Milieu/Mother Nature (Environment)
• Management/Money Power
• Maintenance

The 8 Ps (used in service industry)

• Product=Service
• Price
• Place
• Promotion/Entertainment
• People(key person)
• Process
• Physical Evidence
• Productivity & Quality

The 4 Ss (used in service industry)

• Surroundings
• Suppliers
• Systems
• Skills

There is a great Wikipedia article on Ishikawa Diagrams (link), which provides a lot of context, questions to ask in each branch, and additional resources and links.