4/16/2021 4M Analysis Process – Continuously Improving Manufacturing

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4M Analysis Process
 August 29, 2018 In : Blog Root Cause Analysis 6  42,588  3 min read

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The purpose of this procedure is to de ne 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.

Focused Improvement training can be taken here

4M Analysis Steps

De ne Improvement Statement
List Issues into Categories
Resolve Issues

De ne Improvement Statement

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4M Fishbone Diagram

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Select a process system or item that can be replaced by another type of system if necessary.
Each attribute contains a de nition and a set of details that de ne its purpose

De ne Statement for Fishbone

“Improve”
Select Process
Select Attribute
Statement
Improve
COB Unloading Area
General & Operator Maintainability

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List Issues Into Categories

Put a category on each branch of the shbone and ll in the attributes of each category on the
branch

4M Fishbone Diagram

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List Issues Into Categories

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Man
Skill
Technology
Organization
Resources
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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”. 
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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

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Select Condition from list of Issues on the shbone

Example: “Design – Visual access limited”
Select Proper Problem Solving Methodology
Problem Solving Methodologies
Autonomous Maintenance Process
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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

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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.

TAGS #4M Fishbone Diagram #4M Production #Define Countermeasures #Do Cause & Analysis

#Energy Awarness #Four M analysis #Ishikawa diagram #Man - Machine - Material - Method #Operator Maintainability

#root cause analysis examples

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The Fishbone Diagram

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6 Comments

RADHAKRISHNAN
August 29, 2018 at 7:00 am

kindly send news letter

Reply

Leantpm6s
August 29, 2018 at 7:55 am

Thanks for your interest in our Lean Manufacturing training materials. An email was just sent to
con rm your subscription. Please nd the email now and click ‘Con rm Follow’ to start subscribing.

Reply

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Gayan
September 27, 2018 at 11:28 am

Please send me How to write strategies of zero accident

Reply

Leantpm6s
September 27, 2018 at 1:39 pm

Thanks for interest in our products. Can you please be more speci c about your question, type of
industry, what can of hazards your employees are exposed to, current methods of accident prevention
etc.
Some of the answers can be found here: https://leanmanufacturing.online/safety-health-and-
environment-tpm-pillar/

Reply

Engineer Arif Samman

September 9, 2019 at 9:58 pm

Hi
very useful information , my note is” we can use 5 whys Tool also to de ne root cause for ” Example: “Design –
Visual access limited”.
Thanks.

Reply

Prince
January 30, 2021 at 6:12 am

kindly send a questionnaire on 4M change management min. 40 questions

Reply

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