P dash M Analysis is a systematic Problem-Solving Philosophy for

Chronic Losses. The term P-M Analysis comes from the following
origin: P – Phenomena(non), Physical; M – Mechanism, Relationship
(Machine, Man/Woman, Material, Method)

When To Use P-M Analysis?

Root Cause Analysis
Two Types of Problem Solving Techniques
Why is the 5-why Analysis effective?
Example

Problem: No.1 conveyor stopped.

What is Actually happening (Phenomenon):

Overload and the fuse blew.

Why-1 Why was there an overload?
The bearing was not sufficiently lubricated.
Why-2 Why was it not lubricated sufficiently?
The lubricating pump was not pumping.
Why-3 Why was it not pumping sufficiently?
The shaft of the pump was worn and rattling.
Why-4 Why was the shaft of the pump was worn and rattling.
There was no strainer attached and metal scrap got in.
Why-5 Why was no strainer attached?
There are no checking rules.
 Action is taken for Root-Cause
Why
Why was there an overload?
Why was it not lubricated
sufficiently?
Why was it not pumping
sufficiently?
Why was the shaft of the
pump was worn and rattling?
Why was no strainer attached?
Answer (Observation)
The bearing was not
sufficiently lubricated.
Logical linkage is required
The lubricating pump was not
pumping.
Logical linkage is required
The shaft of the pump was
worn and rattling.
There was no strainer attached
and metal scrap got in.
There are no checking rules.
Action
the bearing was replaced.
The lubrication pump was checked.
The shaft of the pump was replaced.
The strainer was attached and cleaned
up the lubrication tank.
An Autonomous Maintenance
standard has been developed.

How can we identify what is actually happening?

Problem
Do’s
 Identify specific problems, which is the deviation between our expectations and actually happening.
Don’ts
 Before identifying specific problems, jump to action.
 Talking with just feeling.
The 5-why analysis must be used when to identify “Phenomenon” What is
“Phenomenon”.
Phenomenon
Is (What is actually happening)
1. The fact you observed with your eyes and numeric data.
2. The fact without presumption
Is Not
1. Your own opinion, feeling.
5-Why Analysis vs. P-M Analysis
 Features in P-M Analysis
P-M Analysis
(Multiple-Path) 5-Why Analysis (Single-Path)
Phenomenon – The same step requires identifying the “Phenomenon”.
Statement (Analysis – Use 5W1H Analysis (Stratification Step)
Start-Point) – 5-Why Analysis requires highly to start the analysis at a specific phenomenon.
– Describe All Possible factors.
Logical Linkage
(The Linkage
between Why and – In order to describe all possible factors, – Describe clearly Why &
Why) Recommend setting up the “P-M Gap” Statement. Answer (because).
– Before moving the next
why require to verify
(capture) the evidence.
– Identify and describe All Possibilities first, and
then verify which factors can contribute to the
above possibility (“Gap from Principle of – You say “Why”, capture
Operation”) the “evidence”.

Verification Process -Identify “Gap” instead of “Why” -You can say “Because …”
– Understand the differences between “Fish-Bone – Show the “evidence”
Analysis” and/or “Why-Why Analysis” before moving to the next
Key Points for Use – 4M Analysis is Not a “Fish-Bone” why.
– The higher Team Leaders’ Level.
– All Employee
– Operators (Since AM
Who should use – Since AM Step-4 Step-2)
P-M Analysis
 Steps of P-M Analysis
P-M Analysis Step Activity Key Learning
Step-1 Clarify the Phenomenon Phenomenon Statement

Step-2 Examine-in terms of Physical Principle Involved P-M Gap

Step-3 Analyze Contributing Conditions Principle of Operation

Study the relationship between 4M’s

Step-4 (Man (Skill), Machine, Material & Methods) Machine Structure & Function Diagram
Step-5 Study of what the conditions must be Optimal Conditions

Step-6 Study of investigation methods Machine Diagnosis Technique & Measurements

Step-7 Find out All Potential Abnormalities
Step-8 Implement & Plan Countermeasures
P-M Analysis Story Board Layout
Problem-Solving Story by P-M Analysis
 CAP-Do Cycle & P-M Analysis
CAP-Do Cycle Process P-M Analysis Step

1-1 Analyze the “Gap” between Target and Actual situation.1-2 Step-1 Clarify the Phenomenon
Check Prioritize No.1 Contributor as FI Theme (Topics)1-3 Stratify Examine-in terms of the Physical Principle
Problem into Phenomenon Step-2
involved. (P-M Gap)
Step-3 Contribute Conditions

2-1 Principle of Movement (Processing) -Identify the “Gap” Step-4 Study the relationship between 4M’s
between the Principle of Processing and Actual Conditions.
Study of what the condition must be (Optimal
Analyze 2-2 Develop P-M Analysis Step-5
Condition)
-Step-1 to Step-7
* Develop Investigation Plan Step-6 Study of investigation method
Step-7 Point out Abnormal Conditions
3-1 Develop an Action Plan
Plan
3-2 Follow up on the progress of actions
4-1 Take action for each cause and Root- Cause
4-2 Evaluate the effectiveness of each action by OPL Step-8 Implementation and plan of improvement
Do
4-3 Verify the result in 3 months (90 days)
Review
4-4 Feedback the points of sustaining (maintaining)
* Review the Results (Benefit)