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	Answer (Observation)	Action
Why was there an overload?	The bearing was not sufficiently lubricated. Logical linkage is required	the bearing was replaced.
Why was it not lubricated sufficiently?	The lubricating pump was not pumping. Logical linkage is required	The lubrication pump was checked.
Why was it not pumping sufficiently?	The shaft of the pump was worn and rattling.	The shaft of the pump was replaced.
Why was the shaft of the pump was worn and rattling?	There was no strainer attached and metal scrap got in.	The strainer was attached and cleaned up the lubrication tank.
Why was no strainer attached?	There are no checking rules.	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)

The fact you observed with your eyes and numeric data.
The fact without presumption

Is Not

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 Statement (Analysis Start-Point)	– The same step requires identifying the “Phenomenon”. – Use 5W1H Analysis (Stratification Step) – 5-Why Analysis requires highly to start the analysis at a specific phenomenon.
Logical Linkage (The Linkage between Why and Why)	– Describe All Possible factors. – In order to describe all possible factors, Recommend setting up the “P-M Gap” Statement.	– Describe clearly Why & Answer (because).
Verification Process	– Identify and describe All Possibilities first, and then verify which factors can contribute to the above possibility (“Gap from Principle of Operation”) -Identify “Gap” instead of “Why”	– Before moving the next why require to verify (capture) the evidence. – You say “Why”, capture the “evidence”. -You can say “Because …”
Key Points for Use	– Understand the differences between “Fish-Bone Analysis” and/or “Why-Why Analysis” – 4M Analysis is Not a “Fish-Bone”	– Show the “evidence” before moving to the next why.
Who should use	– The higher Team Leaders’ Level. – Since AM Step-4	– All Employee – Operators (Since AM Step-2)

P-M Analysis

What % of Problems can be solved by 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
Step-4	Study the relationship between 4M’s (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
Check	1-1 Analyze the “Gap” between Target and Actual situation. 1-2 Prioritize No.1 Contributor as FI Theme (Topics) 1-3 Stratify Problem into Phenomenon	Step-1	Clarify the Phenomenon
		Step-2	Examine-in terms of the Physical Principle involved. (P-M Gap)
Analyze	2-1 Principle of Movement (Processing) -Identify the “Gap” between the Principle of Processing and Actual Conditions. 2-2 Develop P-M Analysis -Step-1 to Step-7 * Develop Investigation Plan	Step-3	Contribute Conditions
		Step-4	Study the relationship between 4M’s
		Step-5	Study of what the condition must be (Optimal Condition)
		Step-6	Study of investigation method
		Step-7	Point out Abnormal Conditions
Plan	3-1 Develop an Action Plan 3-2 Follow up on the progress of actions	Step-8	Implementation and plan of improvement
Do Review	4-1 Take action for each cause and Root- Cause 4-2 Evaluate the effectiveness of each action by OPL 4-3 Verify the result in 3 months (90 days) 4-4 Feedback the points of sustaining (maintaining) * Review the Results (Benefit)