The 4M1D section helps your Kaizen team list and check potential causes of a problem in 5 categories.
What 4M1D means
4M1D stands for Man, Machine, Material, Method and Design. It is a lean manufacturing framework for analyzing and optimizing the production process.
Each element is a critical factor in the efficiency, quality and overall performance of manufacturing operations:
Man: skilled, motivated workers who help improve the work process, with proper training and involvement in continuous improvement.
Machine: well-maintained, efficient equipment that reduces breakdowns and defects, and reliably meets production needs.
Material: the right materials, of the right quality, available when needed, so they don't cause defects or delays.
Method: standardized processes without unnecessary steps, using lean techniques to improve workflow and quality.
Design: workspace layout and product design that simplify production, reduce costs and improve workflow.
How the 4M1D section works
4M1D gives you 5 categories. Kaizen team members add potential causes under each category. To learn about team members, see About the Team section in Kaizen.
Note: a category together with its causes is called a 4M1D item.
After you add the causes, you assign each item to a person and set a date.
The assignee then examines the listed causes in the workplace, returns to the item and gives feedback using the three decision options on the item card. Further action is decided based on that feedback.
Stage 1 | A 4M1D item is created with its potential causes. |
Stage 2 | An assignee and a date are added to the item. |
Stage 3 | The assignee examines the listed causes. |
Stage 4 | The assignee records feedback on the examination in the item. |
Stage 5 | Further action is decided based on the assignee's feedback. |
Use the 4M1D section
Add the 4M1D section from the available list to the required phase. See Add or remove sections from Kaizen phases.
Expand the section by clicking anywhere in the section field, or on the arrow on the right side. You can also use the arrow to collapse the section.
Click Add Item. When the section is added for the first time, it has no items.
Create a 4M1D item (Stage 1)
Two new fields appear.
In Category, choose Man, Machine, Material, Method or Design.
In Potential Cause, type the potential cause.
When you have added all the causes for the category, click Save.
Tip: you can add several causes to an item at once. After you type the first cause, click the + sign on the right to add another cause field below it. Click the - sign to remove a cause.
A new item card is created with the category, its causes and other options. The add button appears again so you can add more items. Repeat these steps until you have added all the causes you need.
Once an item exists, three filter tabs appear at the top of the 4M1D section. They make it easy to find okay and not okay items when the section has many items.
All 4M1D Items | Okay | Not Okay |
Lists all 4M1D items. | Lists the items marked as okay. | Lists the items marked as not okay. |
Add an assignee and date (Stage 2)
Use the options on the item card to add information to the new item.
Click the avatar icon in the top-left corner of the card. The Add Assignee window opens.
Type the name of the assignee and select them from the results. The avatar is replaced by the user's picture or initials.
Click the calendar icon next to the assignee icon. A calendar window opens.
Choose the date. It appears next to the assignee's avatar.
Record feedback (Stages 3 and 4)
The assignee examines the man, machine, material, method or design in the workplace, then records the feedback in the Kaizen.
To record feedback, open the 4M1D item that was examined and use the icons next to each potential cause. There are three feedback options:
Option | Meaning | How to record it |
Okay | The cause was examined and no problem was found. | Click the thumbs up icon next to the cause. The icon turns green. |
Not Okay | The cause was examined and a problem was found. | Click the thumbs down icon next to the cause. The icon turns red. |
Feedback | A comment with details of the problem, to help find a solution. | Click the chat box icon. In the Approval Comment window, add the feedback and click Save. The chat box turns dark blue. |
Edit or delete an item
Use the pencil (edit) and bin (delete) icons on the item card.
Note: in edit mode you can change only the assignee, date, category and feedback of the causes. You can also add another cause that needs examining. Click Save when you finish.
Related features
RCA Agent: from the Kaizen project toolbar, RCA Agent → Run RCA Analysis can generate a 4M1D analysis (along with 5 Whys and a fishbone) from the Kaizen's fields, linked records and uploaded files, and push the results to the Action Plan.