Section: 4M1D
4M1D, also known as Man, Machine, Material, Method, and Design, is a framework utilized in lean manufacturing to analyze and optimize various aspects of the production process. Each element represents a critical component that influences the efficiency, quality, and overall performance of manufacturing operations:
Man
Focuses on skilled and motivated workers who help improve the work process. Ensures proper training and involvement in continuous improvement.
Machine
Keeps equipment well-maintained and efficient to reduce breakdowns and defects. Ensures machines are reliable and meet production needs.
Material
Keeps equipment well-maintained and efficient to reduce breakdowns and defects. Ensures machines are reliable and meet production needs.
Method
Standardizes processes and removes unnecessary steps to improve efficiency. Uses lean techniques to enhance workflow and quality.
Design
Arranges the workspace and designs products to simplify production. Optimizes layout to reduce costs and improve workflow.
Now that we have an overview of 4M1D, we can understand how the section works inside Kaizen!
4M1D forms 5 categories for which potential causes can be added into the section by the team members.
Useful Facts!
Whenever a Category is added with a cause it is called a 4M1D Item.
Once these causes are added, they are detailed with more information such as Assignee and a Date.
Since they have been assigned to a user, the next process is the cross-examination of the mentioned causes in the categories! Once the inspection is done, the Assignee can return to these listed items and provide a feedback.
This feedback is provided by using the three decision options in the card. Based on the decision, further actions can be taken!
Let’s understand this with a flowchart:
Step 1 | A 4M1D item is created with its potential causes. |
Step 2 | An Assignee is added to the item with a date to keep a record of time. |
Step 3 | The Assignee examines the listed causes in the item/items. |
Step 4 | The Assignee provides the feedback of the examinations in the item/items. |
Step 5 | Further action to be taken is decided based on the Assignee’s feedback. |
We will use these steps as markers to understand how the 4M1D analysis is used inside a Kaizen!
Let’s go ahead and a 4M1D to our kaizen in Plan Phase!
Section: How to use 4M1D
Check out the Video Guide for a step-by-step walkthrough and detailed insights.
(Runtime: 2:52) Watch Now ▶️
Step 1
Add the 4M1D section from the available list to the required phase.
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Step 2
Expand the section by clicking anywhere in the section field, or on the arrow on the right side.
The arrow can also be used to collapse the section.
Initially, there would be no items added as the section has been added for the first time to the phase.
Click on Add Item.
Step 3
Step 1 | A 4M1D item is created with its potential causes. |
Two new fields will be added:
Category
Step 3.1 Choose from Man, Machine, Material, Method & Design (4M1D options)
Potential Cause
Step 3.2 Type the potential cause/causes into the field provided
Tips & Tricks
You can add multiple causes to an item at the same time.
Once you have typed in the first cause use the + sign on the right to add another cause field below!
Similarly, you can use the - minus sign to remove a cause!
Once you have added all the causes associated with the category, click on Save.
A new Item Card be created with the category, its causes and few other options.
The Add New button is restored which will allow you to add more items. Repeat Step 3.1 & Step 3.2 until you have added all the required causes.
Once an item is added, three filter tabs appear on top in the 4M1D Section field:
All 4M1D Items | Okay | Not Okay |
Lists all the 4M1D items. | List the items marked as okay. | List the items marked as not okay. |
These filter tabs make it easy to see the okay & not okay items easily when there are numerous items inside the 4M1D section. |
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Step 4
Step 2 | An Assignee is added to the item with a date to keep a record of time. |
The Item Card will have options to add information to the newly created item.
Step 4.1 Click on the Avatar icon on the top left corner of the card.
A new Add Assignee window will open up.
Type in the name of the assignee you wish to add and choose from the results that show up.
The new assignee will be added to the item and the avatar will be replaced by user picture/initials.
Step 4.2 Click on the Calender icon next to the assignee icon.
A new Calender window will open up.
Choose the date as per requirement.
The date will be added to the item and will become visible next to the assignee avatar.
Step 5
Step 3 happens in the workplace where the man/machine/material/method/design are examined.
The feedback is added into Kaizen in Step 4.
Step 3 | The Assignee examines the listed causes in the item/items. |
Step 4 | The Assignee provides the feedback of the examinations in the item/items. |
Before we learn to add a feedback let’s understand the feedback process:
There are three options to add feedback to a 4M1D option:
Okay | Not Okay | Feedback |
The cause has been examined and no problem has been found. | The cause has been examined and a problem has been found. | With comment field you can add details of problem that can help in the solution finding process. |
To add this feedback into kaizen, pick the 4M1D item for which the examination was done.
Go to the potential causes; navigate to the front of them:
Okay | Not Okay |
Click on the thumbs up icon.
The icon will turn green confirming the feedback has been added as okay. | Click on the thumbs up icon.
The icon will turn red confirming the feedback has been added as not okay. |
Feedback |
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Click on the chat box icon . A new Approval Comment window will open up.
Add the required feedback and click on save.
The chat box will turn dark blue indicating that feedback has been added. |
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Tips & Tricks
A 4M1D item can be edited or deleted by using the pencil (Edit) & Garbage bin (delete) options.
The pencil icon open up the edit mode of the item.
Note: You can only edit the assignee, date, category and feedback of the causes. A user can also add another cause to the list that needs examination.
Click on Save when all the required changes are completed!
Congratulations! We have successfully learned about the 4M1D Section inside Kaizen!
We have nearly covered 1/3rd of the sections! 5 down, 12 more to go!
Let’s move ahead with the next section i.e.