4M

Training on 4M

Trainer R.Bhardwaj
Magneti Marelli Talbros Chassis Systems Pvt.Ltd FI_Training
 4M
Problem Solving Hierarchy

Complexity Advanced
of Problem

Major Kaizen PPA

Standard Kaizen
Quick Kaizen
Kaizen

4M

5W + 1H

5G
1 week 3 months Time
taken

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4M

• Tool for analyzing problems.

• It is based on causes list and hierarchy

• The aim of 4M tool is to help the team in finding true causes by sorting hierarchically

• Causes are grouped together in 4 categories (4M) related to the factory:

Man , Machine, Method, Material

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 4M
Brain Storming
To run a group brainstorming session effectively, do the following:

Define the problem you want solved clearly, and lay out any criteria to be met. Make it
clear that that the objective of the meeting is to generate as many ideas as possible. ( Use
5W , 1 H)

 Go to Gemba and follow 5 G, and set it up ready for the session.

Appoint one person to record the ideas that come from the session. These should be
noted

Everyone can see and refer to. Depending on the approach you want to use, you may want
to record ideas on flip charts, whiteboards, or computers with data projectors.

Give people plenty of time on their own at the start of the session to generate as many
ideas as possible.

Ask people to give their ideas, making sure that you give everyone a fair opportunity to
contribute.

Encourage people to develop other people's ideas, or to use other ideas to create new
ones. Magneti Marelli Talbros Chassis Systems Pvt.Ltd FI_Training
 4M
Brain Storming

Encourage an enthusiastic, uncritical attitude among members of the group. Try to get everyone to
contribute and develop ideas, including the quietest members of the group.

Ensure that no one criticizes or evaluates ideas during the session. Criticism introduces an element of risk
for group members when putting forward an idea. This stifles creativity and cripples the free running nature
of a good brainstorming session.

Let people have Open brainstorming. Encourage them to come up with as many ideas as possible, from
solidly practical ones to wildly impractical ones. Welcome creativity!

Ensure that no train of thought is followed for too long. Make sure that you generate a sufficient number
of different ideas, as well as exploring individual ideas in detail.

In a long session, take plenty of breaks so that people can continue to concentrate.

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 4M
Brain Storming

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FOCUSED IMPROVEMENT
4M: example

Spare parts missed

Tooling by many
operators
Information

Non original spare parts

To much passes
Twisted
Non suitable bins

Thin plate
Maintenance time Training

Wrong
Misunderstanding iof the
next process

BRAINSTORMING
Experience Fatigued
Non followed
instructions

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 FOCUSED IMPROVEMENT
Methodology :-

 Draw an empty diagram (or open the specific form);

 Write the description of the problem to be analyzed on the right

of the diagram;

 Discuss, in team, possible causes which generate the problem

and write them in the diagram (use branches from main
categories for each cause);

 From each branch, iterate analysis creating sub-branches;

 Iterate until is possible to find root causes;

 Once diagram is completed, identify most likely cause

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FOCUSED IMPROVEMENT

Magneti Marelli Talbros Chassis Systems Pvt.Ltd FI_Training

4M
4M: example

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4M

Magneti Marelli Talbros Chassis Systems Pvt.Ltd FI_Training

4M

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