PM Analysis

P-M Analysis Basics
November 10, 2020

0 16,863 8 min read
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
The bearing was not
sufficiently lubricated.
Why was there an overload? Logical linkage is required the bearing was replaced.
The lubricating pump was not
Why was it not lubricated pumping.
sufficiently? Logical linkage is required The lubrication pump was checked.
Why was it not pumping The shaft of the pump was
sufficiently? worn and rattling. The shaft of the pump was replaced.
Why was the shaft of the There was no strainer attached The strainer was attached and cleaned
pump was worn and rattling? and metal scrap got in. up the lubrication tank.
An Autonomous Maintenance
Why was no strainer attached? There are no checking rules. 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
– Identify and describe All Possibilities first, and
(capture) the evidence.
then verify which factors can contribute to the
Verification Process above possibility (“Gap from Principle of
– You say “Why”, capture
Operation”) the “evidence”.
-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
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
Examine-in terms of Physical Principle
Step-2 Involved P-M Gap
Step-3 Analyze Contributing Conditions Principle of Operation
Step-4 Study the relationship between 4M’s Machine Structure & Function Diagram
(Man (Skill), Machine, Material &
Methods)
Step-5 Study of what the conditions must be Optimal Conditions
Machine Diagnosis Technique &
Step-6 Study of investigation methods 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 Step-
situation. 1 Clarify the Phenomenon
1-2 Prioritize No.1 Contributor as FI Theme

(Topics)
Examine-in terms of the
Step- Physical Principle involved. (P-
Check 1-3 Stratify Problem into Phenomenon 2 M Gap)
Analyz 2-1 Principle of Movement (Processing) -Identify Step-
e the “Gap” between the Principle of Processing and 3 Contribute Conditions
Actual Conditions.
2-2 Develop P-M Analysis Step- Study the relationship between
4 4M’s
Step- Study of what the condition
5 must be (Optimal Condition)
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
4-3 Verify the result in 3 months (90 days) 4-4
Feedback the points of sustaining (maintaining)
Do Step- Implementation and plan of
Review * Review the Results (Benefit) 8 improvement

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P-M Analysis Basics

November 10, 2020

P dash M Analysis is a systematic Problem-

When To Use P-M Analysis?

Root Cause Analysis

Problem: No.1 conveyor stopped.

Overload and the fuse blew.

Action is taken for Root-Cause

How can we identify what is

5-Why Analysis vs. P-M Analysis

-Identify “Gap” instead of “Why” -You can say “Because …”

Steps of P-M Analysis

P-M Analysis Story Board Layout

Problem-Solving Story by P-M

1-2 Prioritize No.1 Contributor as FI Theme

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