Phenomenon Mechanism Analysis

“Clarifying the phenomenon” means using our observation skills to grasp facts and illuminate underlying concepts. Key steps involved in defining phenomenon are:

• Eliminate preconceived ideas and prevent errors: Clearly specify items to be observed in order to avoid errors based on supposition and rigid thinking
• Observe on the shop floor: Trace the problem back to the smallest possible units, by personally observing its physical elements at the site
• Classify phenomena: Adequately classify what you have observed (5W1H)
• Investigate Deviations: Clarify the distinction between what is normal and abnormal in what you have observed

Physical analysis means logically explaining how a phenomenon occurred; from a physical point of view to draw logical relationships between phenomena and their potential causes. Here are the key steps of conducting physical analysis:

• Identify Operating Principles: Review machine diagrams and manuals to understand the equipment’s basic operating principles
• Identify Operating Standards: Learn the functions and mechanisms of equipment and devices by sketching simple machine diagrams
• Identify Interacting elements: Draw contact diagrams to identify what relationships define the phenomenon (Use 3D Diagrams, draw free hand standing in front of equipment)
• Quantify the physical changes involved: Identify appropriate physical quantities and changes in those quantities

Contributing condition is any condition that is necessary or desirable for the physical analysis. It is important to consider everything that might contribute to the phenomenon, regardless of preconceived ideas or intuitive judgments. These conditions encompass all causal factors, so this step ensures that no such factors are overlooked. Here are key steps of checking contributing conditions:

• Identify equipment mechanisms
• Understand how mechanisms function together
• Consider Cause & Effect Relationship between mechanisms & abnormal phenomenon
• Identify contributing conditions related to equipment condition
• Identify contributing conditions related to inadequate standards and people not following standards
• Identify contributing conditions related to the quality of previous processes /quality defects in incoming material

The step emphasizes understanding “Primary and Secondary 4M Correlations,” essentially delving deeper to uncover the root causes behind the immediate factors identified. This involves identifying not only direct relationships but also the relationships behind those relationships to create a comprehensive “cause-and-effect chain. This step covers detailed analysis on 4M (Machine, Man, Material & Method)

• Investigation of the equipment assemblies, sub assemblies, parts, jigs, and tools involved
• Analysis of human factors, such as operator actions and knowledge.
• Analysis of materials used in the process and any variations.
• Review of work methods and procedures employed.

This step involves setting standard values to judge whether conditions are satisfactory or not. Clear standards are used to verify whether the identified cause is normal or abnormal. Existing standards are reviewed or new standards are established. 

To establish effective and sustainable standards in manufacturing, it’s essential to evaluate the 4Ms — Machine, Manpower, Method, and Material. 

• Machine: Standards are set based on equipment function, design & Quality Standards
• Methods: Examine & understand current task standards for equipment setup, operation & assembly & Inspection
• Manpower: Identify what skills are required to adhere to the standards and current level of skills
• Material: Quality criteria is used  to clearly identify the characteristics that are established by the previous process

This step involves deciding methods to be used to examine the potential causes for abnormalities. Here are the steps of measurement of casual factors for abnormalities:

• Measure status of all items listed in contributing conditions 
• Review and measure primary 4Ms only for contributing conditions whose mea­sured values are different from the standard values 
• Review and measure secondary 4Ms only for the primary 4Ms whose measured values are different from the standard values

• List the ways in which conditions deviate from the ideal, including slight equipment imperfections and all other causes
• Using investigation methods, all factors are thoroughly investigated by comparing abnormal conditions against standards
• Classify as abnormal any items between border of normal & abnormal
• It’s important to understand causal factors behind each condition classified as abnormal
• Identify all defects, big and small,regardless of how much they might contribute to the problem

• Focus on identifying preventive actions to eliminate abnormalities: Analyze the fuguai to determine their causes of less than perfect situation
• Restoration (to optimal conditions) comes before replacement or design modification
• After restoration, plan improvements that solve hardware prob­lems, update obsolete technologies and prevent recurrence
• In restoring and improving equipment, group as many factors as possible
• Confirm accuracy of each result and work on solutions to prevent the problems or solve problems permanently