Spend time on-site, and you'll notice a pattern:
Product quality issues never arise "suddenly." Either someone is lazy, the machine is aging, or the materials have changed batches… In short, something has changed, but you haven't noticed.
Many experienced technicians rely on decades of "feel" to solve problems. But what about us ordinary folks? Today, I'll give you a universal framework. Just follow this framework, and even if you're a newcomer, you can pinpoint the root cause of the problem like a seasoned expert.
This framework is called-5M1E.
I. What exactly is 5M1E? Let's explain it in one sentence: Don't be intimidated by the fancy name. 5M1E refers to six aspects that affect product quality:
Man, Machine, Material, Method, Environment, and Measurement.
You can think of it as a "production funnel": people operate the machines, handle the materials, follow the procedures, and work in a specific environment; finally, testing is used to judge the quality. If any link in the chain leaks, the finished product will be defective.
Factory workshop image material_Free download_jpg image format_VRF high-definition image 500080968_Photostock
II. Breaking Down the Six Elements: What Exactly Need to Be Checked?
Let's break down these six words and talk about the practical aspects.
1. Man: Don't always think about "replacing people," think about "controlling people."
Many people, when something goes wrong, their first reaction is "This employee is no good, the training was inadequate." This is true, but it's essentially meaningless.
What should be checked on-site?
Does he/she know how? Is he/she new? Has he/she received on-the-job training? Does he/she know the key steps?
Is he/she willing? Is he/she rushing to leave? Is he/she in a bad mood due to a conflict with the person at the next workstation?
Does he/she have the opportunity to make a mistake? If a careless person were to do the job, would a mistake definitely occur? If so, then the process design is flawed, and you can't blame people.
Remember: Humans make mistakes. Good management isn't about constant monitoring, but about using methods to prevent potential errors in advance.
2. Machines: Don't wait until they break down to repair them. A machine isn't fine just because it runs. Many batches of scrapped machines are due to them "slowly deteriorating."
What should you check on-site?
Is the precision still there? How much wear has a three-year-old drill bit done? Is it still within acceptable limits?
Has maintenance been performed? Is simply checking off items on the inspection checklist enough? Is there any oil in the tank?
Has it been repaired? Was it just repaired yesterday? Was there a test run to confirm the effect after repair?
A painful lesson: Many factories operate on the principle of "don't repair unless it breaks down," which is actually the most expensive approach. A true experienced mechanic can tell a machine is about to malfunction just by listening to the sound it makes.
3. Material: Don't blame the "soldiers" for poor quality materials. No matter how hard you try afterward, it's all for nothing if the materials are bad.
What should you check on-site?
Is the incoming material correct? Has the batch been changed? Did the supplier secretly substitute cheaper raw materials?
Is it stored properly? Is this material susceptible to moisture? Has it been exposed to rain outdoors?
Is it clearly distinguished? Are qualified and unqualified products mixed together? Are the labels still on?
In short: Material problems are often disguised as process problems. Check the batch first, then check the machine.
4. Method: Don't let workers "play it by ear."
"Method" means rules. Without rules, there is no order.
What should you check on-site?
Are there rules? Is the operating manual on the wall or on the table? Are the workers relying solely on verbal instructions from the "previous manager"?
Are the rules correct? Are the parameters set reasonably? This adjustment might save a few seconds, but won't it result in defective products?
Is anyone supervising? If no one checks the process discipline, everyone does their own thing, leading to a wide variety of products.
Core principle: A good method is one that even a fool can do without making a mistake; a bad method is one that even a smart person doesn't know how to do it correctly.
5. Environment: The devil is in the temperature and humidity.
Don't underestimate the environment; many strange problems are caused by it.
What should be checked on-site?
Is it dirty? In an electronics factory, a speck of dust on a motherboard could be defective.
Is it too cold or too hot? Glue dries slowly in winter and quickly in summer; should the parameters be adjusted?
Is it shiny enough? In dim lighting, can the inspector spot scratches?
Central Air Conditioning Installation in a 2300㎡ Precision Machining Workshop with Constant Temperature and Humidity - News & Information - Suzhou Tianxiang Electromechanical Engineering Co., Ltd.
6. Measurement: Is the data you see accurate?
The most problematic situation: data fluctuates, leading you to believe the product is faulty, when in fact it's just a broken measuring tool.
What should be checked on-site?
Is the measuring tool accurate? Has the calibration expired? Has it been dropped?
Are the methods consistent? Zhang San measures 10.5, Li Si measures 10.8, whose measurement should be followed?
Are the judgment standards the same? Does this scratch count as a defect? Different standards lead to inconsistent data.
Warning: If you find the data fluctuating wildly, don't rush to adjust the machine; first check if the measuring tool is faulty.
III. Practical Exercise: How to use 5M1E when encountering problems?
Suppose the workshop produces 10 defective products today, what should you do?
Step 1: Lay out the problem openly.
Don't rush into a meeting and yell at people. First, go to the site and examine these 10 defective products. Is the problem in the same location? Or from the same machine?
Second step: Use a six-dimensional approach to "screen" the problem.
Using the six categories of "Man, Machine, Material, Method, Environment, and Measurement," put the possible causes into each category:
Is there a new apprentice today? (Man)
Was the voltage unstable this afternoon? (Machine)
Was a new batch of raw materials used? (Material)
Third step: Verify, don't guess.
If you think it might be a "human" problem, have an experienced worker do the same work and see if the defective products still appear. If they still appear, then it's not a human issue; continue investigating.
Fourth step: Find the root cause and eliminate it completely.
After finding the cause, ensure that it never happens again.
For example, if it's because the wrong oil was added? Then change the spout of the oil can to a different diameter, making it impossible for the worker to add the wrong oil. This is called "error prevention."
IV. Here's a question for you to think about:
5M1E is like a "health checkup report" for your workshop.
Next time something goes wrong on the production line, don't panic. Take out these six words and go through them one by one. You'll find that 90% of the problems are hidden in these six boxes; they can't escape them.
