A gemba walk is a workplace walkthrough that observes workers, how they carry out tasks, and identifies areas for improvement. It stems from the Japanese word Gemba, or the “real place” — the area where the actual work takes place.
Ultimately, a gemba walk in manufacturing is a powerful lean manufacturing approach to cut waste and promote continuous worker and machinery improvement.
Learn more about the key elements of a gemba walk and how to conduct one:
A gemba walk is the process of observing the work being done and shop floor procedures first hand. By observing and engaging with employees, a manager or leader can better understand the manufacturing process and where production waste can be eliminated. This information can then be used to create or improve manufacturing protocols.
Gemba walks in manufacturing are extremely important. They give management a good idea of what shop floor processes are like. They also help reduce faulty assumptions about the workforce.
As a result, these walkthroughs empower manufacturing firms to strive towards continuous improvement and prevent any disconnect between leadership vision and the actual application of operational processes.
Gemba walks are a way to practically achieve the principles of Kaizen, the Japanese methodology for implementing continuous improvement.
Some key elements of gemba walks include:
Gemba walks are great for seeing which areas of production need attending to. Although shop floor processes vary per company, the following steps can be applied to gemba walks in manufacturing.
It’s important to give employees advance notice before conducting a gemba walk to prevent feelings of concern or wrongdoing. This will minimize worries and help workers be more natural when performing their routine duties.
Creating a list of questions to ask workers during a gemba walk helps ensure that important items are not missed. Additional questions may come up, but having a prepared list will help the leader to better understand how operations are run and handled.
The goal is to observe and gather necessary information, not call workers out on the spot. Being an observer and maintaining a respectful attitude can help build trust and morale among employees.
Whatever you do, it’s of the utmost importance to record observations to pinpoint areas of success and areas needing improvement.
Gemba walks can help manufacturing firms gauge where production inconsistencies lie and close gaps.
Some if the benefits include:
Keep in mind that the frequency of gemba walks will depend on business objectives, staff size, and availability of leaders who can conduct the walkthroughs. For instance, if your goal is to consistently meet product quality expectations, then you might conduct a gemba walk more often (e.g., weekly, monthly, or quarterly). Larger manufacturing plants may conduct walks more frequently due to plant and employee size.
Augmentir can help manufacturers with creating customized digital work instructions for conducting gemba walks and many other processes with our connected worker solution. We make it our mission to improve frontline operations, worker productivity, and machine efficiency.
See how Augmentir’s connected worker platform can help digitize your data collection processes and conduct more effective gemba walks.
