Gemba walk Definition & downloadable template

Gemba walk One of lean tools often used in every sector in industry. while it quite often used less known some inside Gemba walk such as meaning, golden rule and how to do Gemba in 5 easy steps

What is Gemba Meaning?

The Gemba words actually from Japanese words Gemba, meaning  actual places.

Is it Genba or Gemba?

Then Why it was written in Gemba in English?

in Japanese words when their “n” letter sometimes they put little echo which not easy to follow by nonnative speaker. it is easier to say and write as Gemba which sounds almost the same with the native people.

Golden rule of gemba

Base on Book developed by Maasaki imai there are five golden rules of gemba management:

How do you structure a Gemba walk?

This article explains about How to do effective Gemba walk. The first thing we separate in 5 steps:

1. Define topics, & member.
2. Define scope of area
3. Deploy checklist.
4. Review findings 
5. Create follow up plan.

well, it sounds very simple, yet difficult to practice. Here our do and don’ts in each step to leverage your Gemba activity become effective one.

Step 1. Define gemba topics & member of Gemba Walks

Why we should mention it since it pretty obvious things in the first place. well it was obvious but yet often neglected that Gemba main ideas were to confirm the actual fact what is happening and also sliding paradigm. why sliding paradigm important?, in aspects of continual improvement sometime new fresh eyes are good to catch up some abnormalities rather than the people work in the area daily.

The topics in Gemba walks is important key element and bridge what are the program all about. Whether it regarding safety habit and workplace environment, or quality defect identification or you just want go through the line with senior leadership team.

This are essentials since the differ the topics the item focused might change. Thus, element supporting the Gemba also different. When we say about the gemba element are the essentials tools that support gemba program such as visual control, kamishibai Boards, Blue tag & red tag etc.

Step 2. Define Gemba Scope of area

To do effective gemba walk we also need to identify the area of Gemba. Take into account the area how many yards, Sqm, Acre that want to Gemba. The time spent can be calculated by assuming human walks speed per area need to sweep according to the source. Normal Human walk speed are 1.4 Meter per second, or around 1.45 Yards per second.

To calculate time spent, we need to know how wide the area of the Gemba program objectives are. let say line of machineries in FMCG industries manufacturing are 75-meter square, or 85-yard square. while 60% of the area consist of machine the remaining Aisle and work area it means only 45-meter square and if we calculate it will become 53 minutes time to complete the gemba for 45 Square meters. in which quite long time for gemba only not yet with team introduction Q&A and also executive summary feedback. An effective gemba walks shall between 30 min until 45 minutes.

Step 3. Gemba checklist template

Checklist were one of tools often used in industry to prevent mistake in the process sequence, item shall be checked even to assure attendance of the event. while checklist was commonly used it is having several main weaknesses which is below:

Gemba walk Checklist Template – Ready to use Downloadable file

a. Checklist content:

     What you write inside the checklist items, sometimes skipped the key element of process or procedure. It may happen since usually we deploy general checklist. Meanwhile each step of process contains different aspects of key element.

b. member Understanding

These are common mistakes that happens everywhere. When the auditee or gemba member did not understand clearly what the checklist questions means. They think the checklist questions out of their own subjective judgement which led to Ambiguous result. To avoid this kind of situation better to get some brief training regarding gemba checklist & it item means.

c. Entry check list items

The entry process from the paperwork to digital sheet are critical. Since sometimes miss typing an input can led to some data not valid or cause some huge noise. To avoid this situation, it is better to scan the paper result and save it in directory file. While it is simple sometimes this condition related to data integrity may cause some loss integrity from your gemba program stakeholder. While checklist was famous there is daunting job to collect and assess each checklist let say in timely basis. We would like to advise using practical yet easy technology such as google form or microsoft form since the result can be easily tabulated and processed.

Step 4. Review Gemba Findings

The review process of gemba walks often people do it after finishing the sessions and go back at obeya room or meeting room. While this practice is common, sometimes item observed are not easy to recall the name of component the name of area might not well informed to the team member. We prefer to do review findings on site to give the team better understanding what the insight are and thought process or key element of machineries concern.

Step 5. Create Gemba walk report.

This is final step and also important part to accertains sustainability of gemba walks program. To get the realistic commitment and to be open mind regarding the feedback were the only way to do this step effectively. sometimes there are certain gemba member that put so much feedback in which not quite related to the program intended. Those situations sign of ineffective gemba walks, we need to full review what are the gemba member are missing in the steps above and how they view the program need to be calibrated.

Those are 5 easy steps regarding how to do effective gemba walks, intended people from shopfloor level. It will be different the stories , when the one to do the gemba walks are senior or top leadership Management.  Whe we did gemba factory works from the senior leadership member we not expected to have some technical feedbacks or advice instead we need to enhance our visual management system so they can easily understand how the workflow and also hot the process going on.

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Tips Senior Managment Gemba walk templates.

Here some key element support that we need to have for effective Senior leadership member:

5S audit

No, this not intended 5S that prepared one shift before the senior leadership came. This is related with the ownership the communication and effectiveness of the 5S program. Majority people when he / she come to new places they will think about safety and cleanliness of the area. Assuming we are not bringing them in dangerous places the the cleanliness was the key.

5S in workplace can easily identify abnormal operation within standard , thus meaning the 5S tagging and 5S boards also essentials tools to give a glimpse senior leadership for operator ownership in the area they have. to have good 5S program please read our article regarding 5S program.

Visual Management

It was key item and insight to assure the operation run within standard. We will had hard time explain about so many things inside the shop floor why the WIP stacks 6 pallets and why it is being placed in the area we have observed. Visual management will give sense of organized workplace and giving sense of built-in quality to the senior leadership member. To better understand regarding visual management board please see our article here

Kamishibai Boards

when kamishibai boards are often used by other industry than automotive. We suggest this tool since it was the best way to show that operation is within our standards. Kamishibai boards can be easily communicate and also give a sense of ownership from the line process way beyond other tools. Since kamishibai boards put the abnormality and also cehck item need to be done in order fulfill the process. to better understanding about kamishibai please visit our article here.

To Summarize here some key element to do effective gemba walks:

• Member of gemba walks whether it is technical team or senior leadership team
• Assure scope of area to define gemba program timing not too long
• Checklist as a tools for gemba member to focus on key item inside checklist query
• Review findings & follow up plan using clear transparent communications with realistic time frame for issue closure.
• Enhance shoplfoor standard using 5S, Visual management & Kamishibai boards to assure gemba identify abnormal conditions.

those are article about how to do effective gemba walk to get other information related lean manufacturing tools and methodology best practice implementation from lean subscribe by email below