Gemba Walk Importance and Benefits in Lean Practices

Summary: Imagine a manager who doesn’t get up from their desk and gets all of their information from meetings and reports about what goes on in the production area. Now, think of a different manager—one who goes out, watches the work firsthand, listens to employees, and finds ways to improve right at the source. This is what a Gemba Walk is all about. It’s more than just inspecting; It’s about truly understanding processes, finding solutions together, and ultimately building trust with the team. By observing, asking questions, and listening carefully, you create an environment where everyone feels heard and valued. This approach not only helps in solving problems but also strengthens relationships, making it easier for the team to work toward shared goals.

What is a Gemba Walk?

Leaders visit the workplace to observe employees in action and discuss their tasks to identify areas for improvement. This practice, called “Gemba,” means “the place.” The goal is to understand work processes better and drive improvements within the team. Toyota’s Lean management system popularized this method to empower teams and boost productivity.

Key Goals

A Gemba Walk is a powerful approach for leaders to connect with their teams, observe workflows firsthand, and drive meaningful improvements. The primary goals of a Gemba Walk include the following:

Gain Insights: First, watch how tasks are done and then find areas that need improvement.
Reduce Waste: Identify inefficiencies and eliminate redundancies and safety risks.
Engage Employees: Ask questions, listen actively, and make employees feel appreciated.

Types

Leaders can use several types of Gemba Walks for different purposes, such as the following:

Safety Gemba Walk: Combines the Gemba approach with a focus on safety by observing daily activities and suggesting safer methods beyond compliance.
Virtual Gemba Walk: Uses video conferencing tools, ideal for remote teams to allow observations and improvements without being on-site.

Benefits

Gemba Walks help dispel misconceptions about work procedures and bring sustainable improvements. They connect leaders’ goals to practical actions, making sure improvements meet employee needs.

Boost Employee Morale: Employees feel valued when leaders appreciate their contributions. Consequently, this motivates them and increases their engagement. Therefore, the team becomes more productive and committed.
Improve Efficiency: Identifying inefficiencies saves time and costs.
Foster a Culture of Improvement: Gemba Walks encourage teamwork and innovation.

Three Key Components

Go See: Visit the workspace, observe if procedures are being followed, and evaluate results using a checklist for consistency.
Ask Why: Use the “Five Whys” to understand the reasons behind practices, helping identify root causes of inefficiencies.
Show Respect: Collaborate with employees, involve them in problem-solving, and build trust.

How to Conduct

Inform Employees in Advance: To begin, let your team know ahead of time to put them at ease and promote openness.
Prepare Questions: Ask questions like “What challenges are you facing?” or “How can we simplify this task?”
Observe Without Interfering: Focus on understanding processes rather than micromanaging.
Record Observations: Take notes and photos (if allowed) for reference and to guide improvements.
Follow-Up Discussion: After the Gemba Walk, share your observations, assign improvement tasks, and track progress.

Common Challenges and Solutions

Employee Resistance: Employees may feel nervous when leaders observe them. However, explain that the purpose is to support and improve, not criticize.
Lack of Focus: Without clear objectives, Gemba Walks can be ineffective. Set specific goals and questions beforehand to ensure meaningful insights.

Gemba Walk Checklist

Use a checklist to ensure nothing important is overlooked. Sample questions include:

What are you working on today?
What difficulties are you facing?
How can we improve this process?
Are there any safety concerns?
How does this task align with our objectives?

Real-Life Example

In a manufacturing facility, the Vice President and department heads conduct Gemba Walks to address issues on “production boards” and assign tasks for resolution. This approach has improved communication, boosted employee involvement, and led to quick, effective problem-solving.

Simplifying Gemba Walks with Technology

The right tools can make Gemba Walks more effective. Tools like flowdit or other lean manufacturing software offer customizable checklists, real-time note-taking, and follow-up tracking to ensure observations lead to real improvements.

Final Thoughts on Gemba Walks in Leadership

Gemba Walks provide valuable insights for leaders looking to understand their operations better and build strong relationships with employees. Start your Gemba Walk today—step into the real workplace and see the positive changes it can bring.

FAQ | Gemba Walk

What is the primary goal of a Gemba?

The goal is to observe and understand the work process to find opportunities for improvement.

How often should Gemba Walks be conducted?

They should be conducted regularly to maintain a culture of continuous improvement. The frequency may vary depending on the organization’s needs and the nature of the work.

Can Walks be done remotely?

Yes, Virtual Gemba Walks use video technology to observe and interact with teams across different locations.

Can Gemba Walks be performed in non-manufacturing industries?

Absolutely! They are not limited to manufacturing industries.

Are Gemba Walks only beneficial for large organizations?

No, they can benefit organizations of all sizes. Whether it’s a small business or a large corporation. It provides valuable insights and opportunities for improvement.

How can Gemba Walks be integrated with Lean and Six Sigma methodologies?

They complement Lean and Six Sigma methodologies by providing a real-time understanding of processes and identifying areas for improvement. The insights gained from Gemba Walks can inform Lean and Six Sigma projects, making them more effective.

Do Gemba Walks replace other forms of data collection and analysis?

No, they should be seen as a complementary approach to data collection and analysis. While it provides qualitative observations and insights, data-driven analysis is still important for a comprehensive understanding of processes and performance.