The 10 points to validate during a health and safety (HSE) tour

Posted on by Gabrièla Bédard

In many factories, health and safety is still approached in a reactive way: we wait for an incident to occur before acting. Yet, every day offers an opportunity for prevention. And OSH tours are one of the most concrete ways to achieve this.

But for these tours to have a real impact, they must be structured, observable, and tracked. That’s why we offer you here the 10 key elements to validate systematically, whether you are a supervisor, manager or OHS manager.

And if you don’t want to forget anything along the way, we have prepared a downloadable checklist for you, which you can also integrate directly into Gemba-Walk for more fluid and collaborative management.

1. Cleanliness and clutter: the often overlooked base

Let’s start with what jumps out at the eyes, but which sometimes we end up no longer seeing. A factory that accumulates bins on the ground, misplaced cables or parts in the aisles quickly becomes a slippery slope… both literally and figuratively.

It’s not just about appearance. A blocked driveway can delay an evacuation. A forgotten oil puddle can lead to a fall. Cleanliness is the first line of defense against accidents.

💡 In Gemba-Walk, you can easily photograph a clutter, create a task and assign it to the right person and track it.

2. Proper use of personal protective equipment (PPE)

We all know this scenario: when you arrive, the employees quickly put on their glasses or helmet. But what about when you are not there?

The wearing of PPE should not depend on the presence of the manager. During your tour, observe discreetly. Are they worn at all times, or only when you pass? Do they look comfortable? Are they in good condition?  These discussions often open the door to improvements.

🔗 How to structure an effective OHS approach thanks to Gemba-Walk

3. Condition of the equipment

It is not a question here of doing a complete mechanical inspection, but of developing your observer’s eye: a machine that vibrates abnormally, an open panel, a neglected indicator light… All that, these are weak signals to pick up.

And if an employee mentions that “the machine has been doing it forever”, this is not a reason to ignore it. On the contrary, this is a good time to check if preventive maintenance is up to date—and if the right communication channels are being used.

💡 Add to your tour a section to ask the operator: “Have you noticed a change in the behavior of the machine?”

4. Signage display: visible does not mean understood

Pictograms hidden behind a pile of boxes, instructions erased or simply ignored: the signage can be omnipresent, but invisible for the accustomed eyes. Ask an employee what a pictogram means – it’s often revealing.

5. Working methods: standardized risk gestures?

It is not uncommon to see an experienced employee adopt risky postures out of habit or concern for efficiency. During your tour, take the time to observe the gestures, the repetitive movements, the physical efforts.

💡 In your tour canvas, add a question like: “Do employees adopt ergonomic and safe postures for all of their tasks?”

Include a comment field to describe or suggest an improvement.

6. Dangerous products: well-organized or within reach of everyone?

Hazardous materials are often used without incident… until the day when a bad label or improper storage causes a reaction, an inhalation or a leak. Your tour should always validate the compliance of the storage locations, but also the accessibility of the data sheets (FDS).

💡 Tip: create a specific check point for chemical areas, with a photo capture of the storage or nearby records.

7. Mechanical and electrical risks: the invisible that hurts

A missing electrical panel cover, an unprotected moving part, a barrier bypassed temporarily… as many small deviations that can lead to serious injuries. These elements are sometimes ‘temporarily accepted’, but quickly become standard.

8. Lighting and ventilation: ambient safety

You may not notice right away that the lighting is low… until an employee has to work in the shadow to read a code or inspect a room. Similarly, insufficient ventilation can impair comfort, alertness, and health.

9. How do you react to risky behavior?

What you see is important, but what others do when you are not there is even more. Observe: is risky behavior reported? Ignored? Corrected? Does the environment reflect a culture of intervention or silence?

10. Follow-up of previous rounds: the credibility of the process

An OHS tour only has impact if the actions that result from it are followed. If employees notice that the same issues are coming back, without corrective action, they will stop taking the process seriously.

👉 If the same weak point comes up three times in the month, it is no longer an oversight, it is a signal of improvement on a larger scale.

📥 Download your customizable SST checklist

To help you structure your next SST tour and ensure complete risk coverage, we have prepared a ready-to-use customizable template.

You can download the document or request a demo of our Gemba-Walk tool to see how our clients structure their SST tours with rigor and simplicity.


Download the SST checklist now 📄


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Why digitize and document your floor tours?

Posted on by Gabrièla Bédard

In today’s industrial world, efficiency and precision are crucial. Floor tours, or Gemba-Walk, are essential to identify opportunities for improvement. However, traditional methods of collecting and documenting information can be tedious and prone to human error, resulting in delays, inconsistencies and loss of valuable data. These drawbacks can compromise your company’s ability to respond quickly to problems and maintain high standards.

Digitization offers a revolutionary solution by transforming the way data is collected, analyzed and used. By moving from a paper-based system to a digital platform, companies can not only streamline their processes but also maximize the impact of their floor tours. This transformation brings many benefits, ranging from improving health and safety to increasing productivity, Eliminating manual inefficiencies and errors.

Simplicity and ease of use

Digital solutions are designed to be intuitive and easy to use. With user-friendly interfaces, even employees with little technical skills can quickly adapt. This reduces training costs and improves user acceptance.

Customization and flexibility

Digital tools for floor tours are highly customizable. You can tailor the inspections to your specific business needs. Whether for daily, weekly or monthly inspections, the flexibility of these tools allows you to create custom floor tours that perfectly meet your requirements.

Strengthening Communication and Collaboration

Digital floor tours promote better communication and collaboration between teams. The data collected in real time can be shared instantly with all relevant members, allowing faster and more informed decision-making. Digital tools also facilitate discussions and feedback, creating a culture of transparency and continuous improvement.

Health and Safety Improvement

The health and safety of your employees is paramount. By scanning your floor tours, you can easily identify and document potential risks. This allows for real-time tracking of corrective actions, ensuring a rapid response to security issues. Digital reporting also facilitates compliance with safety standards, reducing the risk of accidents and injuries.

Increased productivity

Automation of floor tours reduces the time spent collecting and processing data. Information is centralized and easily accessible, allowing managers to focus on analyzing data and implementing improvements. This approach not only saves time, but also minimizes human errors, increasing the overall efficiency of your operations.

Quality assurance

Digital documentation allows full traceability of inspections and corrective actions. Detailed reports and data histories help maintain high quality standards. By quickly identifying deviations and following corrective measures, you ensure consistent quality of your products and services.

Digitizing and documenting your floor tours is not just a modernization; it’s a strategic investment to optimize your business in terms of security, The European Commission has recently published a report on the European Union’s research and development programme. Adopt Gemba-Walk and turn your floor tours into a source of added value.

Ready to transform your floor tours? Contact us today to find out how Gemba-Walk can make a difference in your business!


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Types of questions to ask during floor tours

Posted on by Gabrièla Bédard

Gemba Walks are a powerful tool to improve processes and strengthen the culture of continuous improvement in a company. By going out into the field and asking the right questions, leaders can gain valuable insights on four key areas: health and safety, productivity, quality assurance and collaborative communications.

Here are some questions to ask during your Gemba Walks, as well as an explanation of the importance of each axis and what they can improve.

Health and safety

The health and safety of employees are top priorities. By asking questions about these aspects, you can identify and solve potential problems before they become critical. This helps to reduce workplace accidents, improve employee well-being and create a safer work environment.

Examples of questions

  • Do you always use the appropriate safety equipment?
  • Have you noticed any safety risks in your work environment?
  • Have you received adequate training on safety?
  • Are all personal protective equipment available and in good condition?

Productivity

Improving productivity is a constant goal for any business. By asking questions about productivity, you can identify inefficiencies and bottlenecks. This simplifies processes, reduces downtime and increases overall efficiency, This results in better use of resources and increased outcomes.

Examples of questions

  • Are the tools you use performing well?
  • Are there any tasks that take longer than necessary?
  • Do you have all the resources you need to complete your tasks?
  • Are current processes easy to follow?

Quality assurance

Ensuring the quality of products and services is crucial to maintaining customer satisfaction and the reputation of the company. By asking questions about quality assurance, you can identify quality issues and opportunities for improvement. This helps to ensure high standards, reduce defects and improve customer satisfaction.

Examples of questions

  • Are quality controls carried out regularly?
  • Are there any recurring quality issues that you have noticed?
  • Do you have the tools to perform quality checks?
  • Are the quality procedures clear and followed?

Communication and collaboration

Clear communication and effective collaboration are essential for the success of any organization. By exploring these areas, you can identify barriers to communication, improve coordination between teams and strengthen collaboration. This leads to better team cohesion and faster problem solving.

Examples of questions

  • Is communication between the different departments effective?
  • Do you have access to the communication tools needed for your work?
  • Do you feel listened to by your team?
  • Is important information shared in a timely manner?

Gemba Walks are a valuable opportunity to connect with employees and gain direct insights into operations. By asking targeted questions, you can identify areas for improvement and engage employees in finding solutions. These closed questions allow quick and clear answers, thus facilitating the identification of critical points.

Want to make the most of your Gemba Walks? Contact us today to find out how we can help you ask the right questions and transform your organization. Together we can create a safer, more productive and better working environment!



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The importance of a culture of continuous improvement

Posted on by Gabrièla Bédard

In our ever-changing world, adopting a culture of continuous improvement is essential for any business that wants to remain competitive. This approach, which encourages all employees to constantly seek ways to improve processes, products and services, not only helps to optimize performance but also to enhance customer and employee satisfaction. A key tool to establish and maintain this culture is the Gemba-Walk.

What is a Gemba-Walk?

The term “Gemba” comes from Japanese and means “the real place”. Basically, it’s where everything happens, where value is created. Gemba Walk is about going out into the field, observing processes first-hand, talking to employees and identifying opportunities for improvement. It’s a simple but incredibly effective way to better understand what is really going on in your business.

The advantages of Gemba-Walks

Gemba Walks are great for several reasons. First, by going into the field you can collect data in real time. There’s nothing like seeing things with your own eyes to understand the challenges that your teams are facing.

Then, by looking closely, you can easily identify opportunities for improvement. Maybe there are some inefficiencies or bottlenecks that you couldn’t see from your desk. By being on site, you can also follow the corrective actions taken after your previous visits and make sure they are working.

What’s great about the Gemba Walks is that they are customizable. You can tailor your tours to the specific needs of each sector or department. And contrary to what one might think, setting up Gemba Walks is simple and does not require expensive investment or complex training.

Maintain a culture of continuous improvement

For continuous improvement to become a true part of the company culture, there are some principles to follow. First, management engagement is crucial. Leaders should lead by example by actively participating in the Gemba Walks and supporting all improvement initiatives.

Second, it is essential to train and educate all employees. Everyone needs to understand the principles of continuous improvement and how they can contribute. Open communication is also vital. By encouraging transparent and honest communication, you help to quickly identify problems and find solutions.

We must also not forget to recognize and reward the efforts of employees. Valuing their contributions to process improvement motivates the whole team to get more involved. Finally, regular progress reviews are a good practice to ensure that improvement initiatives are maintained.

Gemba Walks are a powerful tool to establish and maintain a culture of continuous improvement within your organization. By going out into the field, directly observing processes and interacting with employees, you can transform your business significantly.

So why wait for it? Start integrating Gemba Walks into your routine today and discover how they can boost your performance and create a more collaborative and motivating work environment.

Want to know more about how Gemba Walks can transform your business? Contact us now to find out how we can support you in this process. Together, let’s take your organization to the next level!


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How to make floor tours a habit?

Posted on by Gabrièla Bédard

In manufacturing and industry, process optimization is crucial to maintain efficient and high quality production. Floor touring, or Gemba-Walk, is a powerful tool to achieve this goal.

Yet, many managers and supervisors face difficulties integrating this practice on a regular basis. Without consistent adoption, it is difficult to gather the data needed to generate effective action plans and see a tangible return on investment. So how do you turn floor touring into a habit that is rooted in your company’s culture? Here are some tips to get there.

Understand the importance of floor tours

For a habit to take root, it is essential that the entire team understands its value. Floor tours allow not only to quickly detect problems, but also to understand processes in real time and identify opportunities for continuous improvement. They also promote open communication between production teams and managers, creating a collaborative and transparent work environment.

Start with clear communication and proper training

Before starting the floor tours, it is crucial to inform and train your team. Explain the objectives of the Gemba-Walks, how they will be conducted, and the expected benefits. For example, when introducing Gemba-Walk in an auto parts manufacturing plant, supervisors took the time to show how identifying a quality problem on the production line led to a quick and efficient solution, thus improving the satisfaction of the end customer.

Integrating floor tours into the daily routine

For floor tours to become a habit, they must be an integral part of the daily routine. Start by planning specific slots for these visits. For example, you can decide that every morning, from 9am to 10am, supervisors will do their floor tour. Establishing a fixed schedule reinforces the importance of this activity and helps employees prepare mentally and physically.

Use appropriate tools to simplify the process

The use of dedicated software, such as Gemba-Walk, can greatly facilitate the integration of floor tours. Our application, designed to be user-friendly and customizable, allows managers to plan, track and analyze routes effectively. By automating certain administrative tasks and providing real-time reports, Gemba-Walk helps teams focus on the essentials: observation and continuous improvement.

Encourage active participation and feedback

Floor tours should be a participatory activity. Encourage your employees to get actively involved by asking questions and sharing feedback. For example, in a company producing electronic products, operators were encouraged to report small malfunctions of their machines during the Gemba-Walks, which allowed for more effective preventive maintenance. The more feedback you receive regularly, the more you can adjust and improve your processes.

Floor tours, when well integrated, can transform the way your business operates, fostering continuous improvement and open communication. By following these tips and using tools like Gemba-Walk, you can make floor touring a beneficial and lasting habit.

Ready to transform your business with regular Gemba-Walks? Discover how our software can help you simplify and optimize your floor runs. Contact us for a free demo today!


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Overcoming resistance: Integrating Gemba-Walk into a company

Posted on by Gabrièla Bédard

In an ever-changing world, companies must adapt quickly to remain competitive. Integrating a Gemba-Walk application can be a powerful way to improve business processes and foster a culture of continuous improvement.

However, this transition can sometimes encounter resistance within the team.  In this article, we explore the essential steps to successfully integrate a Gemba-Walk application into business while overcoming resistance to change.

Understand the benefits of the Gemba-Walk app

The Gemba-Walk app offers several concrete benefits for businesses of all sizes. First, it enables efficient process optimization by providing real-time visibility into field operations, making it easier to identify inefficiencies and opportunities for improvement. In addition, by reducing waste and improving quality, it directly contributes to increased operational efficiency and customer satisfaction.

For employees, the app dramatically simplifies follow-up tasks by automating tedious manual processes, freeing up time to focus on tasks with higher added value. In addition, it offers employees the unique opportunity to actively contribute to process improvement by allowing feedback and suggestions directly from the field.

Moreover, our Gemba-Walk application is distinguished by its fully customizable character and its user-friendly interface, guaranteeing a smooth integration and a minimal learning curve for users, This is a significant advantage for companies that want to maximize their return on investment.

The essential steps to integration

1. Communicate change effectively

When integrating a Gemba-Walk application into an enterprise, effective communication about change plays a crucial role in the success of the process. It is essential to involve stakeholders from the beginning and provide them with a clear understanding of the objectives and benefits of the application.

By explaining in detail how the app can improve the day-to-day lives of employees and contribute to the overall success of the company, leaders can generate stronger engagement and support from the team.

Concrete examples to share with your team:

Resolve existing issues

“With the introduction of our new Gemba-Walk application, we will be able to quickly identify and solve quality problems in our production process. This will allow us to reduce waste and improve our overall efficiency. ‘

Increase operational efficiency

“By visualizing our processes in real time, we can reduce unplanned downtime, optimize our workflows for increased productivity, and our field teams now have real-time information to make informed decisions. This will allow us to reduce delays in our operations and improve customer satisfaction.”

2. Train and prepare the team

The goal of the Gemba-Walk app is to simplify and improve your existing processes, without adding additional workloads to your schedule. By preparing your teams for training, it will facilitate the integration of the application into their daily work, allowing you to increase your operational efficiency and more effectively solve the challenges encountered.

To ensure a smooth integration of the Gemba-Walk application within your team, offer comprehensive training focused on the ease of use and essential features of the tool. Organize demonstration sessions and hands-on workshops to familiarize employees with the app and ask questions.

Did you know that…

We understand that every company has different training needs, so we offer personalized support.

Online or in-person meetings are available to provide additional support if needed. In addition, to facilitate integration, we have developed short and targeted training capsules, allowing users to train at their own pace.

For those who prefer a more structured approach, we also offer a complete support package, where we plan and implement the training process from A to Z, ensuring your team is perfectly prepared to get the most out of the Gemba-Walk app.


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3. Creating an enabling environment for change

Foster a climate of trust and openness where every employee feels comfortable expressing themselves. Encourage your employees to share their ideas, questions and even concerns about the Gemba-Walk app, so you can meet their needs and ensure an optimal user experience for all.

By working together in a spirit of collaboration and trust, we are confident that you will overcome the challenges of change and achieve your common goals successfully.

4. Manage resistance to change

Effective management of resistance to change is crucial for the successful integration of the Gemba-Walk application into business. To do this, it is essential to identify potential sources of resistance within the team and proactively address them. This may involve providing additional information about the benefits and operation of the app, as well as offering personalized support to address individual concerns.

In addition, by involving opinion leaders and enthusiastic employees, it is possible to actively promote the application and address the concerns of skeptics. By fostering a culture of mutual support, we are better equipped to overcome obstacles and foster a smooth transition to using the Gemba-Walk app in your business.



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After the Gemba-Walk: Put your observations into action to boost your operations!

Posted on by Gabrièla Bédard

After surveying the corners of your business, closely scrutinizing each operation during multiple floor tours and gathering a mountain of data, comes the crucial step: take action! Because for us, floor tours are not only pleasant walks, they are the starting point to find challenges, seize opportunities and trigger change. So, what to do once you have walked the aisles of your company several times?

Here is our guide to turning your observations into concrete actions that will propel operational excellence!

1. Dissecting Data: Understanding Trends and Problems 🧐

After your floor runs, dive into the data collected. Review each observation, each note carefully. Identify emerging trends, patterns and sticking points. This analysis will serve as a basis for setting your priorities and designing effective solutions.

2. Focus your efforts: Prioritize issues 🆙

Not all problems are the same. Prioritize them based on their impact on your operations. Focus on areas where improvements will have the greatest impact. This will allow you to optimize the effectiveness of your actions and manage your resources wisely.

3. Create Together: Engage your team in problem solving 🙋🏽‍♀️🙋🏽‍♂️

Problem-solving is a team effort! Involve everyone in the process. Organize brainstorming sessions to bring out the most creative ideas. Make sure the proposed solutions are practical, feasible and aligned with your goals. The diversity of viewpoints can be a source of innovation!

4. Accurately Plan: Implement Solutions 🔑

Once solutions are defined, develop a detailed action plan to implement them. Set clear goals, realistic deadlines and define responsibilities. Ensure that each team member understands their role and contribution to collective success.

5. Communicating and Encouraging: Creating a Collaborative Environment 🤝

Communication is the key to maintaining the momentum of continuous improvement. Openly share the results of your floor tours with the entire team. Promote exchanges of ideas and feedback. Make sure everyone feels involved and involved in the change process.

6. Evaluate and adjust: Be agile to results 🎯

Your work is not finished once the actions are implemented. Regularly monitor progress and evaluate the effectiveness of implemented solutions. Be prepared to adjust your approach if necessary based on the results obtained. Continuous improvement is a journey, not a destination!

7. Embed in Corporate Culture: Making Floor Tours a Habit ☕

Finally, integrate floor tours into the daily life of your company. Encourage all team members to actively participate and maintain a constant commitment to continuous improvement. Floor tours should not be an isolated event, but a natural part of your corporate culture.

 

In conclusion, floor tours are a powerful tool to identify opportunities for improvement and drive change within your business. By following these steps after your tours, you will turn your observations into concrete actions that will propel your company towards operational excellence! So, ready to take action? If you want to find out how our Gemba-Walk app can help you optimize your operations and implement these recommendations effectively, feel free to schedule a demo with one of our representatives today!

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What types of observations should be made during a Gemba walk?

Posted on by ProstarSEO

Are you ready to take your Gemba walks to the next level? In this article, we explain the types of observations that should be made during a Gemba walk. By setting clear objectives and analyzing workflows, workspaces, safety measures, and communication channels, you can uncover process inefficiencies and drive continuous improvement. Get ready to enhance your Gemba walk experience and elevate your organization’s performance!

Importance of Gemba Walks

Gemba walks are a lean manufacturing technique that allows for real-time observations to be made. These walks give you the opportunity to witness processes in action, which is crucial to identify areas of improvement. During a Gemba walk, it’s essential to allocate enough time for observation, so take your time and carefully observe every step of the process. 

Observations during a Gemba walk should be focused on understanding the current state of affairs. Look for any deviations from standard operating procedures or potential sources of waste and keep an eye out for any safety hazards or quality issues that may arise. As you make your observations, engage with the people involved in the process. Ask questions and seek their input on how things could be improved. Remember, Gemba walks are not about pointing fingers or assigning blame; they are about fostering collaboration within a team.

Setting Clear Objectives for Your Gemba Walk

When setting objectives for a Gemba walk, it’s important to know what you want to achieve. Gemba walks are powerful tools for gaining valuable insights into your workplace and identifying opportunities for improvement. By clearly defining your goals, you can ensure that your Gemba walk activities are focused and productive.

One of the primary objectives of a Gemba walk is to identify areas where improvements can be made. This can include anything from streamlining processes to reducing waste or increasing productivity. By observing the work being done on the shop floor or in other areas of your organization, you can gain a detailed understanding of how things are currently being done and identify potential solutions.

What are the key steps involved in Gemba walks?

5 Observations To Make During A Gemba Walk

It is important to enter a Gemba walk with either a list of questions, a checklist, or key areas of observation in mind that you can use to guide your walk. Process improvements need to be structured so you must approach the production process with clear objectives.

1. Identify Process Inefficiencies

As you embark on your Gemba walk, pay close attention to the various activities taking place. Observe how tasks are being performed and note any bottlenecks or delays. Look for signs of wasteful activities such as unnecessary motion, waiting times, or overproduction. These observations will help you identify process inefficiencies that can be addressed.

Furthermore, keep an eye out for improvement opportunities during your observations. Note any areas where there is room for streamlining processes or reducing waste. This aligns with the lean management philosophy of continuous improvement.

2. Evaluate Safety Measures

Take note of any potential hazards or unsafe conditions on the factory floor, and ensure that safety measures are in place to protect employees. During a Gemba walk, it is essential to make thorough observations regarding the safety measures implemented in the workplace. This is crucial for preventing workplace injuries and minimizing health risks in various industries.

Pay close attention to the layout of the workspace, equipment usage, and adherence to safety protocols. Look for any signs of negligence or areas where improvement is needed. Evaluate if proper safety measures have been put in place to mitigate risk. Are workers provided with personal protective equipment (PPE) such as gloves, goggles, or helmets? Is there clear signage indicating potential danger zones? Have emergency exits been clearly marked and regularly tested?

3. Assessing Equipment and Tools

When assessing equipment and tools, you’ll want to check for any signs of damage or malfunction to ensure they are safe and efficient to use on a daily basis. As you walk through the shop floor, pay close attention to the condition of the products being produced and the machines being used. Look out for any visible wear and tear, loose parts, or unusual noises coming from the equipment. 

Additionally, take a moment during your Gemba walk to assess the general environment on the shop floor. Are there any hazards present that could affect employee safety? Are there clear pathways for movement? Is proper lighting provided? These factors can greatly impact both productivity and employee well-being.

4. Examine Communication Channels

During your Gemba walk, observe how information flows within the team or department. Look for common processes or established processes that facilitate smooth communication. By examining communication channels, you can identify potential areas for improvement that may lead to productivity gains.

For example, if you notice that certain information is not reaching all relevant team members in a timely manner, this could be addressed through corrective action such as implementing regular team meetings or utilizing technology for instant messaging.

Furthermore, don’t forget to seek employee input on communication practices during your Gemba walk. By involving them in the process, you foster stable relationships while gaining valuable insights into their perspective on how information is communicated within the organization.

5. Gauge Employee Engagement

When conducting observations during a Gemba walk, there are several types that can provide valuable insights into employee engagement. Firstly, you can observe how employees interact with their colleagues and superiors. Are they actively participating in discussions? Do they contribute ideas and suggestions? The relationship between managers and employees can give you an idea of the level of engagement within the team as well as an idea of employee morale.

Secondly, pay attention to employees’ body language and demeanor. Are they enthusiastic about their work? Do they appear motivated and focused? Positive body language is often a sign of high employee engagement. Lastly, observe how the project team engages with the decision-making process. Are they included in important decisions? Do they have opportunities to provide input and take ownership of projects? Involving employees in decision-making can greatly enhance their engagement levels.

Are there specific tools and techniques that can be used in Gemba walks?

What To Do After You’ve Made Gemba Walk Observations

After conducting a Gemba walk, the next crucial step is to develop an action plan as part of your continuous improvement initiative. Start by analyzing the observed processes and engaging with the people involved to gather their insights. Collaborate with the leadership team to prioritize areas for improvement and employee evaluation. 

Identify common process bottlenecks and inefficiencies. With these insights, create a comprehensive improvement plan that addresses the key components of the observed business processes. Ensure that the key steps of the plan are clear and actionable, involving both management and front-line employees. The Gemba walk serves as a vital management tool to drive meaningful change and enhance operational excellence.

Invest in a Gemba Walk App

If you want to improve your Gemba walks, you should consider investing in the Gemba walk app. Our app offers several advantages in the realm of continuous improvement. By utilizing mobile phones, it empowers organizations to streamline their future improvement efforts. 

The app enables teams to record observations in real time. This not only ensures accurate data collection but also allows for immediate analysis and action. Furthermore, the app provides a platform for additional insights and collaboration among team members, fostering a culture of continuous improvement.

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Frequently Asked Questions

Yes, virtual Gemba walks can be conducted using video conferencing tools, where team members share their work environments and processes digitally.

Challenges may include resistance to change, lack of time, and the need for a cultural shift towards continuous improvement.

Gemba walks can be beneficial in various industries, including manufacturing, healthcare, service, and software development, as long as there are processes to observe and improve.

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Are there specific tools or techniques that can be used during a Gemba walk?

Posted on by ProstarSEO

Gemba, a Japanese term meaning “the actual place,” refers to the location where value is created. Gemba walks involve going to the workplace to observe firsthand how work is done and interact with employees. It allows managers and leaders to gain insights into the work environment and identify areas for improvement.

While the Gemba walk itself is a valuable technique for continuous improvement, there are specific tools and techniques that can be used to enhance its effectiveness even further. These tools and techniques can help to systematically analyze processes, gather data, and foster a culture of problem-solving and continuous improvement. In this article, wel explore some of the tools and techniques that can be used during a Gemba walk to make it a more impactful experience.

Key Takeaways

  • Regular Gemba walks facilitate prompt corrective action and contribute to a safer, more cost-efficient workspace.
  • Empowering frontline employees through involvement in the improvement process, such as utilizing the 5 whys is a key benefit.
  • Mapping is a great way to get a broad outlook of your processes, whether it be value stream mapping or process mapping. 
  • A Gemba walk app is a 21st century digital tool to make Gemba walks more efficient.

Why Are Gemba Walks Important?

Gemba walks are crucial in lean management philosophy as they provide an effective means to engage with the actual work process at the frontline. They allow team leaders and managers to identify safety concerns, inefficiencies, and opportunities for cost-saving in real time. 

By regularly conducting these walks, organizations can take corrective action promptly, ensuring a safer and more cost-efficient workspace. Gemba walks also empower frontline employees by involving them in the improvement process, making them feel valued and motivated to contribute to future improvement efforts.

In lean management, Gemba walks are the most efficient method to gain a firsthand understanding of the entire process. These regular walks through the workspace ensure that workspace efficiency is continuously optimized. They underscore the importance of direct observation and interaction with employees on the frontlines, making Gemba walks an indispensable tool for any organization committed to the principles of lean management.

Best Gemba Walk Tools And Techniques

In this section, we shed light on effective tools and popular management techniques that empower organizations to maximize their continuous improvement efforts. Discover how these resources can elevate your Gemba Walk experience and drive operational excellence.

1. Gemba Walk App

A Gemba Walk app is an invaluable tool for enhancing the effectiveness of Gemba walks in the context of lean manufacturing and continuous improvement. It simplifies the process by making it easier to record observations and automatically generates detailed reports. With predefined lists of questions, it ensures a comprehensive assessment of the entire production floor. Moreover, it encourages employee input, fostering a culture of collaboration. The app’s automated reporting simplifies follow-up questions and facilitates data-driven decision-making for the leadership team, making it an indispensable asset for continuous improvement efforts.

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2. The 5 Whys Technique

The 5 Whys technique helps identify the root cause of a problem during a Gemba walk. During the Gemba walk, you can engage with employees and ask them a series of “why” questions to get to the underlying cause of a problem. By asking why multiple times, you can uncover valuable insights and dig deeper into the issue at hand.

As a management tool for continuous improvement, the 5 Whys technique is a powerful tool to identify opportunities for improvement. By asking why a problem occurred, you can uncover the underlying factors that contribute to the issue. This helps you to find solutions that address the root cause, rather than just treating the symptoms.

Questions asked during a Gemba walk 

3. Process Mapping

When conducting a Gemba walk with your team, process mapping can be a valuable tool to identify areas for improvement. By mapping out the current process, you can identify bottlenecks, redundancies, and opportunities for streamlining. This visual representation helps everyone on the team understand the process and identify areas where changes can be made to improve efficiency and customer satisfaction.

Process mapping can also be a useful method for developing an action plan. By mapping out the current process and then brainstorming potential improvements, you can identify specific actions that need to be taken to optimize the workflow. This method allows for a systematic approach to process improvement, ensuring that changes are based on data and analysis rather than guesswork.

4. Value Stream Mapping

Value stream mapping is a useful tool for identifying areas of waste and inefficiency in a workflow. It is commonly used during Gemba walks on factory floors to analyze and improve the overall performance of a process. By visually mapping out the entire value stream, from the initial customer request to the final product delivery, value stream mapping provides a comprehensive view of the current state of operations. 

During a Gemba walk, you can use a checklist specifically designed for value stream mapping to guide your observations and analysis. This checklist helps you identify improvement opportunities and gather the necessary data to create a value stream map. It prompts you to observe the actual work processes, gather information on cycle times, lead times, and inventory levels, and assess the overall flow of materials and information.

What are the key steps involved in Gemba walks?

5. Standardized Work

During a Gemba walk, it’s important to document the standardized work procedures and identify any variations or deviations from the established standards. This ensures that the processes are being followed consistently and allows for the identification of potential improvement opportunities. There are several tools and techniques that can be used during a Gemba walk to assess standardized work and drive continuous improvement initiatives.

By engaging with the employees performing the work with direct questioning, the observer can gain valuable insights into their understanding and execution of standardized work. This allows for a more comprehensive performance review and helps to identify any gaps or areas for improvement.

How does a Gemba walk contribute to process improvement?

6. Visual Management Tools

Visual management tools provide a visual representation of the manufacturing process, allowing you to see the flow of the work and the status of each task in real time on a daily basis. This allows you to identify any areas where the flow is interrupted or where there is a backlog of work, enabling you to take action to address these issues and keep the stream of work flowing smoothly.

On the shop floor, visual management tools can be used to create visual cues that guide employees in their routines. These cues can be in the form of visual displays, charts, or boards that provide clear instructions and reminders of important tasks. By using visual management tools in this way, you can improve employee engagement and ensure that everyone is following the same standardized processes.

7. Gemba Walk Checklists

As you conduct a Gemba walk, make sure to utilize checklists to ensure you cover all the necessary areas and tasks. Checklists serve as specific tools that can enhance the effectiveness of your Gemba walks. By using a comprehensive checklist, you can ensure that you ask key questions and cover all relevant areas during your walk.

A Gemba walk checklist should include a list of key questions that address different aspects of the Gemba, such as safety, quality, and productivity. For example, you may include questions like “Are all safety protocols being followed?” or “Is the work area organized and free from unnecessary clutter?” By having these questions on your checklist, you can systematically evaluate each area and identify potential issues or improvement opportunities.

Invest In The Gemba Walk App 

If you want a tried and tested way to improve your Gemba walks, the Gemba Walk App is the ultimate solution. Designed to seamlessly fit into your daily routine, our app is a 21st-century digital approach to Gemba walks. With everything you need to record your walks within the app, you can easily store all your insights in one place. Our innovative app even generates personalized reports in order to make it easier to implement improvements over time. 

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Frequently Asked Questions

Why are Gemba Walks important in Lean Manufacturing?

Gemba Walks are crucial in lean manufacturing because they enable the identification of inefficiencies, waste, and opportunities for improvement by directly observing operations on the shop floor.

Who should participate in Gemba Walks?

Gemba Walks typically involve senior leaders, managers, and sometimes cross-functional teams. Anyone interested in understanding and improving the work process can participate.

How often should Gemba Walks be conducted?

The frequency of Gemba Walks can vary but they are often conducted regularly, such as weekly or monthly, to ensure ongoing improvement and engagement with frontline employees.

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What challenges or obstacles can arise during Gemba walks, and how can they be overcome?

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Gemba walks, originating from the Japanese term “Gemba” meaning “the real place,” involve leaders going to the actual work area to gain insights and make improvements. While they can be highly effective in identifying issues and fostering a culture of continuous improvement, there are common challenges that leaders may encounter during these walks.

In order to ensure the success of Gemba walks, it is crucial to anticipate and address potential obstacles. This article explores the various challenges that can arise during Gemba walks and provides practical strategies to overcome them, allowing leaders to reap the full benefits of this valuable management practice.

Key Takeaways

  • Employees are unwilling to participate when things change too quickly or they don’t understand new processes.
  • Confronting communication barriers is essential so everyone understands the benefits of Gemba walks.
  • By creating a schedule for your Gemba walk you will be able to tackle any time constraints that might be holding you back.
  • Leveraging mobile devices makes Gemba walks far more efficient and improves success rates.

Common Challenges That Arise During Gemba Walks

When done well, Gemba walks are the perfect way to ensure your business is continually improving. In order to help ensure your Gemba walk operations are successful, we have highlighted some of the most common obstacles that arise during Gemba walks and solutions to overcome them.

Lack of Participation From Employees

Lack of participation from employees can be a common challenge faced by management teams when trying to implement Gemba walks as a tool for continuous improvement. Employees may not fully understand the importance of their involvement or may be hesitant to take part due to a lack of clarity on what is expected of them during these walks.

To overcome this challenge, it is crucial for management to effectively communicate the purpose and benefits of Gemba walks to employees. By clearly explaining that Gemba walks provide an opportunity for employees to actively contribute to process improvement, share their insights and ideas, and help create a culture of continuous improvement, employee engagement can be enhanced.

Who should participate in Gemba walks?

Resistance to Change

Resistance to change is a common challenge faced by organizations during Gemba walks. Frontline workers may resist changes due to fear of the unknown, concerns about increased workload, or skepticism about the effectiveness of new practices. However, by adopting effective management practices and leveraging emotional intelligence, these obstacles can be overcome.

To address resistance to change, it is crucial to communicate the rationale behind the proposed changes to frontline workers. By explaining the benefits and involving them in the decision-making process, their concerns can be addressed, and they can become more receptive to change. Additionally, it is important to actively listen to employee feedback and address any issues or challenges they may raise.

Communication Barriers

Communication barriers can hinder the problem-solving process and prevent the effective identification of root causes during Gemba walks. When conducting Gemba walks, it’s crucial to establish clear lines of communication to ensure that information flows smoothly between team members. One common communication barrier is language differences, making it challenging to convey information accurately.

To overcome this barrier, it’s important to provide language support, such as interpreters or translation services, to ensure effective communication. Additionally, hierarchy and power dynamics can create communication barriers. If team members feel intimidated or fear retribution, they may hesitate to speak up or share their ideas. To overcome this barrier, business owners should create a culture of psychological safety where all team members feel comfortable expressing their thoughts and concerns without fear of judgment or consequences.

Digitize your Gemba walks

Time Constraints and Workload Pressures

Due to time constraints and workload pressures, you may struggle to allocate sufficient time for conducting thorough Gemba walks. However, it is crucial to make the time and prioritize Gemba walks, as they are an effective tool for continuous improvement and finding opportunities for optimizing the production process. To overcome the time constraints and workload pressures, consider integrating Gemba walks into your weekly routine.

Set aside dedicated time each week for Gemba walks. By making it a consistent practice, you can ensure that you are regularly engaging with the Gemba and staying connected to the production process. Additionally, you should delegate responsibilities and empower team members to conduct gemba walks themselves. Share the workload and encourage everyone to contribute to the continuous improvement efforts.

How long should a Gemba walk last?

Lack of Management Support and Buy-In

To gain the necessary support and engagement from management, it’s important for you to demonstrate the value and positive impact of Gemba walks on the production process. One of the challenges you may face is a lack of management support and buy-in for Gemba walks. This can hinder the effectiveness of the walks and make it difficult to drive meaningful change on the shop floor.

To overcome this obstacle, it is crucial to effectively communicate the benefits of Gemba walks to management. Highlight how Gemba walks provide valuable insights into the manufacturing process, allowing for identification of bottlenecks, inefficiencies, and improvement opportunities. Emphasize that Gemba walks empower team leaders and frontline employees to take ownership of the process and make data-driven decisions.

Failure to Sustain Continuous Improvement Efforts

In order to sustain continuous improvement efforts, it’s important for you to actively engage in regular follow-up and monitoring of implemented changes. One common issue that can arise during this process is the failure to sustain these efforts over time. This can happen due to a number of reasons, including a lack of real-time visibility into the actual work process and a failure to address quality issues promptly.

One solution to this challenge is to leverage mobile devices to enable real-time monitoring and reporting. By providing employees with the tools to capture data and report issues as they occur, you can ensure that quality issues are addressed in a timely manner. This not only helps to prevent further problems from occurring but also allows for a more proactive approach to quality management.

Difficulty in Identifying Root Causes

One of the main difficulties in identifying root causes during Gemba walks is the lack of visibility into the underlying processes. Sometimes, the issues may be hidden or not immediately apparent, making it hard to pinpoint the exact cause. Additionally, factory floor employees may be hesitant to share their insights or observations, further complicating the problem-solving process.

To overcome these challenges, organizations can implement data analysis techniques to gain a deeper understanding of the processes and identify patterns or trends. By leveraging data, organizations can uncover valuable insights and make data-driven decisions to improve process efficiency and effectiveness. Furthermore, engaging employees in the problem-solving process can provide different perspectives and valuable input. Encouraging open communication and creating a safe space for employees to share their observations can lead to a more collaborative and effective problem-solving process.

How does a Gemba walk contribute to process improvement?

Inadequate Training of Gemba Walk Leaders

When inadequately trained, Gemba walk leaders may struggle to effectively conduct the walks and identify root causes of problems. This can hinder the overall success of the Gemba walk and limit the opportunities for improvement within the organization. Studies have shown that leaders who lack proper training in lean manufacturing often struggle to communicate with workers on the shop floor and fail to ask the right questions to uncover underlying issues.

To overcome this challenge, it is crucial for organizations to invest in comprehensive training programs for Gemba walk leaders. These programs should not only cover the technical aspects of lean management philosophy but also focus on developing strong leadership and communication skills. By providing leaders with the necessary knowledge and tools, they can effectively engage with workers, build trust, and uncover valuable insights.

Invest in The Gemba Walk App

If you have noticed that your Gemba walks are not as effective as they should be, investing in digital solutions is essential. The Gemba Walk App is designed to make Gemba walks as efficient as possible by eliminating all the time-consuming elements of traditional Gemba walk recording. With our state-of-the-art app, all you need is your phone in your hand and you can create a comprehensive outlook of each and every walk. Simply input your observations into your phone and the app will do the rest, creating detailed reports that you can easily look back on, making tracking your continuous improvements easier than ever.

Get the Gemba Walk app

Frequently Asked Questions

What is a Gemba walk?

A Gemba walk is a fundamental lean manufacturing practice where leaders or team members visit the actual work area (Gemba) to observe processes, identify issues, and foster continuous improvement.

Who is responsible for Gemba walks?

Team leaders are generally responsible for Gemba walks, but collaborating with other employees and creating dedicated Gemba walk teams will ensure you get the most out of your walks.

How long should a Gemba walk last?

Gemba walks should take no longer than an hour. In order to maximize effectiveness, doing shorter walks often is more beneficial.

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