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!