7 Steps for an Effective Process Walk

As a manager before walking on the shop floor, it is very important you make a plan and follow the right steps. The plan should consist of the following:

• Choose a Theme

 It is a requirement for Gemba, to choose a theme for your Gemba walk. Examples can include safety, productivity and others. 

• Clarify the Purpose of Gemba

 The purpose of the Gemba walk should be clear with all the team. They should be aware of the purpose of gemba, serving as a technique for continuous improvement for the benefit of everyone in the organization. The advantage of this is that it creates solid ground for effective collaboration. 

• Evaluate Process, not People

 Gemba is primarily focused on process, not on people with the goal of observing, comprehending and enhancing the process for better performance. Questioning people’s abilities will result in resistance. 

Click Here to Download Readymade Editable Toolkits & Templates on Quality Assurance/Quality Control, Lean Six Sigma, Lean Manufacturing, Six Sigma, ISO 9001, ISO 14001, ISO 22000, ISO 45001, FSSC 22000, HSSE, Project Management etc.

• Visit Value Stream

 A best practice to adopt is following the value-chain. This gives the best prospects to identify regions with a huge potential of waste activities. 

• Capture Observations

 Making suggestions during the walk is not necessary. All you need to do at this stage is capturing all that attracts your attention using mobile devices is necessary. Some situations may leave you with no choice but to propose a solution right away, but this wouldn't be the best. Analysis of the current state should be kept for later review when you are more relaxed to provide accurate and precise analysis by employing effective problem-solving tools. It would be better than an instant feeling. 

• Fresh Viewpoint

 Having a colleague from another department for Gemba is usually an advantage. Ideally a person who has entirely different working background is preferred. Experience shows that individuals with less awareness of the daily processes normally have a fresh eye to see things differently and often ask different questions. 

• Follow up

Gemba walk may not always yield substantial observation, but you should still share your experience with with the team for analysis. This should be should be done to ensure objectivity. Ensure not to blame them, but be reasonable about areas of improvement. If you are making actions after the walk, take the team in confidence about the future changes and why they are significant.

Click Here to Download Readymade Editable Toolkits & Templates on Quality Assurance/Quality Control, Lean Six Sigma, Lean Manufacturing, Six Sigma, ISO 9001, ISO 14001, ISO 22000, ISO 45001, FSSC 22000, HSSE, Project Management etc.

About the Author

Adebayo is a thought leader in continuous process improvement and manufacturing excellence. He is a Certified Six Sigma Master Black Belt (CSSMBB) Professional and Management Systems Lead Auditor (ISO 9001, 45001, ISO 22000/FSSC 22000 etc.) with strong experience leading various continuous improvement initiative in top manufacturing organizations. 

You can reach him here.