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This Slideshare presentation is a partial preview of the full business document. To view and download the full document, please go here:

This Slideshare presentation is a partial preview of the full business document. To view and download the full document, please go here:
http://flevy.com/browse/business-document/gemba-walk-543


In business, 'Gemba' refers to the place where value is created and improved. The 'Gemba Walk' is an activity that takes management to the front lines to look for waste (non-value added activities) and opportunities. The objective of Gemba Walk is to grasp the situation by involving everyone touching the process to understand the Purpose, Process, and People. It is only when the situation is understood that improvement is possible and more likely to succeed.

CONTENTS

1. Introduction to Gemba Walk
- What is Gemba?
- What Gemba is Not
- Why Gemba?
- What is the Gemba Walk?
- Why the Gemba Walk?
- Who's Doing It?
- Three Keys to Lean Leadership
- Objective of Gemba Walk
- Your Approach is Key
- Going to the Gemba
- Go to the Gemba - Don'ts

2. The 3M's Defined
- What is Muda, Mura & Muri
- The Gemba Framework
- How Seeing the 3M's Helps our Kaizen Eyes

3. Kaizen Eyes: Ability to See Opportunities for Improvement
- Ways to Develop Kaizen Eyes

4. Taking the Gemba Walk: Tips for Observing
- Implementing the Gemba Walk
- Tips for Observing
- Getting Started

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Gemba Walk Presentation Transcript

  • 1. © Operational Excellence Consulting. All rights reserved. Gemba Walk Observe, Engage, Improve
  • 2. © Operational Excellence Consulting. All rights reserved. Introduction to Gemba WalkThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 3. © Operational Excellence Consulting. All rights reserved. 7 What Gemba Is NOT • Walking around without a purpose • An opportunity to find fault in others • A time for solving problems and making changes • Participating or observing a daily or tier management meeting • One place that is not “Gemba” is a manager’s desk This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 4. © Operational Excellence Consulting. All rights reserved. 10 What is the Gemba Walk? • In business, Gemba refers to the place where value is created and the general notion is that the best improvement ideas will come simply from going to the Gemba (’bottom-up’ vs. ‘top- down’) • The ‘Gemba Walk’ is an activity that takes management to the front lines to look for waste and opportunities This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 5. © Operational Excellence Consulting. All rights reserved. 13 Who’s Doing It? Bob Nardelli – CEO Home Depot “There was a perception that I was going out to catch people,” he says. “Over time they understand that I just want to see it like a customer. I can do my job better if I have firsthand exposure to the good, the bad and the ugly.” Michael Dell – Chairman Dell Computer “Michael Dell was known for popping in, unannounced and without an entourage, at the factories in Austin. He would just walk around, look, and listen to people.” This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 6. © Operational Excellence Consulting. All rights reserved. 16 Your Approach is Key Before you go to the Gemba you have to know how to approach the Gemba: • The observer must have a deep interest in understanding what is really going on • Leave all assumptions and opinions at the officeThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 7. © Operational Excellence Consulting. All rights reserved. 19 Going to the Gemba: 4 Steps to Gemba Success 1. Know Your Purpose 2. Know Your Gemba 3. Observe the Framework 4. Validate This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 8. © Operational Excellence Consulting. All rights reserved. 22 Know Your Gemba • Calling your factory floor “your” Gemba is limiting your ability to improve • The Gemba is wherever the activity is performed that you are trying to understand and improve • Each organization has it’s own unique points of activity • Each point is a new GembaThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 9. © Operational Excellence Consulting. All rights reserved. 25 Observe the Framework • Observe the environment and the 5M’s (man, machines, materials, etc.) along the value stream ManMan MeasurementsMeasurements MethodsMethods MachinesMachines MaterialsMaterials Operational + Materials StandardsOperational + Materials Standards NVA = Muda + Mura + MuriNVA = Muda + Mura + Muri 5S = Housekeeping Discipline5S = Housekeeping Discipline QualityQuality DeliveryDelivery CostCost S DC A P DC A InputInput ProcessProcess OutputOutput Source: Gemba Kaizen by Massaki Imai This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 10. © Operational Excellence Consulting. All rights reserved. 28 Go to the Gemba – DON’Ts • Don’t come preoccupied • Don’t come having already decided • Don’t come to lecture • Don’t come to get it off the list • Don’t come holding your nose • Don’t come as a wolf This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 11. © Operational Excellence Consulting. All rights reserved. 31 The Three MUs • In this way of thinking about waste, the goal is to achieve a condition where capacity and load are about equal • In other words, there are just the right amount of workers and materials and machines to make just the right amount of product that is being ordered and deliver it on time to the customer This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 12. © Operational Excellence Consulting. All rights reserved. 34 Approach for the 3 MU’s • By focusing improvement activities on eliminating the non-value-added activities throughout the production process, and on establishing production flow, balance is naturally achieved between capacity and load. Capacity = Load Capacity > Load Capacity < Load This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 13. © Operational Excellence Consulting. All rights reserved. 37 Mura Looks Like Bumpy Lumpy SpikyUnequal Peak & Valley Up & Down Un-Level Stop & Start Unevenness This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 14. © Operational Excellence Consulting. All rights reserved. 40 How Seeing The 3 MUs Helps Our “Kaizen Eyes” • Improves pattern recognition of issues • Provides lens to observe processes through • Gives routine for practicing our skills of observation • Fosters a language to communicate opportunities • Develops a holistic way to think about processes • Prevents trade-offs between the ill-effects of the 3 M’s This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 15. © Operational Excellence Consulting. All rights reserved. 43 Observing takes… • Time • Effort • Patience • Practice • HumilityThis document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 16. © Operational Excellence Consulting. All rights reserved. 46 Ways to Develop “Kaizen Eyes” 3 33. Start to Kaizen something 34. Join an improvement team 35. Create a poka-yoke 36. Brainstorm possibilities 37. Study other Kaizens 38. Collect examples of improvements from all parts of life 39. Practice at home 40. Teach to a child 41. Take something apart 42. Do a walkthrough with someone else 43. Study problem solving 44. Quiz suppliers 45. Listen to customers 46. What would you do with unlimited budget? 47. Search help forums 48. Create a checklist This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 17. © Operational Excellence Consulting. All rights reserved. 49 Example This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 18. © Operational Excellence Consulting. All rights reserved. 52 What is the Process? Look for: • Standard Processes • Expected State • Variation to Expected State This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 19. © Operational Excellence Consulting. All rights reserved. 55 What is Not Being Maintained? Look for: • Checklists to Review • State of Equipment • Housekeeping of Work Area • Pace and Flow of Process This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 20. © Operational Excellence Consulting. All rights reserved. 58 What is Not Documented? Look for: • Process Steps that are Not Documented or Not Updated • Missing Standard Work This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 21. © Operational Excellence Consulting. All rights reserved. 61 What is Creating Strain (Muri)? Look for: • Poor Ergonomics • Overburdening Activity This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 22. © Operational Excellence Consulting. All rights reserved. 64 Getting Started • Find a process or value stream to review • Review the observation tips • Practice seeing the 3 MUs around us • Observe the process/value stream and share what you have learned • Choose something to Kaizen • Perform the Kaizen • Follow up to see that progress is being made This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/gemba-walk-543
  • 23. 1 Flevy (www.flevy.com) is the marketplace for premium documents. These documents can range from Business Frameworks to Financial Models to PowerPoint Templates. Flevy was founded under the principle that companies waste a lot of time and money recreating the same foundational business documents. Our vision is for Flevy to become a comprehensive knowledge base of business documents. All organizations, from startups to large enterprises, can use Flevy— whether it's to jumpstart projects, to find reference or comparison materials, or just to learn. Contact Us Please contact us with any questions you may have about our company. • General Inquiries support@flevy.com • Media/PR press@flevy.com • Billing billing@flevy.com