Zeeshan Syed – Lean Sigma Practitioner

Topics

• What is The Gemba Walk

• Why Gemba?

• The Gemba Walk

• Who’s Doing It?

• Implementing the Gemba Walk

• Focal Points

• The Bottom Line

What To Do?Reduce Lead Time!

▫ Get each process to produce only what the next process needs when it needs it.

▫ Orchestrate (control, manage, regulate) operations to get ever closer to this ideal, ever shortening the lead time.

ORDER CASH

“All we’re trying to do is shorten the time line…”Taiichi Ohno

TOYOTA PRODUCTION SYSTEMEliminate Waste cost and profit

What is Value?

What is Waste ?

Anything that adds cost without adding value

Defined by the customer

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 a.k.a. to practice Gemba Kaizen.

• Gemba is different with the “western” concept of MBWA (Management by Walking Around)

Gemba Walk & Leadership• Gemba walk is a way to build up the learning

model like sensei’s apprenticeship▫ Senei is also a Japanese work means “teacher or

coach”

▫ The subordinates are just like students or apprentices

• A leader should also instill in the subordinates the discipline needed to effectively sustain a lean conversion and have it improve consistently

• A leader has the responsibility of showing the “True North” direction of his students, coach them, point them in right direction and tell them when to stop and when to go

What is the Gemba Walk?

A leader teaches by stretching ones thinking and perceptions through questions that stimulate

one to consider entirely new possibilities.

▫ What would you learn if you measured in smaller intervals of time?

▫ What is the team leader supposed to be doing in this situation?

▫ How could these expectations be made more clear?

G E M B A .• The gemba walk is a “Check” of Plan-Do-Check-

Act.

• You are checking the health & the pulse of your leadership systems by looking at how they engage their people and processes.

• Walking the gemba is a process of developing your people.

• A model that allows an organization to recognize the “key group” in a lean transition., “the sergeants and lieutenants in the war against waste”.

• A model that helps identify existing communication gaps between operators and leadership and leadership and operators. This group is vital to successful policy deployment, and the development of a cultural of continuous improvement. Gemba walk is a way of learning. A model that

will help you gradually establish a new, lean way of seeing and thinking.

Gemba Walk model

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.”

Walking the Gemba is part of “Check” in Plan-Do-Check-Act.

It is the process of carefully observing to see where things are

not as they should be.

Sometimes there is less walking involved, and more just

standing and watching.

This, of course, begs the question: Watching for what?

This, ultimately, is what makes it different than even just

walking around looking.

Implementing the Gemba Walk

• Take a walk through the core activities of the whole, extended enterprise:

▫ Product and process development.

▫ Supplier management.

▫ Customer management and support.

▫ Fulfillment from order to delivery.

▫ General management system for the extended enterprise. (“What do managers do?” “How do managers lead?”)

The Bottom Line

The currency of leadership is presence.

Where leaders spend their time determines what is important to their organization