Lean Manufacturing Blueprint

A performance-driven strategic planning technique used in Lean manufacturing to promote collaboration among employees and drive continuous improvement. The method involves conducting observations the workplace and observing employees at work to identify inefficiencies and areas where improvements can be made.

One key component of a successful Gemma walk is to have a checklist that outlines what to observe during your evaluations. This ensures that you don't miss important details and will be able to provide constructive feedback that is actionable.

Here are some key items to include on a Gemba walk checklist:

1 Work in Process (WIP): Analyze how much inventory is on hand and whether there is a sufficient supply chain to meet current demand. Consider utilizing tools such as Just-In-Time production or Toyota Production System to reduce waste and minimize waste.

2 Underutilized Equipment: Look for equipment that is idle. Identify the root reason of this inefficiency, and implement a plan to streamline operations or phase out underperforming assets.

3 5S Adoption: Evaluate the level of 5S achievement, which involves organizing and upkeeping the work area. 5S stood for Sort, Set in order, Clean, Establish, and Sustain. Employees who have mastered 5S can reduce waste and work more effortlessly.

4 Energy Efficiency: Check whether all appliances and illumination are being used efficiently to prevent waste and minimize the impact of energy consumption on the environment.

5 Material Waste: Inspect to see if materials and inputs are being used efficiently, and whether unnecessary materials are available in the area. Consider adoption product Kanban to avoid item expiry and optimize inventory levels.

6 Water and Wastewater Infrastructure: Recognize potential sources of waste that can be minimized by implementing an effective water management system, also known as 'water-based waste.' For example, use of leak-proof containers and other hazard mitigation measures can help minimize product loss and waste.

7 Employee Training: Engage with employees about their current condition and problems they encounter daily. Evaluate their training level, recognize areas where personal growth are required, and execute a plan to address knowledge gaps.

8 Employee Feedback Mechanisms: Evaluate how employees give feedback on areas of improvement and develop useful communication systems so that they can provide input assertively. It can also be helpful to evaluate employee suggestions to recognize the most practical ones.

9 Regulatory Compliance: Confirm whether employees comply with local regulations and company policies to ensure compliance.

By following a set of standard evaluation tools, leaders can use the Lean walk strategy to evaluate specific business operations, supply chains, or teams. By evaluating the day-to-day processes, operations managers are given the opportunity to suggest small or minor adjustments that bring immediate improvements to workplaces.