Our advice for a successful Gemba Walk in industry
Gemba Walk: Observing Shop Floor Reality to Improve Industrial Performance
The term Gemba is a Japanese word that literally means "the real place". In an industrial context, it refers to the place where value is actually created: the production workshop, assembly lines, logistics areas, or individual workstations.
It is also on the shop floor that problems emerge, disruptions become visible, and the best opportunities for improvement can be identified.
The principle of Gemba is therefore based on a simple idea:
to improve a process, you must go and observe it directly where it takes place.
In an industrial company, this means leaving the office and getting as close as possible to operators and production processes. This approach is at the heart of Lean Management, which emphasizes direct observation, collaboration, and continuous improvement.
Why Should Managers Go to the Shop Floor?
Every level of an organization has a different perspective on operations.
Executives and production managers make strategic and operational decisions every day. However, these decisions can sometimes be made without an accurate understanding of shop floor reality.
Yet the true sources of improvement are often found where production actually takes place.
The Gemba Walk enables managers to:
- gain a concrete understanding of working conditions
- identify operational issues and performance losses
- detect waste (MUDA)
- engage directly with operators
- verify compliance with Lean standards
This approach promotes faster and more relevant decision-making, as it is based on real observations rather than assumptions.
What Is a Gemba Walk?
The Gemba Walk is the practical application of the Gemba principle.
It involves managers and supervisors taking regular walks through the workshop or production facility, observing operations, interacting with teams, and identifying opportunities for improvement.
Unlike an inspection or an audit, the purpose of a Gemba Walk is to:
- observe processes in real operating conditions
- understand the difficulties faced by operators
- identify abnormalities or deviations from standards
- collectively explore opportunities for improvement
These visits should be conducted regularly and in a structured manner to monitor ongoing improvement initiatives and identify new performance drivers.
The Gemba Walk helps verify:
- whether work standards are being followed
- whether improvement actions are delivering the expected results
- whether new forms of waste are emerging within processes
It is a fundamental pillar of Lean culture and continuous improvement (Kaizen).
The Benefits of a Gemba Walk
Implementing regular shop floor walks offers numerous benefits for an organization.
1. Better Understanding of Problems
Directly observing operations makes it possible to quickly identify the root causes of issues instead of relying solely on reports or KPIs.
2. Faster Resolution of Operational Issues
By being present on the shop floor, managers can immediately engage with operators and gather valuable feedback.
3. Reduced Need for Unnecessary Meetings
The Gemba approach prioritizes action and observation over lengthy theoretical discussions.
4. Greater Team Engagement
Operators are the foremost experts on their own workstations. The Gemba Walk values their expertise and strengthens their involvement in problem-solving.
5. Improved Collective Performance
By encouraging dialogue and collaboration across all levels of the organization, the Gemba Walk helps develop a culture of continuous improvement and teamwork.
The 7 Steps to Conduct an Effective Gemba Walk
To be effective, a Gemba Walk should follow a structured approach.
1. Go Directly to the Shop Floor
When a problem arises, it is essential to go immediately to the affected area to observe the actual situation.
2. Observe the Process Carefully
Analyze how operations are carried out and understand each step of the process before searching for solutions.
3. Ask Operators Questions
Employees on the shop floor possess valuable knowledge about operational challenges and workstation constraints.
4. Listen Without Judgement
The objective is not to find someone to blame but to understand the root causes of the issue.
5. Identify the Root Cause
Use problem-solving tools (5 Whys, Ishikawa, PDCA, etc.) to determine the true source of the problem.
6. Define Corrective Actions
Implement concrete actions that permanently eliminate the root cause.
7. Monitor Actions Over Time
Verify the effectiveness of implemented solutions and measure the results achieved.
The Role of Visual Management After a Gemba Walk
After the shop floor walk, teams generally hold a short meeting at the workstation or management board.
These meetings make it possible to:
- share observations from the Gemba Walk
- analyze performance indicators
- monitor improvement actions
- define priorities for the day
In modern industrial environments, these meetings increasingly rely on connected displays and digital visual management solutions.
Production, quality, and maintenance indicators can therefore be displayed in real time, enabling faster and more collaborative decision-making.
Digitalizing the Gemba Walk with SESAHUB
To make shop floor walks even more effective, it is now possible to digitalize the Gemba Walk using solutions such as SESAHUB.
SESAHUB is a software platform dedicated to industrial performance management within an Industry 5.0 framework. It centralizes production data and transforms it into actionable information for teams.
During a Gemba Walk, managers can use an industrial tablet, such as the E.STATION (10.1-inch touchscreen tablet), to:
- view real-time production indicators
- monitor hourly performance
- record shop floor observations
- report anomalies or machine breakdowns
- enter production and quality results
All information collected on the shop floor is immediately centralized within SESAHUB, enabling instant updates to management dashboards and visual management systems.
A More Effective Gemba Walk with Real-Time Data
Integrating SESAHUB into shop floor walks transforms the Gemba Walk into a true performance management tool.
Managers can:
- access all industrial data from a single platform
- compare results against defined objectives
- monitor improvement actions in real time
- make decisions based on reliable data
This approach also helps reduce paper usage and facilitates information sharing across teams.
Operators gain direct access to the information they need to perform their work, while managers benefit from a comprehensive and up-to-date view of workshop performance.
Gemba Walk in the Era of Industry 5.0
Today, the Gemba Walk is no longer limited to simple observation of the shop floor. Thanks to digital tools such as SESAHUB, it has become a powerful industrial management lever, combining:
- shop floor observation
- visual management
- real-time data
- team collaboration
This approach enables industrial companies to strengthen their Lean initiatives while fully embracing the principles of Industry 5.0: a more connected, more collaborative, and more human-centered industry.