Identify Waste by Going to Gemba

identifying waste

As you may know, “Genba,” which has been popularized as “Gemba,” is a Japanese word meaning “the real place.”

The word is widely used in Japan, where detectives frequently refer to a crime scene as genba, and Japanese TV reporters often refer to themselves as reporting from genba/gemba.

In the business realm, gemba refers to the place where work is done and value created. For example, in manufacturing gemba is typically the factory floor, but looking further afield it can be any location — a construction site,
administrative office, or sales bullpen — where the actual work is being done.

When it comes to Continuous Improvement, problems are most visible in these areas, and the best improvement ideas will come from going to gemba. If your objective is to identify waste, there is no substitute for ‘going to the work’ and there are things that can only be learned by going there and watching the work with a purpose.

Thus a gemba walk, or waste walk, is an activity that takes management and other stakeholders to the front lines to look for waste and opportunities for improvement; to observe the work where the work is being done, and to identify what goes wrong or could go wrong, how often it does or could go wrong, and the associated consequences. The waste walk is designed to help everyone understand the value stream and its problems; it is not to review results and make superficial comments.

Aside from identifying waste and the specific gains made during waste walks, there are also higher-level benefits associated with the practice:

  • Engagement: Since people at all levels are involved, and since the waste walks have proved to be an effective method of detecting hard-to-identify problems as well as solutions which improve both productivity and day-to-day quality of work life, a noticeable increase in workforce engagement is a common by-product. People like it when problems they have known about for a long time are finally solved!
  • Trust: Company leaders are able to establish greater levels of trust with the people closest to the work, by showing interest and seeking the opinions and input of those doing the work.
  • Learn the Truth: Going to gemba enables leaders to identify reality versus what they think (or hope) is happening. Waste walks help leaders to question their assumptions as well.
  • Better Ideas: When the people who are doing the work or executing the process every day start talking, thinking and feeling empowered, the ideas really flow…
  • Ask the Right Questions: as suggested in an earlier post, questions are often the “answer” to making breakthrough improvements. However, the quality of those questions is the key! Getting the data and seeing it for the first time based on direct observation is powerful; and then if you can get customers, suppliers and company personnel working through the chain, the quality of questions that surface promote more innovative and accurate solutions.
  • Improvement vs. Habit-forming Execution: The combination of fresh eyes, diverse perspective, amnesty, and a collective, sincere interest to eliminate waste and continually improve the work process tends to bring about real, often outside-of-the-box solutions; true Improvement versus dong things the same way.