Ever wish you could see how work really happens in your factory in a structured way? Picture yourself walking through the production line, noticing every small issue before they turn into big problems. This is something you can do with a Gemba Walk.
We’ll break down what a Gemba Walk is and why it’s so important, especially in food safety.
We’ll also show you how to use Inspectle Food Safety Inspection app with a Gemba Walk to make your work easier and your food products safer.
Table of Contents
What is a Gemba Walk?
A Gemba Walk might sound like a strange term, but it’s actually a simple idea that can make a big difference in how your factory runs. Let’s start by breaking down what the word "Gemba" means. In Japanese, "Gemba" means "the real place" or "the actual place." In a factory or any workplace, the Gemba is where the work really happens. It’s the production floor, the warehouse, or any area where your employees are getting the job done.
Pro-Tip: Pronunciation of "Gemba"
Before we go further, let’s clear up how to say "Gemba." It’s pronounced "Ghem-ba," with a hard "G" like in the word "go." Now that you know how to say it, you can confidently use the term in your workplace.
Now, what exactly is a Gemba Walk? It’s when you, as a manager or team leader, go to the Gemba — the place where the action is happening — and observe what’s going on. But it takes more than just walking around. A Gemba Walk is about seeing, listening, and understanding.
You cannot do a Gemba Walk while sitting in an office looking at reports. You have to go where the work happens – you have to be on the floor, watching how things are done, and talking to the people who do the work.
This way, you can find out what’s really going on and where improvements can be made.
It’s about getting a real feel for how work is done, how problems are handled, and how things could be improved.
The History and Roots of Gemba Walks
The concept of Gemba Walks comes from Japan, where they were developed as part of the Toyota Production System (TPS). This system was created by Toyota in the 1950s to improve efficiency and quality in their car manufacturing process. The idea behind Gemba Walks was to get managers out of their offices and onto the factory floor, where they could see firsthand how work was done and identify areas for improvement.
Taiichi Ohno, a key figure in developing the Toyota Production System, emphasized the importance of going to the Gemba to truly understand the work. He believed that real improvements could only be made by seeing the processes in action and talking directly to the people involved. This hands-on approach helped Toyota become one of the most efficient and high-quality car manufacturers in the world.
Over time, the idea of Gemba Walks spread beyond Toyota and the automotive industry. It became a key part of Lean manufacturing, a method used by many companies around the world to improve their production processes. Today, Gemba Walks are used in various industries, including food production, to ensure that operations run smoothly and safely.
Purpose of a Gemba Walk
The main purpose of a Gemba Walk is to understand the process, not to blame people for mistakes. During the walk, you focus on the process, not the people. You look for ways to make the work easier, faster, and better. This is especially important in the food industry, where safety and quality are top priorities.
Imagine you’re walking through the production line, and you notice that workers are skipping a cleaning step because the equipment is hard to reach.
By observing this, you can take steps to make that area easier to clean, which can help prevent contamination. This kind of improvement can only be spotted when you’re actually on the floor, watching the work happen.
What You Do During a Gemba Walk
When you do a Gemba Walk, you don’t just stroll around randomly. You have a plan. Start by choosing a specific area or process to observe. Maybe you want to look at how raw materials are stored, or how packaging is done. Pick one area at a time so you can focus your attention.
Once you’re at the Gemba, take your time to observe. Watch how the work is done step by step. Don’t interrupt the workers right away. Instead, try to see the process through their eyes.
What challenges do they face?
What could be improved to make their job easier and safer?
After observing, it’s important to talk to the workers. Ask them open-ended questions like, “What’s the hardest part of your job?” or “Is there anything that slows you down?” Listen to their answers carefully. The people doing the work often have the best ideas for how to improve it.
Documenting Your Observations
As you walk and talk, take notes. Take a picture with an app like Inspectle and write down on the note associated with the picture what you see, what you hear, and what you think could be improved.
When you’ve finished the walk, review your notes on your phone or in the web app. Look for patterns or recurring issues. These might be areas that need immediate attention. Also, notice what’s working well so you can spread those practices to other areas of your factory.
Benefits of a Gemba Walk
The benefits of a Gemba Walk are clear. First, it gives you a real understanding of what happens on the floor, which you can’t get from reports or meetings. Second, it helps build a better relationship between managers and workers. When workers see that you’re interested in their challenges and ideas, they feel more valued and are more likely to speak up with suggestions.
Lastly, Gemba Walks lead to continuous improvement. By regularly visiting the Gemba, you can keep finding new ways to make your processes better, safer, and more efficient. Over time, these small improvements add up to big gains in productivity and quality.
A Gemba Walk is a powerful tool for any manager, especially in food safety. It’s simple to do, but the insights you gain can make a huge difference in how your factory operates. By going to the Gemba, you can see your processes clearly, listen to your workers, and find real ways to improve your operations.
Gemba Walks in Food Production
Food safety is something that can never be taken lightly. The smallest mistake can lead to big problems, like product recalls or even harm to consumers. A Gemba Walk lets you spot these mistakes early. You can see if workers are following safety rules, if machines are clean and working well, and if everything is in order.
During a Gemba Walk you not only find out problems, but you also learn what’s working well. By observing good practices, you can find ways to spread these practices to other parts of your factory. You might see how one team keeps their area super clean and decide to use their methods in other areas too.
The five key elements of a Gemba Walk
1. Observation
The first and most important element of a Gemba Walk is observation.
This might sound simple, but it’s about more than just looking around. When you’re observing, you need to pay close attention to every detail of the process you’re watching. Notice how work is being done, how tools and machines are being used, and how workers move through their tasks.
For example, if you’re observing a packaging line in a food production facility, watch how the workers handle the products, how the packaging machines operate, and how the finished products are stored.
Are the workers following the proper safety procedures?
Are the machines running smoothly without causing any delays?
Are there any signs of wear and tear on the equipment that might cause problems later?
Effective observation means being curious and open-minded. Don’t just look for problems—also look for things that are working well. You might see a worker who has developed a faster way to perform a task or a machine that’s running more efficiently than others. These are things you can learn from and apply elsewhere in your facility.
2. Engagement
The second key element is engagement. In a Gemba Walk you don't watch from a distance; you engage with the people doing the work.
This means talking to the workers, asking questions, and listening to their insights.
When you engage with employees, it’s important to approach the conversation with respect and a genuine interest in their work.
Instead of asking, “Why are you doing it this way?” which might sound accusatory, try asking, “Can you explain how this process works?” or “What challenges do you face with this task?” This opens up the conversation and encourages workers to share their thoughts.
Engagement is crucial because the workers are the ones who know the job best. They do it every day and have valuable insights that you might not see just by observing. They can tell you what slows them down, what frustrates them, and what they think could be improved. By engaging with them, you build trust and encourage a culture of continuous improvement.
3. Questioning
The third element is questioning. Asking the right questions during a Gemba Walk can lead to deeper understanding and uncover hidden issues. But it’s important to ask questions in a way that is constructive and supportive, not critical.
Good questions help you get to the root of a problem. For instance, if you notice that a worker is skipping a step in the cleaning process, instead of jumping to conclusions, you might ask, “What makes this step difficult to complete?” or “Is there something that could make this easier for you?” This kind of questioning helps you understand the challenges from the worker’s perspective and can lead to practical solutions.
Another powerful questioning technique is asking “why” repeatedly. This is known as the "5 Whys" method. By asking “why” multiple times, you can dig deeper into the root cause of a problem. For example, if a machine keeps breaking down, you might ask:
“Why did the machine break down?”
“Why wasn’t it fixed sooner?”
“Why wasn’t the maintenance done?”
Each “why” brings you closer to the core issue, which can help you find a lasting solution.
4. Documentation
The fourth key element is documentation. As you observe, engage, and ask questions during your Gemba Walk, it’s important to document everything. This includes taking photos with notes, recording observations, and making sure you can share them with the right people.
Documentation serves several purposes. First, it helps you remember what you saw and heard. It’s easy to forget details after the walk is over, but having notes and pictures helps you recall everything accurately.
Second, documentation provides evidence that you can use to support your observations and suggestions. If you’re recommending changes, having documented proof of what you saw can be very persuasive.
5. Action
The final and perhaps most important element of a Gemba Walk is action. Observing, engaging, questioning, and documenting are all valuable, but they won’t make a difference unless you take action based on what you’ve learned.
After the Gemba Walk, review your notes and identify the key issues that need to be addressed. Prioritize these issues based on their impact on safety, quality, and efficiency.
Then, work with your team to develop an action plan to address these issues. This might involve changing a process, providing additional training, or repairing equipment.
Gemba Walks can be a tool for making real improvements. When workers see that their feedback leads to positive changes, they’ll be more engaged and motivated to participate in future walks.
Gemba Walk vs. Six Sigma: how they work together
In factories and companies, you might have heard of two important things: Gemba Walks and Six Sigma. They might seem different, but when used together, they can really help improve how work is done. Let’s talk about how these two tools can work side by side.
Understanding Six Sigma
First, let’s explain what Six Sigma is. Six Sigma is a method used to make work better by reducing mistakes and making things more consistent. The goal is to get as close to perfect as possible, where there are almost no mistakes—only about 3.4 errors out of a million chances. This might sound complicated, but it really just means making sure things are done the same way every time to get the best results.
Six Sigma follows a process called DMAIC, which stands for Define, Measure, Analyze, Improve, and Control. This process helps you figure out what the problem is, see how big it is, understand why it’s happening, fix it, and then make sure it doesn’t happen again.
Is a Gemba Walk Part of Six Sigma?
You might wonder if a Gemba Walk is a part of Six Sigma. The truth is, while a Gemba Walk isn’t officially part of Six Sigma, it can be used with Six Sigma to make things even better.
Here’s how they fit together:
Observation and Measurement: During a Gemba Walk, you watch how work is done on the floor. This helps you see and measure what’s really happening, which is the first step in Six Sigma. By being on the floor, you can spot where mistakes might be happening.
Finding the Cause: Six Sigma helps you figure out why problems happen. During a Gemba Walk, you can talk to workers and ask questions to learn more about why certain things are going wrong. This can help you understand the real reasons behind the problems.
Improvement Ideas: Gemba Walks are not just about finding what’s wrong; they’re also about spotting ways to make things better. These ideas can be tested and put into action as part of the “Improve” step in Six Sigma.
Keeping Things Better: After fixing a problem, Six Sigma focuses on keeping the process working well. Regular Gemba Walks can help make sure the improvements stay in place and the process doesn’t slip back into old habits.
The Golden Rule of Gemba: Respect for People
One of the most important things about a Gemba Walk is respecting the people who do the work. This is also key in Six Sigma. When you go on a Gemba Walk, it’s not about finding people’s mistakes or blaming them. It’s about understanding their work and helping them do it better.
Respecting workers is important in Six Sigma too. Six Sigma often involves teams from different parts of the company, and everyone’s ideas are important. By including workers in solving problems, both Gemba Walks and Six Sigma help build a team spirit where everyone works together to keep getting better.
Using Gemba Walks to Make Six Sigma Projects Better
If your factory already uses Six Sigma, adding Gemba Walks can make these projects work even better. Here’s how:
Getting Real-World Info: Gemba Walks give you real-time information that you can use in the first steps of Six Sigma. This info is often more accurate because it’s based on what you see right there on the floor.
Building Team Support: When workers see that their ideas during a Gemba Walk lead to real changes, they are more likely to support Six Sigma projects. This support is very important for making sure these projects succeed.
Finding Quick Fixes: Gemba Walks can help you spot small improvements that can be made right away. These quick fixes can boost team morale and help build energy for bigger Six Sigma projects.
Keeping Improvements Going: Regular Gemba Walks after a Six Sigma project is finished can help keep the improvements in place. They ensure that new ways of doing things are followed and that any new problems are quickly dealt with.
Gemba Walks and Six Sigma are different tools, but they both aim to make work better and smoother. Gemba Walks bring a human touch to Six Sigma projects by letting you see and understand the work as it happens.
Gemba Walks vs Kaizen and 5S
It’s also important to understand how Gemba Walks fit in with other popular methods used in factories, like 5S and Kaizen. Each of these methods has its own strengths, but they work best when used together to create a well-organized, efficient, and safe workplace.
What is 5S?
5S is a system used to organize and maintain a clean and efficient workplace. It comes from Japan, just like Gemba Walks, and it’s all about making sure that everything in the workplace is in its right place. The name 5S comes from five Japanese words that all start with “S”:
Seiri (Sort): Get rid of things you don’t need. Keep only what is necessary for the job.
Seiton (Set in order): Arrange everything in a way that makes it easy to find and use.
Seiso (Shine): Clean the workplace regularly to keep it neat and tidy.
Seiketsu (Standardize): Create standards and rules to maintain the first three S’s.
Shitsuke (Sustain): Make it a habit to follow these steps and keep the workplace in order.
5S is often the first step in making a workplace more efficient and safe. By getting rid of clutter, organizing tools, and keeping the workspace clean, workers can do their jobs faster and with fewer mistakes.
What is Kaizen?
Kaizen is another Japanese concept that means “continuous improvement.” The idea behind Kaizen is that small, ongoing changes can add up to big improvements over time. In a workplace, Kaizen encourages everyone—from managers to workers on the floor—to look for ways to make processes better, safer, and more efficient.
Kaizen isn’t about making one big change all at once. Instead, it’s about making lots of small changes that gradually lead to better results. This might include finding ways to reduce waste, improve safety, or make a job easier to do. The goal is to create a culture where everyone is always looking for ways to improve.
How Gemba Walks, 5S, and Kaizen Work Together
While Gemba Walks, 5S, and Kaizen are different tools, they all work towards the same goal: improving the workplace. Here’s how they can work together:
Gemba Walks and 5S: During a Gemba Walk, you can check to see if the 5S principles are being followed. For example, you might notice that tools are not organized properly (a Seiton issue) or that an area is not being cleaned regularly (a Seiso issue). By spotting these problems during a Gemba Walk, you can take steps to fix them and make sure that 5S is being practiced consistently.
Gemba Walks and Kaizen: Gemba Walks are a great way to find opportunities for Kaizen. As you observe work on the floor, you might spot small problems that could be improved. These could be things like a worker having to reach too far to grab a tool or a machine that takes too long to start up. By identifying these issues, you can encourage the team to make small changes that improve the process bit by bit, in line with the Kaizen philosophy.
5S and Kaizen: 5S and Kaizen often go hand in hand. Once a workplace is organized using 5S, it becomes easier to spot areas where improvements can be made. A clean and organized workspace allows workers to see inefficiencies more clearly and think of ways to improve them. This sets the stage for Kaizen, where continuous improvement becomes part of the daily routine.
Is Gemba a Part of Kaizen?
You might wonder if Gemba Walks are considered part of Kaizen. The answer is yes! Gemba Walks are actually a key part of the Kaizen process. By regularly walking through the workplace, observing, and talking to workers, you’re practicing Kaizen. You’re continuously looking for ways to improve, which is what Kaizen is all about.
What is the Difference Between 5S and a Gemba Walk?
While 5S and Gemba Walks both aim to improve the workplace, they do it in different ways.
5S focuses on organizing and maintaining the physical workspace—making sure everything is in its place, clean, and ready to use. On the other hand, a Gemba Walk focuses on understanding the work itself—how tasks are done, where there might be problems, and how things can be improved.
Think of 5S as setting up the stage for work to happen smoothly, and a Gemba Walk as watching the play to see how well everything is working together. Both are important, and when used together, they create a powerful system for continuous improvement.
Taking a Gemba Walk: step by step guide
Here’s a simple guide to doing a successful Gemba Walk.
Step 1: Get Ready for the Walk
Before you start your Gemba Walk, it’s important to get ready. Think about what you want to learn and which areas you want to focus on. Do you want to make things safer? Are you interested in seeing how a specific process works? Having a clear goal will help you stay focused during the walk.
Make sure to let the team know that you’ll be doing a Gemba Walk. This isn’t to make them nervous but to make sure they know what’s happening and can help you understand their work better. Also, gather any tools you might need, like Inspectle.
Step 2: Watch and Talk
When you start the Gemba Walk, the first thing to do is watch. Walk through the area you picked, and pay attention to everything you see. Watch how the work is being done, how workers use the equipment, and how they follow the steps. Notice both the good and the bad.
As you watch, it’s also important to talk to the workers. Ask simple, open-ended questions like, “Can you show me how this works?” or “What’s the hardest part of this job?” The goal is to learn from the people who know the job best. Their ideas and experiences can show you things you might not notice just by watching.
Remember to approach workers with respect and curiosity. You’re not there to criticize them but to understand their work and find ways to help them do it better. When workers see that you really care about their input, they’re more likely to share valuable information with you.
Step 3: Write Down and Think About What You See
As you watch and talk, it’s important to write down what you see and hear. Take detailed notes, and if possible, use a checklist to make sure you’re covering all the important points. You might also take photos or videos to capture specific details that need attention.
After the walk, take some time to look over your notes. Think about what you saw and heard, and look for any patterns or common issues that need to be fixed. This step is very important because it helps you figure out which areas need attention first. For example, if several workers have trouble with the same piece of equipment, that’s a clear sign that something needs to be done.
Step 4: Take Action and Tell the Team
The most important part of a Gemba Walk is what happens after it’s over. Once you’ve identified the problems and ways to make things better, it’s time to take action. Work with your team to come up with a plan to fix the problems you found. This could involve fixing equipment, changing how a job is done, or giving more training.
After you make the plan, it’s very important to tell the workers what’s going to happen. Let them know what changes will be made and how these changes will help them do their jobs better or safer. This shows that you value their ideas and helps build trust. It also encourages them to share more ideas in the future.
Step 5: Check Back Later
A Gemba Walk doesn’t end when you finish walking or make changes. It’s important to check back later to see if the improvements are working the way you hoped. This might mean doing another Gemba Walk in the same area to see if the changes are helping.
If you find that the changes aren’t working as expected, don’t be discouraged. Making things better is a process that takes time, and it’s normal to make adjustments as you go. Use what you learn from checking back to make more improvements.
Doing a Gemba Walk with Inspectle is a great way to understand how work is done and find real ways to make it better. You can do a free trial to see how easy and enjoyable it is.
About the Author: Robert Jakobson
Robert Jakobson has worked in the manufacturing industry since 2010. With over a decade of experience in B2B marketing, he specializes in helping companies improve their operations with software and hardware solutions. His deep knowledge of the industry and passion for technology make him a trusted expert. Robert’s experience ranges from product development to marketing, giving him valuable insights into how businesses can use tools like the Inspectle Food Safety Inspection software to stay compliant and improve their processes.