What Is A Gemba Walk? Gemba Walk Examples

Learn about Gemba Walks, see some examples, and learn how popular companies like Amazon are using them for continuous improvement.

Gemba Walks: An Overview

"Gemba" is a Japanese word that means "Go see, ask why, show respect."

As part of lean and Six Sigma practices, Gemba Walks refer to walking through your business and observing tasks being performed and asking employees how the company operates and how processes are completed. As part of the exercise, managers record the information gathered on these walks and create action plans for improvement. During walks they identify problems.

Video: What is a Gemba Walk?

Who Uses Gemba Walk Checklists?

Businesses whose leaders regularly do these walks find they lead to continuous improvement and aid in lean manufacturing. These walks hold benefits for just about all other industries as well. These walks are a powerful tool for understanding how your company actually operates, so you can make improvements towards how it’s supposed to operate.

An Example: Amazon Gemba Walks

Many top executives in many industries see successful Gemba Walks as a key component of their improvement processes. Amazon CEO Jeff Bezos has managers work for a while in customer service. 

Industry giant Amazon includes walks as a key part of their ongoing safety efforts. The Amazon website discusses the Japanese term and how they use walks as part of their safety culture:

What are best practices for effective Gemba Walks?

Not all Gemba Walks are created equal, though. They need to be performed in the right way. The blog post, “Gemba Walk: Where the Real Work Happens,” recommends that you first prepare your team for them, so they know exactly what will be done, and the benefits of doing them.

A Gemba Walk isn’t the time for evaluating the performance of team members, the post says. It’s not the time to critique people. It’s a time to focus on business processes, not individuals.

The post also recommends that you “be where the value stream is.” It says: “Following the value chain will give you the best opportunities to identify areas with a high potential for waste activities.”

“Record your observations. Don’t make suggestions during the walk.” That’s key because you need to examine what you find before you find solutions to problems," the post says.

“Leave the analysis for later. You will be much more precise after you have all the facts available.”

How often should you conduct Gemba Walks?

Companies should do Gemba Walks regularly, so current processes can be observed regularly and continually improved. Companies that rely on this management technique on their shop floors or factory floors reduce waste, increase production line up-time, improve safety records, and realize cost savings.

The article stresses that you should always do a follow up after a Gemba Walk. “Even if you don’t find anything significant during your Gemba walk, you need to share with the team what you have learned or seen,” it recommends. “Otherwise, the team will only have the feeling of being watched. If you are going to take action after the walk, inform the team about the upcoming changes and why they are necessary.”

What are common mistakes to avoid during Gemba Walks?

Avoiding common mistakes during Gemba Walks is essential to maximize their effectiveness and foster trust and improvement. Here are some pitfalls to watch out for:

1. Turning Gemba Walks into Audits: One of the most significant mistakes is approaching Gemba Walks with a mindset of checking compliance or catching mistakes. This undermines trust and makes employees defensive. Instead, focus on observing and understanding the process, not judging or policing.

2. Insufficient Preparation: Walking into a Gemba Walk without prior preparation can lead to vague observations and missed opportunities. It's important to understand the process being reviewed and have clear objectives to make the most of the visit.

3. Lack of Active Listening: Failing to engage with employees or only superficially listening to their feedback reduces the value of the walk. Leaders should ask questions and actively listen to workers’ insights, as these often uncover root causes of inefficiencies or issues.

4. Overwhelming the Team with Immediate Changes: Implementing too many changes at once based on observations can disrupt workflow and create resistance. Prioritize findings and take a phased approach to implementing changes, ensuring that employees can adapt smoothly.

5. Focusing Solely on Problems: If the Gemba Walk only highlights issues, it can demotivate employees. Leaders should also acknowledge and reinforce positive aspects of the process to balance constructive feedback with recognition of what’s working well.

6. Not Documenting or Following Up: Failing to document observations or neglecting to follow up on identified issues makes the effort ineffective. Documentation helps track trends and ensures that findings translate into actionable improvements. Following up demonstrates commitment and reinforces a culture of continuous improvement.

7. Disrupting Workflows: Interrupting employees or creating disruptions during the walk can reduce productivity and lead to frustration. It’s crucial to observe in a way that minimally impacts the workflow and to ask questions at appropriate times.

8. Neglecting Cross-Functional Insights: Gemba Walks that only involve leaders from a single department can miss cross-functional opportunities. Including diverse perspectives helps identify interdepartmental issues and creates more comprehensive solutions.

Avoiding these common mistakes helps ensure that Gemba Walks are constructive, foster trust and collaboration, and lead to sustainable improvements.

How can remote teams conduct Gemba Walks effectively?

Remote teams can conduct virtual Gemba Walks effectively using technology and mobile apps. While physical presence on the floor is ideal, virtual Gemba Walks can still yield valuable insights and foster continuous improvement when conducted thoughtfully. Here’s how remote teams can do it:

1. Leverage Mobile Apps and Collaboration Tools

Mobile apps and digital tools play a crucial role in facilitating virtual Gemba Walks. Tools like video conferencing software (e.g., Zoom, Microsoft Teams) and mobile apps designed for real-time data collection and reporting (e.g., Tulip, iAuditor) enable remote teams to observe processes, gather feedback, and document insights as they would in person. Apps with real-time video streaming capabilities can allow leaders to “walk” the production floor virtually.

2. Use Video and Live Streams

Remote team members can join a live video stream of the the walk. On-site employees equipped with mobile devices or cameras can guide remote leaders through the processes, capturing footage and facilitating real-time discussions. This setup allows leaders to observe operations, ask questions, and provide feedback as if they were physically present.

3. Prepare with Clear Objectives

To make virtual Gemba Walks effective, teams should set clear objectives beforehand, just as they would for an in-person walk. Knowing what to focus on (e.g., efficiency, safety, workflow) ensures that the virtual walkthrough is productive and meaningful.

4. Ensure Quality Communication

Communication is key to a successful virtual Gemba Walk. The team conducting the walk should establish clear protocols for interaction, including how questions will be asked and how feedback will be managed. Clear audio and high-resolution video are essential for observing details accurately.

5. Utilize Collaborative Digital Platforms

Platforms that integrate features for note-taking, task assignment, and data analysis (e.g., Trello, Asana, Miro) can enhance the documentation process during a virtual Gemba Walk. These platforms make it easier for remote teams to collaborate, share insights, and track action items derived from the walk.

6. Record the Walk for Future Analysis

Recording the Gemba Walk allows teams to review observations, analyze processes in greater depth, and identify details that may have been missed in real time. It also provides a reference point for training purposes or to include stakeholders who couldn’t join the live session.

7. Engage On-Site Employees

Remote leaders should actively engage on-site employees during the virtual walk with open-ended questions. This includes asking questions and soliciting feedback to get a firsthand perspective on challenges and opportunities. Employees should feel involved in the process, reinforcing the collaborative spirit of Gemba Walks.

8. Follow Up with Action Plans

As with physical walks, virtual walks should culminate in an actionable follow-up plan. Document findings and ensure that feedback and insights are used to make tangible improvements. Mobile apps that allow task tracking can be utilized to monitor progress and maintain accountability.

Remote walks can be effectively conducted with the right approach and digital tools. Mobile apps and collaboration software provide the means for real-time observation, data collection, and team collaboration. While remote Gemba Walks require careful planning and clear communication, they can still offer significant value for continuous improvement in remote or hybrid work environments.

What digital tools or apps are best for documenting and analyzing Gemba Walk findings?

In order to get the most out of effort, you need to make sure you can capture your observations accurately and clearly. Paper lists are helpful, but they cannot be quickly and easily shared, and sometimes not all information is captured accurately. The best way to do that is with a mobile app that the manager can use right on his or her smartphone or tablet. That way, as you do the walk, you can record all your observations. Digital tools and apps can significantly enhance the documentation, analysis, and follow-up process. 

Choosing the Right Tool

When selecting a tool, consider your specific needs: ease of use, integration with existing systems, data visualization capabilities, and team collaboration features. The right tool can transform the process of documentation and analysis from manual and time-consuming to seamless and insightful, supporting a culture of continuous improvement. Here are some of the best tools available for streamlining Gemba Walks:

1. Alpha TransForm Gemba Walk App

• Features: Allows real-time data collection with support for photos, notes, audio recordings, and GPS data. Customizable forms make it adaptable for various industries.
• Benefits: Works offline with automatic synchronization, optimized for smartphones and tablets, and supports rich media (image annotation, audio recordings, voice-to-text). Offers digital signature capture for verification.
• Best For: Organizations looking for a comprehensive and customizable mobile app that streamlines data capture and analysis during Gemba Walks, even in areas without internet connectivity.

2. iAuditor by SafetyCulture

• Features: iAuditor is a popular app for conducting inspections, audits, and Gemba Walks. It allows users to create customizable checklists, capture photos, and take notes directly within the app.
• Benefits: It facilitates real-time data collection, offers offline functionality, and integrates with analytics dashboards for trend analysis.
• Best For: Teams looking for an all-in-one solution to document, track, and analyze findings across different locations.

3. Tulip

• Features: Tulip is a no-code platform that helps teams digitize processes and gain real-time insights. It enables the creation of interactive apps for documenting observations and collecting data during walks.
• Benefits: Offers robust customization, integrates with existing enterprise systems, and supports real-time data visualization and process tracking.
• Best For: Manufacturing and production environments that require comprehensive, customizable solutions.

3. Trello

• Features: Trello is a visual project management tool that can be adapted for Gemba Walk documentation. Users can create boards, lists, and cards to document findings, assign tasks, and track progress.
• Benefits: Simple and user-friendly interface, easy collaboration, and the ability to attach photos and documents to cards.
• Best For: Teams that prefer a straightforward, flexible tool for organizing observations and follow-up actions.

4. Microsoft OneNote

• Features: OneNote is a note-taking app that allows users to capture text, images, and voice notes. It is highly flexible for documenting findings during walks.
• Benefits: Integrates with other Microsoft products, supports collaborative note-taking, and provides easy access across devices.
• Best For: Teams already using Microsoft 365 and looking for an integrated solution for documentation.

5. Google Workspace (Docs and Sheets)

• Features: Google Docs and Sheets offer a straightforward way to document findings and collaborate in real-time.
• Benefits: Free to use with a Google account, allows multiple users to edit and comment simultaneously, and supports integration with other Google tools for streamlined reporting.
• Best For: Smaller teams looking for cost-effective, easy-to-use solutions for collaborative documentation.

6. EASE Audits

• Features: EASE is designed for conducting audits and Gemba Walks with customizable Gemba Walk checklists, photo capture, and real-time reporting features.
• Benefits: Provides detailed analytics, easy-to-use mobile interface, and integration with larger quality management systems.
• Best For: Organizations that require a focused tool for auditing and quality control.

7. Miro

• Features: Miro is an online collaborative whiteboard platform that can be used to map out findings, create process flowcharts, and visually organize observations during a Gemba Walk.
• Benefits: Engages teams in real-time collaboration, supports adding sticky notes, images, and diagrams, and offers integration with other productivity tools.
• Best For: Teams that prioritize visual collaboration and mapping out complex processes during walks.

8. Lucidchart

• Features: Lucidchart is a visual workspace that helps teams document processes through flowcharts and diagrams.
• Benefits: Intuitive drag-and-drop interface, easy sharing, and integration with popular apps like Slack and Microsoft Teams.
• Best For: Documenting process flows and visualizing data captured during a walk.

A Free App to Improve Your Walks

The  Alpha TransForm Gemba Walk App solution accelerates your continuous improvement process with real-time data collection, rich media, easy customization, and more. It speeds observations collected during a walk, including manager notes, photos, measurements, and more.

Here are just some examples of its features:

• Optimized interface for tablets and smartphones
• Audio recording and voice-to-text for notes capture
• Image capture with annotation
• Offline data capture of data in remote locations, such as warehouses without an Internet connection or cell signal
• Signature capture
• Easy to customize - add your own interview questions and measurements to match your Gemba process.

You can get the app for free from Alpha Software. Also view other manufacturing solutions from Alpha Software.

Watch: An overview of the app: