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Gemba Kaizen


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Kaizen means continuous improvement. Theword implies improvement that involves

everyoneboth managers and workersandentails relatively little expense.

Gemba is a Japanese word meaning 'real place,'where the real action takes place. In business,Gemba is the shopfloor or production place

where the value-adding activities to satisfy thecustomer are carried out.

Gemba Kaizen


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5- gemba principles


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5-gemba principles

1. When a trouble (abnormality)happens, go to gembafirst.


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2. Check with gembutsu :Machine, tools,rejects

Gembutsuanother Japanese, means sometangible things on which you can put yourhands. If a machine is down, the machine

itself is gembutsu. If a customer iscomplaining, the customer is gembutsu.


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3. Take countermeasures on the spot.

For instance, if the machine is down, you haveto get it started because the show must go on.Sometimes you kick the machine to get it

started.If a customer is angry, you will need toapologize, or even give some gift to appease.But these are only temporary measures and donot address the real issue, which leads to the

next point.


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4. Find out the root cause.

By repeating the question why severaltimes, you can find out the root cause of theproblem.


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5. Standardize for prevention ofrecurrence.

Once you identify the root cause, and comeup with a countermeasure, you should

standardize such a countermeasure so thatthe same problem will not recur.


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Gemba KAIZEN - Low cost approach

Gemba KAIZEN

There are two approaches to problems solving. The firstinvolves innovation applying the latest high-cost technology,

such as state-of-the art computers and other tools, andinvesting a great deal of money. The second uses commonsensetools, checklists, and techniques that do not cost much money.This approach is called kaizen. This article will show how kaizencan achieve significant improvement as an essential building

block that prepares the company for truly rewardingaccomplishments.


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Three ground rules for practicingKaizen in gemba:

3 ground rules for practicing Kaizen in Gembaare: -

1. Housekeeping,

2. Mudaelimination.3. Standardization.


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1. Housekeeping

Housekeeping is an indispensable ingredient ofgood management. Through goodhousekeeping, employees acquire and practiceself-discipline. Employees without self-disciplines make it difficult to provide productsor services of good quality to the customer.


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2. Muda elimination

In Japanese, the word mudameans waste.

Any activity that does not add value ismuda.

People in gembaeither add value or do not addvalue. This is also true for other resources, suchas machines and materials.

Mudaelimination can be the most cost-effectiveway of improving productivity and reducingoperating costs.


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Types of waste

Waste of over production This is regarded as the worst type of

waste. If you produce more than your customer needs, you have extrapieces that need to be taken care of, such as handling and keeping instock.

Waste of inventory This is the result of over production. If you

process only Produces what the next process needs, you can eliminatemuda of inventory altogether.

Waste of waiting How often do you see operators just waiting forthe material to arrive or the machine to start? No value is added whenoperators are waiting and looking.

Waste of motion When the operator is moving around, looking fortools or going to get the work pieces, no value is added.


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Types of Waste

Wasteof transportation When materials are moving on thetrucks, forklifts, or on the conveyer, no value is added.

Waste of producing rejects Producing rejects leads torework, or else rejects must be thrown away, a big muda.

Waste of processing By rearranging the working sequence,often you can eliminate a particular process.


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