Shut up and go to GEMBA!
What is 3G?
3 G means that “In case of an abnormality, all the concerned members should actually go to the place where the problem has occurred, see the actual thing and take realistic action to solve the problem”.
In Japanese language this point is compiled in 3 words:
Genchi – ACTUAL PLACE
Genbutsu – ACTUAL THING
Genjitsu – ACTUALLY
The best approach is to go to the shop floor many times during the day to understand the problem rather than depending on feedback which may not be correct all the times.
For the most part, western management is aware that sustained continuous improvement must involve every employee and that top management must demonstrate their support for such programs, but the true value of the Gemba is often missed.
The Golden Rules of Gemba Management are:
Go to Gemba – when abnormality occurs
Check Gembutsu – Machine, Materials, Failures, Rejects, etc
Search for – Muda (waste), Mura (variation/inconsistency), Muri (strain/ burden on people & machines)
Speak with data – Take temporary countermeasures on the spot
Make Kaizen – Remove root causes
Standardize – Standardize to prevent recurrence
Another paradigm shift for western management that Imai San emphasizes is that Kaizen projects must improve Quality, Cost, and Delivery simultaneously.
QCD activities therefore must bridge such functions as research and development, engineering, production, sales, and after-sales service. Management activities in achieving QCD goals can be categorized as either maintaining or improving current standards. Maintenance activities are required when rejects from internal customers or returns from dissatisfied external customers occur. Either situation can usually be traced to issues arising in the Gemba. Here, managers must be concerned with determining the root cause and should implement the Standardize-Do-Check-Act derivation of Deming’s cycle. When seeking to improve the current standards, the Plan-Do-Check-Act cycle is used. Both adaptations along with relevant case studies are fully explained by Imai San.
Gemba is the real place where you can meet real people, identify real problem & offer real solutions.
Going to the gemba has become popular for the simple reason that it is powerfully effective. In today’s marketplace, every business is looking for ways to stay competitive. Imai Sans GEMBA KAIZEN book appeals to all levels of any organization implementing lean strategies to achieve performance results. Imai San has successfully brought it out of the training room and back to its roots in the Gemba.