Gemba Walk: The key to continuous improvement in the field

In an industrial sector where every second counts, the Gemba Walk method has become a pillar of continuous improvement. The Gemba Walk is a hands-on approach, carried out by managers, executives or any member of the operational team, which consists in going directly to the workplace to observe a process, identify a problem, and launch a concrete action.

The objective? Create value, strengthen operations management and engage employees, while connecting production to a Lean approach. This simple but effective approach often reveals unsuspected levers of performance.

Understanding the Gemba Walk

Definition and meaning of the word ‘Gemba

The term Gemba comes from the Japanese 現場, literally meaning “the real place”, i.e. the place where work actually takes place. In the context of industrial organization, it refers to the production floor, where value is created. Gemba Walk involves going there to observe processes, understand the reality of operations, identify problems, and initiate continuous improvement in direct relation to the facts.

📌 Did you know?
In Japanese, Gemba It means ‘the real place.’ This is where the most reliable data can be found to improve your performance

Origins of the practice in Lean management

The Gemba Walk is part of the Lean management legacy, formalized within Toyota in the 1950s. Taiichi Ohno, one of the founding fathers of the Toyota Production System, conceptualized this method as a tool to stay connected to real work. The connection with Kaizen (continuous improvement) is strong: the Gemba Walk helps identify, directly on-site, simple actions with high impact on quality and operational performance.

Differences with Kaizen, MBWA and Six Sigma

🧠 Myth vs. reality
The Gemba Walk is not a symbolic tour. It is a structured Lean tool designed to observe methodically and take concrete action.

Why integrate Gemba Walk into your manufacturing process?

Gemba Walk objectives

The Gemba Walk has several strategic objectives for the company :

• Aligning managers and teams with reality in the field
• Identifier les déviations de processus en temps réel
• Create a culture of continuous improvement rooted in everyday life
• Encourage information useful for decision-making
• Enhancing quality through direct observation

These objectives serve to develop effective operations, while actively involving employees in the transformation.

Concrete performance benefits

A well-executed Gemba Walk brings tangible benefits:

• Rapid detection of waste (time, movements, defects)
• Bridging the gap between theory and operational reality
• Improved collaboration between support functions and production
• Greater visibility on the value chain and action levers
• Enhanced reactivity to malfunctions

📌 Key benefit
Simple active observation can reveal opportunities for performance gains without major investment.

Team commitment and leadership in the field

By going to the workplace, the leader or manager demonstrates the importance of the shop floor in decision-making. It sends a strong signal of respect, attentiveness, and consistency. The Gemba Walk then becomes a powerful management tool to engage teams, value operational knowledge, and improve internal communication.

💡 Expert advice
Don’t come with solutions in mind. Observe without judging, ask open-ended questions, and listen attentively. Therein lies the power of the Gemba.

Preparing your Gemba Walk

Choosing the right participants

• Operational manager (to drive the process)
• Field operators (true process experts)
• Quality manager (to identify discrepancies)
• Maintenance technician (to diagnose technical causes)
• Support functions representative (if required)

These players form a functional teamcapable of informing the process and act effectively.

Define visit objectives

Use the SMART :

➤ A good lens framing ensures that the Gemba Walk will not remain a mere actionless visit.

⚠️ Frequent error :
Doing a Gemba without a clear objective is a waste of time and creates frustration.

Organize the tour (time, place, tools)

Preparation checklist :

1. Choose slot (shift, fixed time)
2. Define the field route
3. Prepare tools :

• Checklists (paper or digital)
• Tablet, camera, QR code
• Real-time TEEPTRAK indicators

📌 Checklist: downloadable in Excel format or integrated application, it reinforces the rigor of the approach.

Key stages in a successful Gemba Walk

Active observation and respect for the terrain

The heart of Gemba Walk lies in direct, discreet, attentive observation of real work. The idea is to watch flows, postures, tools and interactions without intervening. The observer positions himself as a learner, not a controller. It’s this respectful stance that helps to bring out the gaps and friction points in the process, often invisible from a distance.

⚠️ Point of vigilance :
Never interrupt an operator during a task. Wait for a break or structure the exchange after the observation phase.

Ask operators relevant questions

Dialogue is an integral part of Gemba Walk. Here are some open-ended questions to encourage understanding:

• What do you do at this stage?
• What difficulties do you regularly encounter?
• Do you have everything you need to work effectively?
• What slows down your work?
• How would you know if a problem occurs?
• What would you change if you could?
• What would you change if you could?

💡 Astuce pratique :
Notez vos questions à l’avance, mais laissez place à l’adaptation selon ce que vous observez sur le terrain.

Note-taking, photos, and points of attention

During the walk, it is essential to document what you see: anomalies, gaps, repetitive gestures, waiting areas, queues, etc.
Use :

• 📸 Photos to illustrate real-life situations
• 📝 Summary notes Facts, findings, questions to explore
• 📍 Visual symbols (colored dots, temporary markings) to mark field observations

This material will be used to feed post-walk analyses and facilitate collective feedback.

On-the-spot debriefing with the team

In the hours that follow, organize a structured exchange with participants. Typical structure :

This collective feedback avoids the loss of information and enhances contribution.

📌 Case study :
During a Gemba Walk at StellantisOur tools enabled us to identify the time wasted by double manual data entry. Result: automation of information feedback, and measurable gains in OEE within the first few weeks.

Analyzing and acting after a Gemba Walk

Exploiting the data collected

To turn observation into action, apply the cycle: observation → analysis → action. Analyze field data (cycle times, stoppages, non-conformities), identify trends, then plan corrective actions. This visual diagram reinforces the importance of a structured processlinking Gemba Walk to operational improvement operational improvement improvement.

Identify levers for improvement

Use a sorting table to classify your observations according to their potential impact:

• High value/low effort → priority
• High value / high effort → planned project
• Low value / low effort → fast action
• Low value/high effort → to be reconsidered

This approach (simplified MoSCoW) focuses actions on real gains for theteam, l’companyand the customer.

Implement and monitor an action plan

1. Formalize actions who does what, when, how
2. Assign a manager (employee or manager)
3. Define indicators (e.g. OEE rate)
4. Schedule interim updates (weekly/monthly)
5. Field reviews with the team to adjust
6. Capturing results with TEEPTRAK digital tools

📌 Checklist of actions to formalize : task, responsible, deadline, indicator, status – to be integrated into your digital tracking system.

Examples of Gemba Walk in an industrial context

Hidden waste revealed by observation

During Gemba Walks, our customers often identify invisible waste: unnecessary movements, poorly designed accesses, machine micro-stops. For example, one operator reduced his movements by 30% by reorganizing the space following a field observation.

Transformation of a workstation

A workshop rethought the ergonomics of a workstation in line with Lean principles, repositioning tools and creating a dedicated place for consumables. The result: a 15% reduction in cycle times and enhanced employee satisfaction thanks to a more fluid and efficient working environment.

Case studies with TEEPTRAK solutions

Case study: Nutriset, a long-standing TeepTrak customer, used digital Gemba Walks to detect machine microstops. Thanks to PerfTrak, they increased their OEE by 10 to 15 points, saving valuable time for their operational teams.

This example examplebased on real data, demonstrates the power of Gemba + digitization integration to drive performance performance.

Digitizing the Gemba Walk for greater impact

Digital checklist and follow-up tools

Digital tools help structure the Gemba Walk while facilitating the collection of field observations. The use of digital checklists, QR codes positioned on workstations or connected tablets provides direct access to operational data. Thanks to PerfTrak, our customers can visualize performance indicators (OEE, stoppages, anomalies) in real time during the walk, enabling faster decision-making based on observable facts.

How do we facilitate digital Gemba Walk for our customers?

Our tools are intuitive, standardized and compatible with all types of industrial equipment. Thanks to our Plug & Play solution, our customers can digitize their supervision routine in less than an hour. Data becomes actionable immediately, reinforcing the efficiency of Gemba Walk.

📊 Key figure Our customers are seeing increase of 10 to 15 TRS points and up to 29% productivity gains after deployment.

Benefits of digitalization

Digitization accelerates the impact of Gemba Walk, while ensuring better operational management.

Make Gemba Walk a pillar of your continuous improvement culture

Role of top management

When top management actively participates in Gemba Walks, it sends a strong signal to teams that the reality on the ground is taken seriously. The presence of senior management fosters a culture of transparency and enhances the value of the employees who live the processes on a daily basis.

📝 Please note A Gemba Walk without a managerial presence quickly becomes a mere formality. Legitimacy comes from the top.

Regular management routines

Establishing a regular ritual – weekly or monthly – helps to anchor the Gemba Walk in operational management practices. For example:

• Gemba Walk every Tuesday at 8 a.m.
• Scorecard shared after each tour
• Follow-up of actions on collaborative tool

These routines make continuous improvement visible, measurable and collectivereinforcing long-term commitment.

Connecting field, data and decisions

A good Gemba Walk connects field observations to strategic decisions. The data collected becomes transformation levers, translated into indicators, projects or trade-offs.
This link is visualized as a pyramid:

• Base : Operators → raw observations
• Middle : Managers → analysis and prioritization
• Summit : Management → decision and investment

This is how we transform a simple step into a powerful powerful, structuring management tool.

Use cases: for which sectors, which environments?

Production plants and workshops

Gemba Walk is particularly effective in production environments where processes are complex and interdependent. It enables bottlenecks, microstops and waste to be identified rapidly and in real time. Direct observation, combined with TRS data, is a powerful lever for improving performance.

Maintenance, quality, safety

Whether applied to preventive maintenance, quality control or safety audits, Gemba Walk enables you to anticipate risks and correct deviations before they become critical. It’s a proactive tool for strengthening risk management and operational reliability.

Tertiary environments and services

Even outside the factory, the Gemba Walk can be adapted to offices, service centers or supply chains. It helps to streamline exchanges, improve workflows and eliminate everyday irritants. Good observation in the field, even dematerialized, helps optimize the value delivered to the end customer.

Gemba Walk FAQ

Managing performance in the field

Gemba Walk as a lever for transformation

Adopting the Gemba Walk means choosing a simple, humane and powerful method for reconnecting strategy with operational reality. By observing processes where value is created, executives and managers trigger concrete dynamics of continuous improvement, reinforce the performance culture and accelerate decision-making based on facts.

The TEEPTRAK approach: making visible for better action

At TEEPTRAK, we believe that the field holds the key to industrial transformation. Our solutions enable us to pick up on weak signals, objectify observations, and act quickly where it matters most.

✅ Key benefit: Thanks to our digital tools, Gemba Walk becomes a real lever for analysis, commitment and performance management.

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