What Is Gemba Kaizen?

Many manufacturing plants have turned to lean manufacturing concepts in order to reduce errors and defects that are arising within the company. As you turn to lean manufacturing to aid in reducing errors and controlling waste you have to study the different lean concepts that are available for you to use.

Kaizen events can help you indentifying errors and finding a way to create a stronger company overall. You need to take a look at how Kaizen events are used to give you reduced defect ratios. It is also important that you look into a newer program known as Gemba Kaizen. What is Gemba Kaizen exactly and how does it give you the right type of results you need with lean manufacturing? Let's define it into a series of steps to make it easier.

Identify the Problem
Once you notice a problem arise you need to use Gemba Kaizen to give you an idea of what to do. It is a smart idea to consider using Gemba as soon as you can in order to identify the problems that have come up so you can get on top of the issue before it gets worse. The goal is to use Gemba to solve problems instead of just worrying about that you have a problem. Solving problems means you need to identify the root cause of the problem and to gain clarity as to what you need to do in order to increase productivity.

Checking With Machines
You have to focus on using the machines properly in order to create the right type of output for the organization. The machines have a large impact on Kaizen events. The machines can have slow productivity or they can be responsible for the defects. You have to always use events that will check on the events for the company to give you the right type of outputs. Kaizen events are going to show you not only machinery issues but also some issues related to your customers complaints to help you figure out what you need to do to create a better company overall.

Quick Fix
With Gemba Kaizen you will need to take immediate action when you have issues that come up. Gemba helps with a long term approach but it really helps to solve the immediate issues at hand. You have things that can help quickly like using checklists of having immediate results given to you by using a daily reporting schedule. How can you identify the issues at hand? Using data collection is a great way to help you out but you can also find out more when you take the time to ask your staff members. Your employees can have a large impact as they will give you the right type of information to learn and work with so you can make the right type of changes to improve the company.

Dummy Applications
As you become proficient with Gemba Kaizen you will be able to quickly see the problems that are happening and you can find ways to fix them right away. You need to work on problem identification in order to give your organization a fighting chance at success. A lot of companies will create dummy applications as they can help in creating different scenarios and routes for you to use.

Standardized Procedures
Now you want to work on creating solutions for the company that are going to come in the form of standardized procedures. You have to provide proper training to your staff so they know what needs to be done and how to have confidence in their abilities to do their jobs.