1. GEMBA WALK STAGE

Gemba Walk Strategy and Setup

2. BRIEF DESCRIPTION

PDCA is a four-step process (Plan-Do-Check-Act) repeated over time to ensure continuous improvements and learning. It teaches organizations how to Plan an action, how to execute or Do it, how to Check the way it adapts or impacts the process and targets, and, lastly, how to Act on what has been learned.

3. HOW TO USE THE PDCA CYCLE IN THE GEMBA WALK

The PDCA Cycle is used to systematically encourage a continuous improvement mindset at all process stages. In the strategy and setup stage of the Gemba Walk, the employees are trained in the PDCA cycle and empowered to adopt the mindset to identify and solve problems. During the Gemba Walk, the leader visits the process or department where the problem occurs, as part of the Plan stage of the PDCA cycle. The team plans the improvement activities needed to address the problem, create the improvement plan, assign responsibilities and metrics. In the Do stage, the responsible team members complete the agreed improvement activities. Once the improvements are implemented, all team members, including the leader, Check the improvements and validate them against the defined metrics. If the check stage indicates that the implemented improvements were successful, then, in the Act stage, the team decides on mitigation actions to prevent the re-occurrence of the same problem or standardize the new way of working through Standard Operating Procedures (SOPs). If the implemented improvements were not successful, the team initiates a new PDCA cycle.

4. ROLES AND ACTIVITIES

1. Leader: Facilitates teamwork, encourages the PDCA practice, facilitates problem-solving through questions, ensuring the right people are empowered and made responsible for the improvement actions
2. Facilitator: Provides PDCA training, supports teamwork, coaches the leader, supports the team with the right tools, and initiates any needed Kaizen event
3. Team member: Highlights the challenges, helps to identify the root cause of the problems, brainstorms and proposes possible solutions, implements solution(s), monitors and reports the effectiveness of the solution(s)

5. EXPECTED BENEFITS FOR THE GEMBA WALK

• Represents the foundation of the Continuous Improvement process
• Empowers employees to systematically and continuously improve the process and solve problems
• Provides a structured approach for leaders to guide initiatives
• Encourages knowledge-driven decision-making
• Reduces process and knowledge waste
• Creates better team alignment

6. ORGANIZATIONS THAT APPLY PDCA CYCLES

Airbus Defence and Space, Barry Callebaut, Bocar Group, CEMEX, IMC, Interface, Rolls-Royce Motor Cars, Swisscom and Thermo Fisher Scientific