Production reports show the numbers. The Gemba Walk reveals reality. This is one of the fundamental lean management practices, which involves managers going down to the shop floor and observing the process where it actually happens, instead of analyzing data from the office. It's a simple idea, but in practice, it requires discipline and skills that aren't acquired overnight.
No manager can see everything. An operator who spends eight hours a day on the same machine sees things that aren't visible from the office: minor hiccups, recurring problems, areas where something could work better. A plant that can gather and utilize this knowledge improves faster than one that relies solely on management's ideas.
Effective and thoughtful design of marking, transport and logistics is the key to creating a safe, effective and profitable work space. By improving the organization of processes and ensuring adequate marking, the company can achieve greater performance, reduce costs and increase the margin.
