How do you apply Gemba and Genchi Genbutsu in your Lean Six Sigma projects?

1 What is Gemba?

Gemba is a Japanese word that means "the real place" or "the place where value is created". In Lean Six Sigma, Gemba refers to the location where your process operates, such as a factory floor, a customer service center, or a warehouse. By going to the Gemba, you can observe the actual flow of work, the interactions between people and machines, the sources of waste and variation, and the voice of the customer. Gemba helps you gain a deeper and more accurate understanding of your process and its performance.

2 How to do Gemba?

In order to do Gemba effectively, you should plan your visit, prepare questions, and respect the people who work there. To start, define the purpose and scope of your visit, and involve process owners and stakeholders. Ask open-ended questions to explore the process, and observe and listen more than you talk. Don’t forget to take notes, photos, or videos to document your findings. Additionally, thank the people who work at the Gemba for their time and cooperation, and share your observations while asking for their feedback and suggestions.

3 What is Genchi Genbutsu?

Genchi Genbutsu is another Japanese phrase that means "go and see for yourself" or "actual thing, actual situation". In Lean Six Sigma, Genchi Genbutsu means going to the source of the problem or opportunity and verifying the facts and data with your own eyes. By doing so, you can avoid relying on second-hand information or opinions that may be inaccurate, incomplete, or biased. Genchi Genbutsu helps you find the root causes of the problem and the best solutions for it.

4 How to do Genchi Genbutsu?

To do Genchi Genbutsu, you need to collect and analyze data, test your hypotheses, and validate your solutions. Begin by defining the problem or opportunity clearly and quantitatively. Then, use data collection sheets, histograms, Pareto charts, or control charts to organize and display the data. Analyze the data with fishbone diagrams, 5 whys, or cause and effect matrices to identify potential root causes. Test your hypotheses with design of experiments, hypothesis testing, or ANOVA to compare the results of different factors or levels. Finally, validate your solutions by measuring their impact and sustainability using run charts, SPC charts, or capability analysis to monitor performance after implementation.

5 Why are Gemba and Genchi Genbutsu important?

Gemba and Genchi Genbutsu are essential for applying the scientific method and PDCA cycle in Lean Six Sigma projects. They help to define a problem or opportunity based on facts and data, measure the current state of the process, analyze root causes, improve the process by testing solutions, and control the process by ensuring solutions are effective and sustainable. Ultimately, utilizing Gemba and Genchi Genbutsu can result in improved process quality, efficiency, and customer satisfaction.

6 How to integrate Gemba and Genchi Genbutsu in your project?

Gemba and Genchi Genbutsu are not two distinct activities, but rather integrated principles that guide your project through all its stages. During the Define phase, you can use Gemba to understand your customer's and process' needs, while Genchi Genbutsu can help you collect data on the problem or opportunity and define its scope and magnitude. In the Measure phase, Gemba can map the current process and identify its inputs, outputs, steps, and resources; Genchi Genbutsu can measure the key performance indicators and establish a baseline for improvement. During the Analyze phase, Gemba can observe the sources of waste and variation in the process, while Genchi Genbutsu can analyze the data and identify root causes. When it comes to the Improve phase, Gemba can be used to brainstorm and prioritize potential solutions; Genchi Genbutsu can test and validate them with experiments or trials. Finally, in the Control phase, Gemba helps implement and standardize solutions; Genchi Genbutsu can monitor and control the process with charts and tools.