Gemba-walk-system-updated

©2012EatonCorporation.Allrightsreserved.Gembawalksystem–BA22©2012EatonCorporation.Allrightsreserved.Agenda-Gemba/Gembawalkdefinitions&characteristics-Gembawalkmechanism-Gembawalkimplementation-Gembawalkbenefits-Gembawalktips-Gembawalkquestions-LOOKFORareasduringGembawalk3©2012EatonCorporation.Allrightsreserved.Gemba/Gembawalkdefinitionsandcharacteristics4©2012EatonCorporation.Allrightsreserved.Gemba/GembawalkdefinitionsGemba:AJapanesewordmeaning“realplace”wheretheactiontakeplace,wherethevalue-addingactivitiestosatisfythecustomersarecarriedout.GembaWalk:Ameansofgatheringreal-timefirst-handinformationonthestatusofproductionprocessorbusinessprocessbywalkingagainsttheprocessandobservingwhatishappening,itiscalledasMBWA(ManagementByWalkingAround).5©2012EatonCorporation.Allrightsreserved.GembaWalkpurposes•GembaWalksLeadersgoingtowheretheworkisdone,personallyobservingtodeeplyunderstandthecurrentcondition,reflectingandstimulatingahigherlevelofthinkingaboutprocessdesignandeffectiveness,systeminterdependencies,barriersandfutureresourceallocationGoodGembaWalkdesign:•Thepurpose/typeofawalkisclearoDeeplyunderstandthecurrentconditionoMentoringoConformancechecksoImprovementopportunities•ThewalkfollowsasystematicapproachGembaWalksarerealwhen:•Walksarenot“checkthebox”exercises•Theyareseenasanopportunityforreflectionandengagement•Theyareusedtomentorthenextgeneration•Theyareviewedasacriticalmeansofevaluatingthemanagementsystem6©2012EatonCorporation.Allrightsreserved.GembaWalkCharacteristics•Time/Pace•Path•Agenda•Identifywastes•Learning•Assignactions7©2012EatonCorporation.Allrightsreserved.GembaWalk:Time/Pace•Establisharoutine•Gembawalksshouldoccurregularly,atadefinedtime•Ensurethatthetimeintervalbetweenwalksissmallenoughtomaintainasenseofpaceandanticipation•Thetimeintervalmayvarybypositionorpurpose8©2012EatonCorporation.Allrightsreserved.GembaWalk:Path•Establishapath•Followadefinedpathandgototheplace,orplaces,wheretheactionis•Seetheaction•Watchtheprocess•Lookatvisualcontrols•Talktothepeople9©2012EatonCorporation.Allrightsreserved.GembaWalk:Agenda•Establishanagenda/focus•BasetheagendaontheVSMorperformancegaps•Definetopicsanddetailthemwith“Whatyoushouldsee”and“Whatyoushouldknow”•Sometopicsmayremainontheagendaforseveralwalks,whileothertopicsrotatebasedonbusinessneeds10©2012EatonCorporation.Allrightsreserved.IdentifyWaste•EveryGembaWalkisanopportunityto“see”waste•8CommonWastesOverproductionProducingmoreproductthanisneededforimmediateuseDefectsAnyproductionthatresultsinreworkorscrapInventoryWIPthatexceedswhatisrequiredtomeetcustomerneedsExcessMotionUnnecessarymovement,suchaswalking,lifting,andreachingOverProcessingAddingmorevaluethancustomerswillpayforTransportationUnnecessarymovementofproducts,materials,orinformationWaitingAdelaybetweentheendofoneactivityandthestartofthenextLostCreativityNotcapturingtheknowledgeandcreativityofallemployees11©2012EatonCorporation.Allrightsreserved.GembaWalk:LearningEstablishexpectations•AGembaWalkisadialog,notaone-waytalkorperformanceaudit•Openchannelsofcommunicationtogetthebestinformation•Createlearningmoments•Actlikeacoach12©2012EatonCorporation.Allrightsreserved.AssignActions•Donotjustspotissues,addressthem•Donotwalkpastwithoutdoingsomething•Assignatleastthreeactionsperwalk•Followuponassignedactions13©2012EatonCorporation.Allrightsreserved.GembaMechanism14©2012EatonCorporation.Allrightsreserved.KPIStructure–focusingondailyoperationLevel1SafetyQualitySupplyChainEmployeeengagementEHSaction/ProjectCompletion/5S+InternalDPPM(IPQC&FQC&OOBA)PlantEfficiencyCostFirstaid/Nearmiss/5S+Level2LineFPY/Reworkhours/BatchdefectQTYOTTR/OTTPEmployeeabsentrate/EstarW/OCompletionRate/Shortage/BatchrejectQTYLevel3QTYAtriskbehaviorDPmasterplanTracking/oneonone/IssuestrackingEmployeesuggestionDept.(byshift)Efficiency/OEERepairedQTYLosstimeDailyplanCompletionRate(line)ZICtrackingFAIKaizenTrackingShippingplancompletionIssuestrackingMulti-skillCyclecountCAR/SCARPPEPhaseoutprojectPullin&PushoutOPOcancelationCommodityendoflifeProcessscrapcostOTTransferpractice5S+Incidentsharing15©2012EatonCorporation.Allrightsreserved.GembawalkteamstructureGembawalkteamstructureSafetyQualitycostsupplychainEmployeeengagementLevel1TeamleaderEHSmanager/plantmnagerQAmanager/Plantmanager/ProductionmanagersProductionmanagers/Plantcontroller/plantmanagerMaterialmanager/Procurementmanager/PlantmanagerHRmanager/PlantmanagerTeammembersPlantseniorleadershipteam+areasupervisor+EHSengineers+leancoordinatorsPlantseniorleadershipteam+areasupervisor+qualityengineer+leancoordinatorsPlantseniorleadershipteam+areasupervisor+costaccountant+leancoordinatorsPlantseniorleadershipteam+areasupervisor+leancoordinatorsPlantseniorleadershipteam+areasupervisor+HRspecilist+leancoordinatorsLevel2TeamleaderAreamanagerAreamanagerAreamanagerAreamanagerAreamanagerTeammembersAreasupervisors+otherspecialistsinvitedAreasupervisors+otherspecialistsinvitedAreasupervisors+otherspecialistsinvitedAreasupervisors+otherspecialistsinvitedAreasupervisors+otherspecialistsinvitedLevel3Team