Lean Manufacturing Observation Techniques

Examining areas outside of the main focus (e.g., entrances, storage) to uncover insights and hidden issues in lean practices.

Primary work areas that are often the main focus of lean improvement efforts.

Areas outside the primary work areas.

A lean methodology involving five steps (Sort, Set in order, Shine, Standardize, Sustain).

Examining how a waste management area reflects a company's overall lean commitment.

Analyzing entries to understand organizational values and commitment to lean by checking entry-point cleanliness and organization.

Peripheral observation can challenge preconceived notions.

Basic business practices centered on the avoidance and reduction of waste to optimize efficiency.

Unusual events, behaviors, or data point to changes in processes or culture.

Hidden patterns or evidence of past actions indicating potential improvements.

Recognizing shadows as evidence of past events and activities.

Tracking customer behavior to understand preferences and future plans.

In exchange shops, currency displays show tourist demographics and spending trends.

Uncovering hidden opportunities, and risks through analysis of unusual or unexpected observations.

Deliberate analysis of unusual observations can reveal hidden opportunities or risks.

Continuous improvement and efficiency via observation of unusual occurrences.

Haphazard arrangement of items (like chairs) shows a lack of consistent application of 5S principles throughout an organization.

A CEO's wall made of stone symbolizes long-term vision and commitment to the organization.

Unique window design in a building signifies openness and clear decision-making within an organization.

Organizational symbols and design elements reveal the underlying values that impact the lean implementation approach.

Comparing elements (e.g., before-and-after images, peers) helps evaluate the success and identify areas for improvement in achieving lean goals.

Benchmarking against similar companies/organizations helps identify strengths and weaknesses in your organization's process.

Evaluating performance over time (past, present, future) to identify progress and needed changes in processes.

Photographs and pictures help track improvements and communicate progress in a lean implementation.

The skill and dedication used to make high-quality, unique products, often emphasizing tradition and artistry.

A production approach focused on eliminating waste and improving efficiency to create value for customers.

Ancient potters deeply understood the properties of clay and firing techniques to create durable and beautiful pottery.

Pottery served practical needs while also showcasing cultural motifs and artistic expression.

Pottery often reflects the traditions, values, and artistic expressions of a civilization.

Ancient potters used local materials and adapted techniques to different environments, showcasing resourcefulness.

Products should meet customer needs while also being aesthetically pleasing and unique.

Incorporating cultural elements into product design can create a deeper connection with consumers and enhance value.

A change in the company's values and behaviour, often leading to better communication and employee engagement.

Significant increase in sales by INR 300 crores, exceeding the target of INR 1,000 crores.

The rate at which employees leave a company. Lower turnover signifies higher job satisfaction.

Addressing the underlying problems rather than just the symptoms.

Methods of carefully watching processes and behaviours to gain crucial insights.

Detailed observation focused on identifying subtle patterns and inefficiencies.

A superficial observation, lacking the focus to uncover the deeper meaning in processes and patterns.

The process of observing work directly where it happens in a manufacturing setting, with the aim of understanding the flow of work and identifying areas for improvement.

When observing in Gemba, prioritizing understanding the 'why' and 'how' of a process, rather than relying solely on numerical measurements.

Entering an observation with an open mind, free from assumptions, to ensure a neutral and unbiased understanding of the situation.

Analyzing how the physical environment and layout of the workspace affect the effectiveness and well-being of workers.

Problems in the workflow or environment that are not immediately obvious but can significantly impact production efficiency.

Using observation as a tool not only to find problems but also to identify areas for continuous improvement and innovation.

To improve efficiency and reduce waste in production processes by understanding and addressing issues through observation and analysis.

Going beyond the surface symptoms of a problem to uncover the underlying cause, allowing for a more effective and lasting solution.