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Tuesday, December 9, 2008

Gemba Kaizen

For everything you wanted to know on building leadership andmanagement, refer Shyam Bhatawdekar’s website:http://shyam.bhatawdekar.com

(Refer our High Quality Management Encyclopedia “ManagementUniverse” at: http://management-universe.blogspot.com/)

Gemba Kaizen (Commonsense Low-cost Approach to Management)

(Also refer Kaizen and 5S Housekeeping at URLs: http://kaizen-improvement.blogspot.com/ (Kaizen) and http://5s-housekeeping.blogspot.com/ (5S Housekeeping)

Gemba = Workplace

Gembutsu = The tangible objects in gemba: machines, equipment, tools,jigs, fixtures, rejects etc

A process of continuously

Going to the workplace (where problem/abnormality is)Identifying the problem and it's root causesReducing and eliminating muda (waste), mura (inconsistency) andmuri (strain)Solving the problem or improving the situation

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gemba-kaizen-improvement.blogspot.com 1/11

Three Segments of Kaizen or Gemba Kaizen Practice

Management oriented kaizen or gemba kaizenGroup oriented kaizen or gemba kaizenIndividual kaizen or gemba kaizen

Five Principles of Gemba Kaizen

1. When a problem/abnormality/opportunity occurs, go to gemba (theworkplace) first

2. Check with gembutsu like machines, equipment, tools, jigs,fixtures or rejects etc

3. Take immediate or even temporary counter-measures on the spot4. Find out the root cause and remove the root cause of the

abnormality5. Implement the solution and standardize to prevent further

trouble/recurrence

Gemba Kaizen: Doctor and Patient Analogy (As enunciated by ShyamBhatawdekar: copy right with the author)

Doctor attends to the illness/sickness of the patient immediately.He never asks the patient, “come back to me later, we will seethen (which often time happens in a business/industrialorganization).He immediately treats the patient and with limited and fresh ofsymptoms/causes, starts the treatment.He may ask for more information (tests etc) but that informationalways is the most recent.He finds out the real cause(s) (diagnosis) and administers the finaltreatment accordingly.

In gemba kaizen, it is more appropriate to follow this analogy for betterand early results.

Gemba Kaizen: Operation Theater Analogy (As enunciated by ShyamBhatawdekar: copy right with the author)

Patient’s sickness is determined by checking the patient based onthe most recent information regarding the ailment (though someprevious information may also be referred/gone through).An earliest possible date is fixed for the operation (surgery).Patient is brought to the operation theater.All types of specialist doctors, nurses, paramedic staff etc (many ofwhom have not seen each other earlier) reach operation theater onthe appointed time punctually.They follow prescribed procedures and techniques which areunderstood by each and every body present there (and not presentthere but who are connected with the operation).They are locked up in the operation room till the entire operationhas been performed.

In gemba kaizen it is more appropriate to follow this analogy for better

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and speedy results.

Gemba Kaizen: Learn from Medical Profession (As enunciated by ShyamBhatawdekar: copy right with the author)

Ascertain problem/opportunity.Meet that problem/opportunity at the gemba (workplace) at theearliest possible time.Measure the latest data/information available at the gemba (don’tsay that we will look into it and come back at a later date or let usdig out the previous data/information etc).Size up the problem/opportunity and quantify the possible benefitsand they are your targets to be achieved.It can be tackled individually or by a well selected and well trainedcross functional group of experts from various fields.Concerned people work on it together using the systems/proceduresand techniques, work out the alternate solutions and implementthem immediately.They measure the results and continue following the above-mentioned steps (also find out the root level causes in the process)till they achieve the targeted results.

Innovations/Breakthroughs and Daily Continuous ImprovementsThrough Gemba Kaizen

Innovations/breakthroughs are brought about in any organizationoccasionally or intermittently. There is a high jump inimprovements. These high jump improvements are incorporated inthe new practices/systems/processes.Then, after one innovation/breakthrough, there may be a lull.During this lull period and in absence of daily management orcontinuous improvements through kaizen or gemba kaizen etc,these dramatically improved processes start degrading ordeteriorating. And the processes become inefficient/ineffective.Lots of advantages of innovation disappear or are lost.This is where daily management through continuous improvementscomes in. It insists on daily performance and also, dailyimprovements. It keeps on maintaining and further improving theprocesses. The fall or degradation of processes is now just notpossible.Therefore, daily management and daily improvements throughkaizen, gemba kaizen, quality circles etc is in fact a managementimperative. You cannot do without it (you may occasionally dowithout an innovation/breakthrough).It may not be as stunning or exciting as an innovation, yet,effective daily management and daily improvements are thefoundation on which maximization of advantages due to innovationand company viability firmly stay.

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Other Topics of Interest

All Management Topics (General Management, Marketing and Sales,Service, Operations/Manufacturing, Quality, Maintenance, HumanResources, Finance and Accounts, Information Technology, LifeManagement)

The topics are listed in alphabetic order:

(Home Pages for All the Management Topics) http://management-universe.blogspot.com/ and http://management-universe-enotes.blogspot.com/(Building Leadership and Management) http://shyam.bhatawdekar.com(Alphabetic List of All Management Topics) http://management-enotes.blogspot.com/(Home Page for Writings of Shyam Bhatawdekar) http://writings-of-shyam.blogspot.com/(5S Housekeeping) http://5s-housekeeping.blogspot.com/(Activity Based Costing- ABC) http://activitybased-costing.blogspot.com/(Advertising) http://advertising-mass-communication.blogspot.com/(Anger Management) http://controlling-anger.blogspot.com/(Assertiveness) http://assertiveness-skill.blogspot.com/(Assessment Centers) http://assessment-centers.blogspot.com/(A to Z of Management Systems) http://a-z-management-systems.blogspot.com/(A to Z of Quality Techniques) http://a-z-quality-techniques.blogspot.com/(Balanced Scorecard) http://balanced-scorecard-system.blogspot.com/(Basic Statistics) http://statistics-basic.blogspot.com/(Behavioral Safety) http://behavioral-safety.blogspot.com/(Benchmarking) http://benchmarking-system.blogspot.com/(Body Language or Non-verbal Communication) http://body-language-communication.blogspot.com/(Books- Best Management Books) http://best-management-books.blogspot.com/(Boundaryless) http://shyambhatawdekar.blogspot.com/(Brainstorming) http://brainstorming-technique.blogspot.com/(Business Ethics and Ethics in Management) http://business-management-ethics.blogspot.com/(Business Plan) http://business-plan-document.blogspot.com/(Business Process Reengineering- BPR) http://business-process-reengineering-bpr.blogspot.com/(Career Planning within Organizations) http://organizational-career-planning.blogspot.com/(Case Method) http://case-method.blogspot.com/(Case Studies in Management) http://corporate-case-

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studies.blogspot.com/(CEO Roles, Qualities and Competencies) http://ceo-qualities.blogspot.com/(Change Management) http://manage-change.blogspot.com/(Coaching) http://coaching-skill.blogspot.com/(Communication) http://communication-for-business.blogspot.com/(Competencies- Life Management) http://shyam-bhatawdekar.blogspot.com/(Competency Matrix) http://competency-matrix.blogspot.com/(Conflict Management) http://manage-conflict.blogspot.com/(Corporate Governance) http://corporate-governance-policy.blogspot.com/(Cost Management) http://cost-management-control.blogspot.com/(Cost of Quality- COQ) http://cost-of-quality.blogspot.com/(Counseling at Workplace) http://counseling-skill.blogspot.com/(Creativity and Innovation) http://creativity-management.blogspot.com/(Critical Thinking skills) http://critical-thinking-skills.blogspot.com/(Cross Cultural Etiquette and Manners) http://cross-cultural-etiquette.blogspot.com/(Customer Orientation) http://customer-orientation.blogspot.com/(Customer Relationship management- CRM) http://customer-relationship-crm.blogspot.com/(Daily Management) http://daily-management.blogspot.com/(Decision Making) http://decision-making-function.blogspot.com/(Delegation) http://delegation-skill.blogspot.com/(Design for Manufacture) http://design-for-manufacture.blogspot.com/(Dining Etiquette and Table Manners) http://dining-manners.blogspot.com/(Discipline at Work) http://discipline-at-work.blogspot.com/(Do This Today) http://do-this-today.blogspot.com/(Dream Exotic) http://knol.google.com/k/shyam-bhatawdekar/my-exotic-dream/6txz9nck6g3/8#(Effectiveness and Efficiency) http://effectiveness-efficiency.blogspot.com/(Effectiveness Management: HSoftware)http://humansoftware.blogspot.com/(Efficiency Techniques: Work study: Motion and Time Study) http://work-study-measurement.blogspot.com/(Efficient Work Methods or Practices) http://efficient-work-methods.blogspot.com/(Email Etiquette) http://email-etiquette-manners.blogspot.com/(Emotional Intelligence) http://emotional-quotient-intelligence.blogspot.com/(Empowerment) http://employee-empowerment.blogspot.com/(Enterprise Resource Planning- ERP) http://erp-management.blogspot.com/(Entrepreneurship and Entrepreneur) http://entrepreneurship-entrepreneur.blogspot.com/(Executive Etiquette and Manners) http://executive-manners.blogspot.com/(Exit Interview) http://exit-interview.blogspot.com/

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Gemba Kaizen



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Prodcons Group is a managementconsultations/training andinformation technologyconsultations/training group offirms. Prodcons Group is a group offour firms. They are ProductivityConsultants (ManagementConsultancy Firm), I T Maximum(Information Technology Firm),PRISM (Sales and Marketing Firm) andThree Sixty Degrees (Firmspecializing in Three Sixty DegreesHR, Leadership Development andPerformance Appraisal Systems). Ithas provided consultations and

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(Work Methods or Practices: Efficient) http://efficient-work-methods.blogspot.com/(World Class Manufacturing) http://world-class-manufacturing.blogspot.com/(Writings of Shyam Bhatawdekar on Management) http://writings-of-shyam.blogspot.com/(Written Communication) http://written-communication.blogspot.com/(Zero Based Budgeting) http://zero-based-budgeting.blogspot.com/

Counseling: General and Psychological(Anger Management) http://controlling-anger.blogspot.com/(Children’s Behavior Problems) http://child-behavior-problems.blogspot.com/(Cholesterol Control) http://controlling-cholesterol.blogspot.com/(Counseling: Psychological) http://counselingfamily.blogspot.com/(Counseling: Psychological) http://counseling-family.blogspot.com/(Cross Cultural Etiquette) http://cross-cultural-etiquette.blogspot.com/(Do This Today) http://do-this-today.blogspot.com/(Emotions) http://emotion-feeling.blogspot.com/(Executive Etiquette and Manners) http://executive-manners.blogspot.com/(Exercises) http://exercises-plan.blogspot.com/(Family Counseling) http://family-harmony.blogspot.com/(Health: Homeopathy) http://homeopathy-medicines.blogspot.com/(LifeManagement: Competencies) http://knol.google.com/k/shyam-bhatawdekar/competency-matrix/6txz9nck6g3/4#(Life Management: Effectiveness Management: HSoftware)http://knol.google.com/k/shyam-bhatawdekar/management-in-life-profession-family/6txz9nck6g3/3#(Life management: I Am Liberated) http://knol.google.com/k/shyam-bhatawdekar/i-am-liberated/6txz9nck6g3/6#view(Marriage Counseling) http://marriage-counsel.blogspot.com/(Ownership on Job) http://job-ownership.blogspot.com/(Parental Responsibilities) http://parental-responsibilities.blogspot.com/(Personality) http://human-personality.blogspot.com/(Qualities of Spouse) http://spouse-qualities.blogspot.com/(Quit Smoking) http://quit-smoking-plan.blogspot.com/(Self Development) http://managing-self.blogspot.com/(Self-confidence) http://self-confidence-improvement.blogspot.com/(Spiritual Quotient/Intelligence) http://spiritual-quotient.blogspot.com/(Stress Management) http://managing-stress-strain.blogspot.com/(Stress Management) http://management-of-stress.blogspot.com/(Success in Life or Success) http://success-achievement.blogspot.com/(Success in Life or Success) http://knol.google.com/k/shyam-bhatawdekar/success-in-life/6txz9nck6g3/14#view(Swine Flu and Its Prevention) http://swine-flu-precaution.blogspot.com/(Telephone Etiquette) http://telephone-etiquette.blogspot.com/(Walking) http://walking-plan.blogspot.com/(Winners and Losers) http://winners-losers.blogspot.com/

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