Gemba walk checklist template for manufacturing

Start by explaining that the walk is about process improvement. Share the checklist in advance so everyone understands what you’ll be observing. Schedule the walk during normal operations and encourage team members to speak openly about challenges they face. Remember that building trust is essential—emphasize that their insights are valuable for making meaningful improvements.

The ideal frequency depends on your improvement goals, but most manufacturing facilities benefit from weekly walks initially, then bi-weekly once processes stabilize. Focus on different areas or shifts each time to build a comprehensive understanding. Consistency matters more than frequenc. Regular walks with proper follow-up create more value than frequent walks without action.

Document specific findings during your walk, then hold a debrief meeting within 24 hours to discuss observations. Prioritize issues based on impact and feasibility, assign clear ownership for improvements, and set specific timelines. Most importantly, schedule follow-up walks to verify that changes have been implemented and are effective. Without this accountability loop, even the best observations won’t translate to improvements.

Approach the situation with curiosity rather than judgment. Ask open-ended questions about why the standard isn’t being followed—often you’ll discover the standard is outdated or impractical. Document the gap, discuss it with the worker and supervisor, and collaborate on updating the standard or providing additional training.