Lean manufacturing · Kaizen
The PDCA cycle: the order behind Kaizen
Plan, do, check, act. Where each step of the cycle sits in an improvement record.
13 October 2026 · 1 min
How to run a Gemba walk: a short guide for managers
Gemba is where the work happens. The aim of the walk is to understand, not to inspect. Preparation, questions and follow-up.
6 October 2026 · 1 min read
A Gemba walk is a manager going to where the work is done and seeing the process first-hand. The aim is not to find someone to blame but to understand where the system struggles.
Before the walk
- Pick a theme: safety, quality, flow or sustaining an improvement.
- Look at the board indicators: where are the red days?
- Tell the team leader; this is a look together, not a surprise audit.
On the floor
- Ask: “How do you do this job? What makes it hardest?”
- Listen and take notes; don't dictate a fix on the spot.
- Name the good practice you see.
Afterwards
Topics from the walk are opened as actions from the board, with an owner and a due date. The first question on the next walk is whether last time's promises were kept.
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How to write a One Point Lesson (OPL)
One topic, one page, plenty of visuals. The pattern for passing on knowledge in five minutes on the floor, and tracking who read it.
12 October 2026 · 1 min
Sample company · demo data Lean manufacturing
Yokoten: taking what works in one place everywhere
The same problem exists on other lines and in other plants. How to plan and track the roll-out of a good practice.
11 October 2026 · 1 min