Gemba Playlist:


I was talking to my manager last week and he mentioned about “walking the line” to do process audits. We both exclaimed, “Johnny Cash”. My manager commented that he can see a post in the works and smiled. So here I am.

In today’s post, I am suggesting 10 songs to keep in mind at the Gemba, and I am calling it the “Gemba Playlist”. You can click on the song titles to open it on YouTube.

The “Man in Black” [1] said it right. As a Lean Leader, you have to walk the line every day. Go to the Gemba and observe, and learn. This is a great opportunity to learn, and to develop oneself and others. Walking the line allows you to develop your observation muscles to see waste. The more you walk the line, the more you can see waste. And the more you see waste, the better you can improve the process and develop oneself and others. Go and walk the line!

One of the basic tenets of Toyota Production System is one-piece flow. The song from Johnny Cash (again) reminds us of following this. The production should follow one-piece flow – make it one piece at a time. This improves the flow, eliminates excess inventory, and improves quality. It is easier to correct the process since you get fast feedback from the next process if there is a problem. Great advice!

It appears that Johnny Cash is a Lean guy after all. His advice to Get Rhythm is an important one. You have to produce product based on takt time – a beat or cadence for the production based on customer demand. This ensures that we stay on top of producing exactly what is needed and nothing more. This brings me to the next song.

Henry Ford is attributed to have said that “you can have any color car you want…. as long as it is black”. A Lean Leader would say, “you can have it any way you want it.” This is because of “heijunka” or production leveling. It might be more efficient to make the same color or style car again and again. However, the customer may not want a black car. Utilizing the Toyota Production System principles allows you to say – you can have the product any way you want it. Heijunka ensures that you are flexible in meeting the variety of demands imposed by the customers by making product in the right mix daily.

Sammy Davis Jr. might be on to something here. A Lean Leader knows to resist placing the blame on the operator when there is a problem. You have to look at the process and see what might have happened. It is too easy to blame the operator. However, replacing the operator can still result in the same problem happening. The operator is doing what he or she thinks is rational at that time, based on all the information available. Start with the process when you are addressing a problem at the Gemba.

This needs to be mantra of every Lean Leader – I (We) can make it better. This is the idea of kaizen. You are responsible to make things better than yesterday, no matter how small or insignificant the improvement is. The small improvements add up, and they also change the mindset. There is always a better way of doing things. The title of the song captures the essence of continuous improvement.

Just-In-Time (JIT) is one of the two pillars of the Toyota house. I have written about this many times before. JIT is the brainchild of Kiichiro Toyoda, who founded the Toyota Motor Corporation. He came up with the idea of making the right parts at the right time, and in the right amount. The essence of JIT is to make product almost on time. Kiichiro called this the first principle of improving efficiency. He believed that JIT would eliminate all the excess inventory and also avoid a shortage of parts since only the right part in the right amount will be made with proper resource utilization.

No list is complete without a song from The Beatles. TPS is not about Superman or any other Super Action Hero. TPS is about teamwork and working together. One of the two pillars of Toyota Way – Respect for People, is based on Teamwork. TPS is everybody working together everyday for the common betterment. Yoshio Ishizaka, a Toyota veteran stated in his wonderful book, “The Toyota Way in Sales & Marketing”, Toyota realized that the starting point and the building block for its production system was the employees.

At the Gemba, there are always Things That Make You Go Hmmmm.Why is that operator reaching out for a tool every time? Why does this part always have a flash at this corner? Why is there a pool of oil here? Why do we have to record this information twice in different formats? Why am I entering this information when it can be accessed anytime? These things are good because they set you on the right journey – the journey to eliminate waste and improve your process.

Taiichi Ohno, the father of TPS, is said to have drawn chalk circles on the floor and have the supervisor or engineer stand inside it to observe a process. The idea was to make them see the waste that he saw. This Christmas song has three questions that are very applicable at the Gemba.

  • Do you see what I see?
  • Do you hear what I hear?
  • Do you know what I know?

These questions are great starting points to train and develop a leader. Some sample questions might be  – Do you see the wastes that I see? Or Do you hear the abnormal sound coming from the machine? Following or shadowing a person and observing them at work is a great way to absorb his or her knowledge.

Always keep on learning…

In case you missed it, my last post was Rules of 3 and 5:



Leave a Reply

Fill in your details below or click an icon to log in: Logo

You are commenting using your account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s