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Run: Gemba Walk Daily Round

Daily Gemba walk inspection for reviewing safety, quality, delivery, cost, morale, and visual board status on the floor. Use it to spot defects early, assign...

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Safety

Walkway, aisle, and egress paths are clear and unobstructed critical (required)

Verify primary travel paths, exits, and access to emergency equipment are free of stored materials, cords, spills, and trip hazards.

Yes No N/A

Required PPE is worn in the observed area critical (required)

Confirm employees and visitors are using task-appropriate PPE such as eye protection, hearing protection, gloves, or high-visibility apparel as required.

Yes No N/A

Machine guards, interlocks, and safe operating controls are in place critical (required)

Check exposed pinch points, missing guards, bypassed interlocks, and unsafe machine conditions visible during the walk.

Yes No N/A

Electrical panels, cords, and temporary power connections are in safe condition critical (required)

Look for open panels, damaged cords, overloaded outlets, exposed conductors, or unsafe temporary wiring.

Yes No N/A

Fire extinguishers, alarms, and emergency equipment are accessible and not expired critical (required)

Confirm extinguishers are mounted, visible, in their designated location, and that emergency equipment is not blocked.

Yes No N/A

Housekeeping conditions do not present a slip, trip, or contamination hazard

Check for spills, debris, excessive dust, leaking fluids, or waste accumulation that could affect safe work or product quality.

Yes No N/A

Any observed safety deficiency has been escalated to the responsible owner critical (required)

Document whether hazards were assigned, contained, or escalated according to the site escalation process.

Yes No N/A

Quality

Workstation output matches the current standard work and quality criteria

Confirm operators are following the current method and that visible work instructions match the process being performed.

Yes No N/A

Defects, rework, or scrap are identified and contained critical (required)

Check whether non-conforming material is clearly labeled, segregated, and dispositioned per procedure.

Yes No N/A

First-pass quality checks are being completed at the required frequency

Verify in-process checks, layered process audits, or verification steps are being performed as scheduled.

Yes No N/A

Measurement and inspection tools are available and within calibration status critical (required)

Confirm required gauges, scales, or inspection tools are present and show current calibration or verification status.

Yes No N/A

Process abnormalities or customer-impacting issues are visible and understood

Check whether recent defects, complaints, or process deviations are posted and being actively addressed.

Yes No N/A

Quality containment actions are current and effective critical (required)

Verify temporary controls, hold tags, or inspection containment actions are in place where needed.

Yes No N/A

Delivery

Current production or service plan is posted and understood

Confirm the team can see the current target, priority, and sequence for the shift or day.

Yes No N/A

Actual output is tracking to plan

Compare current performance against the posted target and note any gap or recovery plan.

Yes No N/A

Material, parts, and consumables are available for the next planned work critical (required)

Check whether shortages, missing kits, or late deliveries could interrupt flow in the next interval.

Yes No N/A

Bottlenecks, downtime, or waiting time are identified

Document the primary constraint affecting throughput, including equipment downtime, staffing gaps, or upstream delays.

Escalation path is clear for delivery risks

Confirm the team knows who to contact when schedule risk, shortages, or equipment issues threaten delivery.

Yes No N/A

On-time completion risk is within acceptable tolerance

Record whether the area is on track, at risk, or behind, based on the current day plan.

Cost

Visible waste is being identified and removed

Look for excess motion, waiting, overproduction, unnecessary transport, or duplicate handling.

Yes No N/A

Rework, scrap, or damage is trending within target

Check whether visible scrap, damage, or rework is above the expected daily level.

Yes No N/A

Energy, compressed air, water, or consumable waste is controlled

Observe whether equipment or processes are leaking, idling, or otherwise consuming resources unnecessarily.

Yes No N/A

Preventive maintenance or housekeeping gaps are creating avoidable cost

Check for conditions that could lead to breakdowns, quality loss, or repeat labor.

Yes No N/A

Top cost driver observed during the walk

Capture the most significant visible cost issue found during the round.

Immediate cost-saving action assigned

Record whether a practical action was assigned to reduce waste or prevent recurrence.

Yes No N/A

Morale and Engagement

Team members appear engaged and aware of priorities

Observe whether employees can explain current priorities, blockers, and expected outputs.

Yes No N/A

Workload and staffing appear balanced for the current demand

Check for signs of overload, understaffing, or uneven task distribution that could affect morale or performance.

Yes No N/A

Employees have access to support for issues raised during the walk

Confirm concerns are being heard and routed to the correct owner without delay.

Yes No N/A

Recognition or positive feedback was provided

Record whether the leader acknowledged good performance, improvement, or safe behavior.

Yes No N/A

Morale concerns or employee feedback

Capture any concerns, suggestions, or observations shared by the team.

Visual Board and Action Tracking

Safety, quality, delivery, cost, and morale metrics are posted and current

Confirm the board reflects the latest available daily or shift data for the core performance categories.

Yes No N/A

Action items have clear owners and due dates critical (required)

Check that open actions are assigned to a responsible person with a target completion date.

Yes No N/A

Overdue actions are visibly escalated

Verify overdue items are highlighted and have an escalation path or recovery plan.

Yes No N/A

Board reflects the current top issues and countermeasures

Confirm the board shows the most important problems, root causes, and countermeasures rather than stale information.

Yes No N/A

Next follow-up date

Record the planned date for the next review or follow-up on open actions.

Overall leadership round summary

Summarize the key observations, risks, and commitments from the walk.

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