On-site process audit (Gemba)

When you need it

The service is relevant if the company faces:

• before any automation, so that a process that does not work is not carried into the system
• the company has grown while the processes stayed as they were when everyone fitted into one room
• the owner does not trust the numbers being brought to them
• the same data is entered in several places and the versions disagree
• a report for management is put together by hand and takes several days
• nobody owns the process end to end, each person owns only their part

What you get

On completion the client receives:

• a process map as it is, with owners and points of loss
• a list of root causes based on Ishikawa diagrams and the five whys
• an estimate of losses in time, rework and downtime
• a prioritised change plan split into organisational steps and steps that need a system
• requirements for automation, where it is needed
• decisions agreed with the managers, with owners and deadlines

How it works

The work is carried out in stages.

1. We set the scope. We agree which areas, processes and period we look at and what counts as a result.
2. We work on site. We walk the chain from request to result together with the line staff, not through questionnaires.
3. We collect the facts. We go through documents, logs and system exports, and measure the time of operations and waiting.
4. We look for root causes. We break losses down with Ishikawa diagrams and the five whys, separating symptoms from real causes.
5. We agree the changes. We discuss the decisions with process owners and explain why they matter, so resistance is removed before the project starts.
6. We hand over the plan. We deliver a prioritised plan with owners and deadlines and support the first steps.

The outcome

The company gets a clear picture: where time and money are lost, why it happens and what to change first. Some changes start immediately without any automation, the rest becomes the requirements for the system.