Gemba Walk Checklist - FREE PDF

Conduct Gemba walks to observe processes and identify improvement opportunities.

Industry: Manufacturing
Frequency: Daily / Weekly
Estimated Time: 30-60 minutes
Role: Manager / Supervisor / Lean
Total Items: 32
Compliance: Lean Manufacturing, Toyota Production System, Kaizen

Pre-Audit/Pre-Task Verification

Verify conditions before proceeding.

Scope/area defined?
Required documentation available?
Required personnel available?

Process/System Evaluation

Evaluate processes per Lean Manufacturing requirements.

Procedures followed correctly?
Equipment functioning properly?
Controls effective?
Records accurate and complete?

Compliance Verification

Verify compliance with Lean Manufacturing, Toyota Production System, Kaizen.

Standards requirements met?
Objectives achieved?
Improvement opportunities identified?

Findings and Actions

Document findings and required actions.

Overall Result
Findings Description
Corrective/Preventive Actions
Signature

Pre-Shift Verification & Setup

Initial verification before operations begin

Operator / Inspector Name
Date
Shift Number
Production Line / Area
Previous shift handover notes reviewed?

Safety Protocols & Compliance

Verify all safety measures are in place per OSHA standards

LOTO procedures verified for all equipment?
All machine guards in place and secured?
Emergency stop buttons tested and functional?
Required PPE worn by all operators?
Safety signage visible and current?

Equipment & Operational Readiness

Verify equipment is calibrated and operational

Equipment calibration current and documented?
All gauges and instruments reading correctly?
Lubrication schedule maintained?
Any abnormal sounds, vibrations, or leaks?

Quality Control Standards

Verify product quality meets specifications

Current specifications/work instructions available?
First article inspection completed?
Measurement tools calibrated and in tolerance?
Reject/scrap rate within acceptable limits?

Related Manufacturing Checklists

Related Lean Checklists

Why Use This Gemba Walk Checklist?

This gemba walk checklist helps manufacturing teams maintain compliance and operational excellence. Designed for manager / supervisor / lean professionals, this checklist covers 32 critical inspection points across 8 sections. Recommended frequency: daily / weekly.

Ensures compliance with Lean Manufacturing, Toyota Production System, Kaizen. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Gemba Walk Checklist cover?

This checklist covers 32 inspection items across 8 sections: Pre-Audit/Pre-Task Verification, Process/System Evaluation, Compliance Verification, Findings and Actions, Pre-Shift Verification & Setup, Safety Protocols & Compliance, Equipment & Operational Readiness, Quality Control Standards. It is designed for manufacturing operations and compliance.

How often should this checklist be completed?

This checklist should be completed daily / weekly. Each completion takes approximately 30-60 minutes.

Who should use this Gemba Walk Checklist?

This checklist is designed for Manager / Supervisor / Lean professionals in the manufacturing industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.