Gemba Walk Observation Checklist - FREE PDF
Conduct Gemba walk for process observation.
- Industry: Manufacturing
- Frequency: Daily / Weekly
- Estimated Time: 30-60 minutes
- Role: Leadership / Managers
- Total Items: 32
- Compliance: Lean Manufacturing, TPS
Compliance Verification
Verify Lean Manufacturing requirements.
- Procedures followed correctly?
- Records complete and accurate?
- Standards/specifications met?
Equipment/Process Condition
Assess equipment or process status.
- Equipment operating properly?
- Maintenance current?
- Calibration/verification current?
Safety & Environment
Verify safety and environmental controls.
- Safety guards/devices in place?
- Required PPE used correctly?
- Housekeeping acceptable?
Findings & Actions
Document findings and required actions.
- Overall Result
- Findings
- Corrective Actions
- Follow-up Date
- Auditor 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?
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Why Use This Gemba Walk Observation Checklist?
This gemba walk observation checklist helps manufacturing teams maintain compliance and operational excellence. Designed for leadership / managers professionals, this checklist covers 32 critical inspection points across 8 sections. Recommended frequency: daily / weekly.
Ensures compliance with Lean Manufacturing, TPS. Regulatory-aligned for audit readiness and inspection documentation.
Frequently Asked Questions
What does the Gemba Walk Observation Checklist cover?
This checklist covers 32 inspection items across 8 sections: Compliance Verification, Equipment/Process Condition, Safety & Environment, Findings & 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 Observation Checklist?
This checklist is designed for Leadership / Managers 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.