1. Updated
In advance of delivering this module, make sure you have the following all set…
Everyone has a copy of their ATD Toolkit.
Make sure you have staged the DC and know where each of the DC Leader teams will be doing their GEMBA Walk so that they do not run into each other.
Make sure to set up a mock Accountability Board for each team (placed where they would finish their GEMBA Walk)
Make sure to alert the DC Leader/Leads that this is happening.
On the DC maps, outline the area each of the GEMBA Walks will take place (you will need a different area for each team)
Things to stage include:
Misc. tires in aisle.
Dock lights(used for loading/unloading) not working
Fire Extinguisher out of its place
Equipment board – blank
Pallets blocking anyone of the following - aisle way / tunnel / or exit
When delivering
Use this slide to welcome the team to this module
The SEAL Gemba Walk

2. Who is Gemba and why are we walking with him?
What is X?
Who is Gemba and why are we walking with him?
Say “so you are probably wondering, who is Gemba and why are we walking with him?”

3. What is a SEAL Gemba Walk at ATD?
What is X?
What is a SEAL Gemba Walk at ATD?
“Gemba” is Japanese for The Real Thing” and that’s exactly what you’ll discover when you put it into practice.
An informational tour of an area where work is taking place to find opportunities to improve a process and drive out waste.
It’s part observation and part engagement. During the walk, it’s important to talk to the workforce performing the work with the goal of gaining a comprehensive understanding of the process.
Focus on the important details. The goal is to look at existing visual workplace items in place to determine the point-in-time health of the operation. If you see something that is an issue, you can dig in further. if you see an area of opportunity to remove waste, it can be noted and followed up on with your team.
Review the bullets

4. The Gemba Walk is a critical part of our Daily Activities
What is X?
Gemba Walk…
Review the slide reinforcing where the Gemba Walk fits into the Daily Activities
The Gemba Walk is a critical part of our Daily Activities

5. The ATD Discussion board
What is X?
The ATD Discussion board
Topic – Gemba Walks
How will Gemba Walks help create an environment of continuous improvement for your DC?
2. How will they impact the culture of your workforce?
3. What do you think you should you do on a Gemba Walk and how often should you do them?
Ask each question. Take comments.
The last question will be hard for them to answer completely as they haven’t been exposed to it yet but get their initial thoughts as to what they think is important to cover.

6. Our Mission: The Importance of The SEAL Gemba Walk What is X?
CUSTOMER IMPACT.
Our warehouse to delivery processes and activities have a direct impact to on-time and accurate delivery.
The Gemba walk is one of the most important continuous improvement tools to drive relentless problem solving – designed to radically improve customer satisfaction.
INTERNAL IMPACT. A Gemba walk is also about engagement and developing strong relationships with our workforce – an opportunity to drive collaboration that leads to continuous improvement – together.
Our Mission:
In order to operationalize ATD’s vision to become known as the most customer centric distributor that the industry has ever seen, we must drive consistent standards of excellence so that the entire supply chain has a shared vision to succeed together, to foster a great culture and to serve our customers with excellence.
Review what’s on the slide

7. The Anatomy of an Effective Gemba Walk…
What is X?
The Anatomy of an Effective Gemba Walk…
The Purpose of Your Gemba Walk
Jointly observe the work place with your leadership team. During the group walk, the team should:
Make observations at every functional area of your DC
During the walk, engage the workforce performing the work with the goal of gaining a comprehensive understanding of the process
Begin to consider suggestions for improvement
During the walk, make sure someone is capturing notes
Review what’s on the slide
At the end of the walk, use the “Accountability Board” to assign action items for follow up to be completed that day

8. When you go to Gemba to observe a process…
What is X?
When you go to Gemba to observe a process…
Will you spend time “LOOKING”,
or will you strive to actively and deliberately “SEE”?
Review what’s on the slide
What should you see?
SEE how the process works
SEE what is really happening in the current state
SEE what kind of waste / obstacles exists in the process
Remember the 5 Whys
Remember to ask “Why” at least 5 times to drill down to the root cause as opposed to just uncovering a symptom.

9. Anyone know TIM WOODI? What is X?
You can start out by having some fun with this slide.
Ask the team if they knew Tim Wood?
Say Tim has been to your DCs although you might not have realized it.
Transition to the next slide.

10. What To Look For (See) – The 7 Types of Waste
What is X?
What To Look For (See) – The 7 Types of Waste
Review what’s on the slide.
Tell them there is actually one more type of waste and does anyone want to take a crack at what that is. Take comments.
Transtion to next slide...

11. And it’s about the wasted potential of people...
What is X?
The 8th Type of Waste is “Wasted Intellect”
And it’s about the wasted potential of people...
“We need to be disciplined and hungry to tap into the thoughts, ideas and intelligence of our people.
That’s why this is perhaps the most disappointing type of waste. We can’t accept a “check your brain at the door mentality” if we want to realize our mission of becoming the most customer-centric distributor that the industry has ever seen”.
Review what’s on this slide
David Dickey, Chief Supply Chain Officer

12. 1 2 3 Gemba Walk Fundamentals The AM Walk The PM Walk
What is X?
Gemba Walk Fundamentals 1
The AM Walk
Performed daily after AM dispatch
Make a difference in your
DC by consistently performing three types of Gemba Walks 2
The PM Walk
Performed daily during or after PM dispatch
Share that you are now going to get into the fundamentals of a Gemba Walk and transition to the next slide
The Leadership Lap
To drive a culture of engagement at your DC 3

13. Performed at time outlined in the DC Leader Daily Leader Activity SWD
What is X?
SEAL Gemba Walk – The AM Walk Checklist
Performed at time outlined in the DC Leader Daily Leader Activity SWD
The AM Walk 1
Activity
Checklist details/Questions
Safety
Focus on safety details in accordance with current safety policies.
AM Dispatch Progress
On time dispatch
Review dispatch control sheet for any adjustments that were made
End of Shift Checklist
View End Of Shift board for completion
Shift leader must provide reasons for incomplete
Process Compliance
Warehouse processes are being followed to the standard work
Accountability Board
What is ahead for the day?
Are we on track today?
If volume is lighter than plan, are adjustments being made?
Receiving Board
RMA Completion
Are all of yesterday’s returns put away?
Area should be empty
Dock Leadership
Is there a presence on dock?
Will Call
Is there a customer back up? Adjust manpower if needed
Review previous day’s aged will call in stage report for items > 72 hours
Do we have cash drawer accountability?
Inventory
“All Counts” from AM pick have been or are being resolved
“Scheduled Counts” are on pace
Equipment
Is all equipment active?
What is status and progress on any equipment that is down?
Visual Workplace
Are tools in the correct storage place?
Is striping being adhered to?
Is there product out of place?
PREPARATION
– START OF WALK
Grab notepad/standard form
Walk through warehouse hitting each of the defined stops.
COMPLETION
– END OF WALK
Circle back to accountability board and add any actions needed
Add any notes to Daily Report that need to be reported out
Review what’s on the slide 1 6 9 4 3 7 5 2 8

14. Performed at time outlined in the DC Leader Daily Leader Activity SWD
What is X?
SEAL Gemba Walk – The PM Walk Checklist
Performed at time outlined in the DC Leader Daily Leader Activity SWD 2
The PM Walk
Activity
Checklist details/Questions
Housekeeping
Breakroom, bathroom, and warehouse floor for cleanliness
Select at least one full aisle to do a full walk reviewing stacking and sanitation
Safety
Commercial tire storage
Egress
PPE
Eyewash Stations area clear and clean
First aid kits supplied
Fire Extinguishers in place / not damaged.
PM Dispatch Progress
On time dispatch
Review dispatch control sheet for any adjustments that were made
End of Shift Checklist
Ensure that ASNs are fully received and partially received ASNs are reconciled in Oracle ASN workbench
Ensure that all ISO and PO discrepancies have been filed in SharePoint
Ensure that all receiving lanes are cleared in the Material workbench
Ensure that the RMARCV sub inventory is cleared in the material workbench
Ensure that the staging lanes are cleared except for the CPU lane in the material workbench
Ensure all tasks are completed both inbound and outbound in the WMS control board
Ensure that all cycle counts are completed in WMS Control board
Ensure that all Cycle Counts variances are addressed in Oracle Approve counts
Ensure that all outbound shipping has been completed in the Logistics workbench  
Accountability Board
Review items with today’s deadline
Update on items due later in the week
Add any items from today’s walk that are needed
Receiving Board
What is ahead for the day?
Are we on track today?
If volume is lighter than plan, are adjustments being made?
Dock Leadership
Is there a presence on dock?
CPU Flow
Is there a customer back up?
Review previous day’s aged will call in stage report for items > 72 hours
Inventory
“All Counts” from AM pick have been or are being resolved
“Scheduled Counts” are on pace
Verify that root cause is being found on errors
New Employee Training Update
Check in with new employee on-on-one
Review onboarding document for progress
Visual Workplace
Are tools in the correct storage place?
Is striping being adhered to?
Is there product out of place?
PREPARATION
– START OF WALK
Grab notepad/standard form
Walk through warehouse hitting each of the defined stops.
COMPLETION
– END OF WALK
Circle back to accountability board and add any actions needed
Add any notes to Daily Report that need to be reported out
Verify that all RMA’s and WRMA’s are checked in accurately and processed each day
Verify that all invoices are accounted for and checked in on the branch copy of the manifest
Verify that all Invoices have proper POD
Verify that all cash and checks are present and have been handled in accordance with company policy  
 Is this covered in a separate doc?
 Yes, Driver Check-in.
Review what’s on the slide pointing out difference from the AM Gemba Walk

15. 3 What is X? SEAL Gemba Walk – The Leadership Lap
The Leadership Lap is a daily exercise to drive strong engagement and communications to develop a unified team 3
The Leadership Lap
To drive a culture of engagement at your DC
WHAT’S THE PURPOSE OF THE LEADERSHIP LAP?
Engagement with employees
Validation of progress on projects
Performance observations.
LEADERSHIP LAP 101
Meet and touch base with every employee on the shift.
Ask how their day is going, ask if there is anything challenges that you can help them with
Follow up on any projects or open items that you have for them, etc.
Don’t forget to ask about non-work topics (family, kids, sports) and check in frequently if there are any personal challenges that I know they may be experiencing to check on them and see how I can help.
Take notes to remember important information – you can also capture housekeeping/safety notes that you uncover during the exercise.
Review what’s on the slide.
Ask why this is a critical piece of the Gemba Walk. Take comments.
Ask what happens if this doesn’t exist. Take comments.
Tie it back to Gotta Know Them To Grow Them from the Coaching Excellence segment
Every day, take a minimum of 2 laps around the building to engage your workforce. Each lap should take minutes

16. The Accountability Board
Each ATD DC should have an Accountability Board to track any items that are not daily occurrences and provide a visual timeline and accountability to any root cause and counter measure items uncovered on the Gemba Walk
MHE not filled in. Fix by EOD.
Ben
Mark
Luis
Eddie
Jose
Tires fell over. Fix by EOD.
Dock Lights Not Working. Fix by Wed.
Tires fell over. Fix by EOD.
MHE not filled in. Fix by EOD
Ask who currently uses an accountability board.
If anyone does, ask them what the value has been and if there is any advice they would give to their teammates when using.
Review the importance of the accountability board.
MHE not filled in. Fix by EOD.
Dock Lights Not Working
Pallets blocking

17. Gemba Walk LSW
Refer the team to their Gemba LSW in their Toolkit

18. Let’s Practice – GEMBA Walk
What is X?
Let’s Practice – GEMBA Walk
Each DC Leader has a GEMBA WALK LSW and map of the DC where their GEMBA Walk will take place
You will be working in teams of 2 to do your GEMBA Walk Practice
Take 15 minutes to prepare together.
We will then transition to the DC. You will have 30 minutes to do your GEMBA Walk. There will be 1-2 SEAL facilitators shadowing you.
Once the GEMBA Walk is complete, your SEAL Facilitator will lead a debrief. Focus points will include:
What did you observe during your GEMBA Walk?
What did you add to the Accountability Board based on your GEMBA Walk?
What would you add to your Daily Report based on your GEMBA Walk?
Once the debrief is complete, everyone will come back to the main room for a team debrief
Prep for Practice…
Done PRIOR to delivering this module
Make sure you have staged the DC and know where each of the DC Leader teams will be doing their GEMBA Walk so that they do not run into each other.
Make sure to set up a mock Accountability Board for each team (placed where they would finish their GEMBA Walk)
Make sure to alert the DC Leader/Leads that this is happening.
On the DC maps, outline the area each of the GEMBA Walks will take place (you will need a different area for each team)
Things to stage include:
Misc. tires in aisle.
Dock lights(used for loading/unloading) not working
Fire Extinguisher out of its place
Equipment board – blank
Pallets blocking anyone of the following - aisle way / tunnel / or exit
Done DURING delivery of this module
Divide the DC Leaders into teams of 2. Assign 1-2 SEAL Facilitators to each team.
Make sure they take their toolkit during their Gemba Walk so they can refer to their LSW
Distribute a map of the DC to each team with their GEMBA Walk outlined
Tell the teams they have 15 minutes to prep
During the Practice
The teams will have 30 minutes to perform their GEMBA Walk
SEAL Facilitators shadow their assigned team
After Practice – 15 minutes
Staying in their GEMBA Walk area, each DC Leader team shares what they observed.
SEAL Facilitators share feedback on this
This should take no more than 15 minutes.
Once complete, teams go back to the main room

19. SEAL Leadership Academy Knowledge Check
Which answer is not part of the importance of Gemba Walks?
To find ways to practice “continuous improvement”
To problem solve
To improve customer satisfaction
Workforce engagement
To lend a hand to get work done on the DC floor
Where do you identify items discovered from your Gemba Walks?
On the accountability board
Tell your RSVP via
Share with your workforce during a huddle
Why is it important to perform leadership laps every day?
To improve workforce communications and engagement
To get to know your team
To drive a great culture with your employees
All of the above
None of the above
Ask them to take out their notepad and answer the following questions.
Give the team a few minutes.
When everyone is complete, unveil the answers.

20. SEAL Leadership Academy Knowledge Check
Which answer is not part of the importance of Gemba Walks?
To find ways to practice “continuous improvement”
To problem solve
To improve customer satisfaction
Workforce engagement
To lend a hand to get work done on the DC floor
Where do you identify items discovered from your Gemba Walks?
On the accountability board
Tell your RSVP via
Share with your workforce during a huddle
Why is it important to perform leadership laps every day?
To improve workforce communications and engagement
To get to know your team
To drive a great culture with your employees
All of the above
None of the above
Ask them to take out their notepad and answer the following questions.
Give the team a few minutes.
When everyone is complete, unveil the answers.