Continuous improvement is the battle cry of most manufacturing companies. Truly embracing this mindset and driving change, however, requires transparent communication between those on the shop floor and those in the front office who make business decisions.
Gemba walks are a type of management practice that allows company leaders to connect with shop floor employees and directly observe the workplace. These visits allow them to better understand processes and discover areas for improvement. First implemented by Toyota Motor Corporation in Japan more than 70 years ago, Gemba walks have become an important practice for companies worldwide striving to improve efficiencies and gain a competitive advantage.
Gemba (現場) — the Japanese term for “actual place” or “where things happen”
The loud environment of a factory floor, however, makes it difficult for leaders to engage in conversations with workers or each other. Using headsets for Gemba Walk tours is the best way to maximize their effectiveness.
What to Look for in Gemba Walk Tour Guide Systems
When considering a Gemba Walk headset system, be sure it includes the following features:
Two-Way Communication
Interactive dialogue helps break down barriers between upper management and shop floor workers, so it’s critical to use a headset system with two-way communication.
Unlike one-way communication methods — or worse, simply yelling above the noise — two-way audio headsets allow participants to ask questions and share insights on the spot. This immediate feedback fosters collaboration and helps teams address concerns as they arise. By creating a conversational environment, you build trust and engagement, making the Gemba walk more impactful for driving continuous improvement.
Easy-to-Use Talk-Back Features
Keeping things simple is important. Workers and leadership don’t need to be tech-savvy to stay engaged when all it takes is the touch of a button to communicate back and forth. With intuitive controls, participants can quickly share their observations or respond to questions without fumbling with complex devices or interrupting the flow of the walk.
Hands-Free Operation
Not all audio headset systems require the users to push a button to talk. Some advanced headsets feature full-duplex, hands-free operation. The full-duplex function means that team members can communicate in real-time without ever having to push a button. Being completely hands-free makes it easier to take notes, demonstrate features and point out observations.
Noise Canceling Microphones
Noise-canceling microphones are essential for effective communication during Gemba walks in loud environments like factory floors. These specialized microphones filter out background noise, allowing participants to hear and be heard clearly when surrounded by the hum of machinery or other industrial noises. The noise-canceling features also improve safety. Rather than turning up the volume, participants can speak and be heard at a conversational level.
Language Interpretation Mode
Considering additional features for your headset system is always a good idea in the event you want to use it for other types of events like investor day tours or when showing a prospective employee your facility. The language interpretation feature allows international guests or non-English-speaking employees to hear their interpreter on a separate channel from the main conversation.
The nice thing about a tour guide system is that it can be dual-purpose, serving as your Gemba walk communication system one day and offering factory tours the next.
RELATED: Manufacturing Plant Tour Planning Guide
Recommended Audio Communication Solutions
When choosing a Gemba walk system, there’s no one-size-fits-all solution, so make sure you work with a provider who offers options. Each facility and team are different. At Implecho, we offer multiple systems that are tailored to your unique needs.
Here are our top three recommendations for Gemba Walks based on common scenarios.
ListenTALK by Listen Technologies
ListenTalk is an excellent option for Gemba walks, offering a portable, easy-to-use communication system. Features include:
- Two-way communication
- Noise-canceling technology
- Multiple headset/earbud options
- Hands-free microphone option
- Push-to-talk functionality
- Language interpretation mode
- Encrypted audio for privacy
Williams AV Digi-Wave
The Williams AV Digi-Wave two-way system boasts many of the same features as ListenTALK like noise-canceling technology and language interpretation mode, but in a more rugged housing. Government agencies often rely on these industrial-strength units for harsh environments. It also comes with NRR-rated headset options.
CrewPlex
CrewPlex is among the few two-way headset systems that feature truly hands-free full-duplex technology for up to 10 people in a group. While other systems can be configured with hardhats, CrewPlex is the most versatile and offers multiple NRR-rated headset options. Users can also mute their microphones by simply flipping the microphone boom above their hard hats. It’s rugged and doesn’t require a base station or FCC license, making it an easy choice for many.
Request a Gemba Walk Headset System Demo
You’ll want a Gemba walk system that meets your needs for years to come. That’s why we strongly encourage you to request a free demo to try in your facility. A trial system not only helps you assess whether the features align with your goals but also gives your team confidence in using the technology.
By experiencing the system firsthand, you’ll minimize the risk of investing in equipment that doesn’t fully support your Gemba walk objectives. Here at Implecho, we work with you to narrow down your options and will send you a fully functional system to try on your own.
Give us a call at 866-428-8608 or share your contact information and we can talk through the options.
