Before deciding, connect to the field: activate 3G!

Are you facing recurring problems on your production lines despite multiple corrective actions? Do your meetings drag on with assumptions like "we think that..." without real progress on the ground? The 3G method offers a clear and powerful response: go see, observe, measure.

In an industrial SME, getting the right diagnosis from the start is essential to avoid wasting time, energy... and credibility. This is where the 3G – Gemba, Genbutsu, Genjitsu (yes, more Japanese words!) – comes in, putting operational common sense back to the heart of decisions.

Why the 3G are essential in an industrial SME

In industrial environments, especially in SMEs, resources are limited. It is vital to focus improvement efforts in the right places. Yet, too often, decisions are made from a distance without a real understanding of the problem.

Result: the actions taken are inappropriate or incomplete, the same mistakes recur, and the operators lose confidence. By redirecting managers to the field, the 3G enable:

• To solve problems faster and sustainably

• To restore managerial credibility

• To gather unfiltered and real information

• To re-engage teams around "real work"

In an industrial performance context, it is better to have a well-understood problem than a poorly applied solution.

The 3G: a simple and powerful tool to reconnect management to the field

The 3G approach is based on three Japanese principles from Lean:

• Gemba – The real place: go to the field, where things actually happen.

• Genbutsu – The real object: observe what is actually at stake (machines, products, tools, defects…).

• Genjitsu – The real data: rely on measurable, quantified, observed facts.

Example:

The management team of an SME observes a gradual decrease in productivity on a production line.

In a meeting, assumptions pile up: "We're short-staffed", "The new software slows everything down", "The operators are less motivated".

💡 The production manager decides to apply the 3G method:

1. Gemba: he goes to the line several times, at different times of the day. He observes the flows, gestures, and minor disruptions.

2. Genbutsu: he inspects parts in production, notices that many products need to be repositioned manually at a specific stage of production.

3. Genjitsu: he measures the micro-stops on this machine, retrieves the actual cycle times, and analyzes the causes of interruptions.

Result: it was neither a HR issue nor software related. A simple worn-out jig was causing the systematic misalignment of parts → leading to extra movements and hidden time losses.

Thanks to this on-site analysis, the solution was simple: replace a tool costing €120... to regain 10% productivity.

Without field visits, we would have probably launched a training session on the new software or looked for temp workers. With the 3G, we found the real cause and acted where it mattered.

How to implement the 3G in your workshop?

1. Prepare the approach

• Objective: understand a recurring problem with facts, not assumptions.

• Who?: one manager + the relevant operators.

• Duration: 2 to 3 short site visits over a few days.

2. Gemba – Go to the real place

• Go directly to the concerned area, at different key moments.

• Be an observer first, without judging.

• Take notes or photos directly on site.

3. Genbutsu – Look at the real object

• Study the parts, the machines, the gestures.

• Manipulate if possible (while respecting safety and quality guidelines).

• Talk with operators to identify pain points.

4. Genjitsu – Measure what you see

• Collect precise data: duration, frequency, deviation from the standard.

• Rely on tracking systems (ERP, job sheets...).

• Stick to what you've seen, avoid interpretations.

5. Analysis and action

• Share your findings with the operators present.

• Search together for possible root causes.

• Take immediate action if a “quick win” is possible.

Best practices & pitfalls to avoid

✅ Make the approach visible:

• Set a regular Gemba slot for managers.

• Display observations and actions directly in the workshop.

✅ Practice active listening:

• Let the operator express themselves without interruption.

• Validate what you see together to avoid misunderstandings.

❌ Do not turn Gemba into a meaningless tour: Without a clear objective, it becomes an empty ritual.

❌ Do not remain passive: An obvious mess or a poorly organized tool? Correct it immediately. Every quick action shows the team they're being heard.

Conclusion: Observe to act better

The 3G method is a simple yet highly effective approach to bring common sense back to the field. By reconnecting managers to the real-world challenge of operations, it enables faster, smarter, more effective decisions.

👉 Implement your first 3G visits this week: choose a workstation, set your objective, and start observing. Your operators will quickly see the difference… and so will you.

Don't wait to make the field your best source of continuous improvement!

🔍 Explore even more tools, thematic courses, and indicators in IndustrialOS Guide: https://leguide.industrialos.io

➡️ Explore, test, progress at your own pace.