genbutsu

Genbutsu, from the Japanese 現物, literally "the actual thing," refers to tangible items or events used as the basis for analysis in lean management and problem solving. It is closely related to genba, the actual place, but focuses on the object itself rather than the location. The concept encourages going to the source to observe the real object or process that is the subject of inquiry, rather than relying on reports or secondhand data.

In practice, genbutsu means collecting direct evidence by examining the product, machine, or work process, measuring relevant attributes, and watching how work is performed. This direct observation supports fact-based decision making, root-cause analysis, and PDCA cycles. It is commonly used with the 5 Whys technique to uncover underlying issues.

Examples include inspecting a defective part on the line, checking tool setups, validating a process parameter at the point of operation, or reviewing a failure in the field. By experiencing the genbutsu firsthand, teams can develop more accurate countermeasures and avoid solution biases driven by abstraction or rumor.

Beyond manufacturing, genbutsu is applicable to services and software, where visibility of the actual artifact or user interaction is sought to understand issues and improve outcomes. The term remains a core element of lean thinking and the Toyota Production System.