LSS Tool The Spaghetti

Diagram
Agenda
What is a Spaghetti Diagram
Uses of a Spaghetti Diagram
Examples of a Spaghetti Diagram
How to put together a Spaghetti Diagram
Spaghetti Exercise
Questions
What is a Spaghetti Chart?
a.k.a Physical Process Map, Point-to-Point Flow Chart, or
Work-flow Diagram
Used to Graphically Depict The Movement of the Product or
Documents (or people!) through a Process
An Illustration of a Systems Inefficiency
An Illustration of a Systems Inefficiency
Spaghetti Chart to Identify Waste
Differ from Detailed Process Maps and other Value Stream Maps
Do not require sequential process steps
Seek to highlight wasted motion
Built around specific work area layouts
Construction:
Sketch current work area arrangement in detail
Draw a line to describe every trip each person or unit makes from
one point to another
As more trips are made, more lines are added
The more wasteful/redundant trips, the thicker the chart is with
lines
Spaghetti Charts make poor layouts and wasted motion
obvious in the Value Stream Analysis.
Example Spaghetti Chart
Spaghetti Charts make poor layouts and
wasted motion obvious.
Before
After
Could be:
Movement of people walking around
Movement of documents through an office
Example Spaghetti Chart
Spaghetti Charts make poor layouts and
wasted motion obvious.
Fotokopi Makinas
Printer
Dolap
Stun
Toplant Odas
Olgun Kntay / Genel Mdr Yardmcs
Giri
Giri
Asl Berksoylu /
Sekreter
Emre enol / Hayat
Teknik
Meral ter / Hayat
Teknik
Blent Ondur /
Akterya
Nesrin Koyiit /
Hayat Teknik
Glay Doan / Hayat
Teknik
Esra uhadar /
Salk Teknik
Ege Yks
Salk
Marion Hanm /
Akterya
Nilay Tun /
Salk Teknik
Il Arcan /
Salk
B
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Oturma
Grubu
Fotokopi Makinas
A. Giri
Mge Makarolu /
Hayat Tazminat
Meral ter / Hayat
Teknik
Berkant Diigil /
Hayat Teknik
Nesrin Glaydn /
Salk Tazminat
Ayla zdemir /
Salk Tazminat
Glay Doan / Hayat
Teknik
ebnem Kaya /
Hayat Operasyon
Ege Ykselolu /
Salk Teknik
Alev nder / Salk
Teknik
Mteri likileri
IPA
Muhasebe
Sat
Tazminat
Operasyon
Ynetici
MTER SATI KANALI
Tahsilat
BLGE
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Construct a spaghetti diagram
draw arrows depicting workflow
optimize the movement of the product and employee
revise your layout to minimize unnecessary motion
Before After
Spaghetti diagramming as part of Lean & 5S
Example :Central Processing Area -Before
Example :Central Processing Area -After
Spaghetti Chart Example - Before
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Column Test
Desk
Test
Desk
A
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Oven
Drill Press
Alligator
Solder
Expense
Expense
Tools
As-Is Product Flow
Incoming Material Racks
Spaghetti Chart Example - After
To-Be Product Flow
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Bench
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Expense
3

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Hand Tools
Expense
3

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Hand Tools
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Bench
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Riveter
Drill
Press
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T e s t
C a b l e / F ix t u r e
C a b i n e t
Paint Process Station 6 Station 5
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Station 1 Station 2
Station 7
Oven
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Spaghetti Chart Advice
Dont just draw one line for a route
draw a line for every trip
Color code
to distinguish different people or products
Look for differences
by time of day, person, job function, etc.
Construct a Spaghetti Chart as you walk the process
Use whatever is useful to aid communication and understanding.
Looking at Flow using Spaghetti Diagram
Track the route of the product
Measure the distance traveled
Look for potential problems:
Long route
Confusing routes
Back tracks/loop backs
Crossing tracks
The result of these problems may be:
Long lead times
Lost product
Defects
What else?
Does the product/process move from one value-adding step right to the next one?
A Spaghetti Diagram as a track of the physical flow of a product
Benefits of Spaghetti Charting
Identifies Inefficiencies in Area/Plant Layout
Identifies Opportunities For Less Handling
Identifies Opportunities For Better Workforce
Communication
Identifies Resource Allocation Opportunities
Identifies Opportunities For Safety Improvements
Construction of a Spaghetti Chart
Where is There Excessive or Unnecessary Movement?
Where is There Excessive or Unnecessary Movement?
Sketch or Obtain Facility Layout, Map
Become the Product
Walk the Process As if Your Were the Product (a requisition,
a specimen Tube, a file, etc.)
Mark the Process Locations and Steps on the Layout
Connect the Dots in Accordance With the Actual Travel or Walk
Patterns -- use arrows to show workflow
Calculate the Distance
Revise layout to minimize unnecessary motion and conveyance
time
Get concurrence on a new layout and implement it
Current State Flow Spaghetti Diagram
Receiving
Shipping
Hanging racks
One per store
Shelves
Bulk & boxed
Boiler
To store
FGs
Roll in
basket
Dry
Cleaning
Machines
Supply
Shelves
Washers
Dryers
Laundry
Prep
Dry Clean
Spot
Dry Clean
Inspect/Sort
Laundry
Inspect/Sort
Laundry
Hand
finish
Laundry Flat Press
Laundry Press/Hang-shirts
Shirt Racks
Dry Clean
Press/Hang
R
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Racks
Receive
Bag
DC L
Whats Wrong with this Flow?
There is no continuous flow
Travel distance is long and time consuming
The track is confusing
There are a number of collision points
It is difficult to determine what to work on next
There are many opportunities for product to wait
What else?
Questions
Exercise
Spaghetti Exercise
(Handout)
Spaghetti Chart Exercise-
Getting Lunch
Get lunch as directed by the provided SOP (handout)
Use the Cafeteria Layout provided in the SOP
Create a Spaghetti Diagram
Next Steps
Form teams of 2 4 people :
Get With Your Team and Identify Improvement Opportunities:
How Can We Reduce Travel Distance?
How Can We Reduce Product Handling?
How Can We Layout the Process to Improve Workforce Communication?
Can We Positively Impact Employee Safety?
Develop Plans For Implementation
Using a flipchart, re-layout the cafeteria to minimize travel through the
cafeteria in addition to reducing the opportunity for an accident.
Choose a spokesperson to explain your improvements to the class.