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
AnIllustration
Illustrationof
ofaaSystems
SystemsInefficiency
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

Before
Could be:
Movement of people walking around
Movement of documents through an office

After
Spaghetti Charts make poor layouts and
wasted motion obvious.

Example Spaghetti Chart

MTER

Nilay Tun /
Salk Teknik

Ege
Ege Yks
Ykselolu /
Salk Teknik
Salk

Alev nder / Salk

Teknik

Marion Hanm /
Akterya
Nesrin Koyiit /
Hayat Teknik

Fotokopi Makinas

Nesrin Glaydn /
Salk Tazminat

Glay
Glay Doan
Doan // Hayat
Hayat
Teknik
Teknik

ebnem Kaya /
Hayat Operasyon

Ayla zdemir /
Salk Tazminat

Ynetici
Fotokopi Makinas

Oturma
Grubu

Operasyon

Akterya

Meral
Meral ter
ter // Hayat
Hayat
Teknik
Teknik

Semin Diren /

Emre enol / Hayat

Teknik

Muhasebe

BLGE

Salk Taminat

Burak Uygun /

Esra uhadar /
Salk Teknik

Taeron / MFK

Blent Ondur /
Akterya

Il Arcan /
Salk

Taeron / MFK

Toplant Odas

SATI KANALI

Tazminat

Sat

Berkant Diigil /
Hayat Teknik

Asl Berksoylu /
Sekreter

Tahsilat
Giri

IPA
Printer

Mge Makarolu /
Hayat Tazminat

/ Hayat Tazminat

Oturma
Grubu

ebnemGndodu

Olgun Kntay / Genel Mdr Yardmcs

Giri
Dolap
Stun

Spaghetti Charts make poor layouts and

wasted motion obvious.

Mteri likileri

A. Giri

Spaghetti diagramming as part of Lean & 5S

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

Example :Central Processing Area -Before

Example :Central Processing Area -After

Spaghetti Chart Example - Before

As-Is Product Flow
Solder

Adhesive

Expense

Expense

Tools
Test

Desk
Incoming Material Racks

Column

Test

Desk
Final Benches/Inspection

Alligator

Drill Press
Paint

Oven

Spaghetti Chart Example - After

To-Be Product Flow

3 X 8
Bench

Hand Tools

Ex pense

Test
Cab le/F ix ture
Cab ine t

Ex pense

3 X 8
Bench

Station 5
Hand Tools

Station 6

Paint Process

Oven

Hand Tools

Ex pense

Flammable
Cabinet

3 X8
Bench

3 X 8
Bench

Station 4

Ex pens e

Station 7

Hand Tools

3 X8
Bench

Station 1

Ex pense

Riv eter

3 X 8
Bench

Station 2

Hand Tools

In
Ma comin
ter i
g
al C
art

3 X 8
Bench

Hand Tools

Drill
Press

Ex pense

Hand Tools

Station 3

Ex pens e

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

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

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?

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

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
Where
Where is
is There
There Excessive
Excessive or
or Unnecessary
Unnecessary Movement?
Movement?

Current State Flow Spaghetti Diagram

Receiving
Shipping

Hanging racks
One per store
Receive

FGs

Boiler

Shelves
Bulk & boxed

To store
Bag
Dry
Cleaning
Machines

Dry Clean
Spot

Racks
Dry Clean
Inspect/Sort

Racks

Dry Clean
Press/Hang

Roll in
basket
Shirt Racks
Laundry Flat Press

Laundry
Hand
finish

Laundry
Inspect/Sort
Laundry
Prep

Laundry Press/Hang-shirts

Dryers

Washers

DC

Supply
Shelves

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 ExerciseGetting 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.