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 System’s InefficiencyAn Illustration of a System’s 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

linesSpaghetti 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 Makinası

Printer

Dolap

Sütun

Toplantı Odası

Olgun Küntay / Genel Müdür Yardımcısı

Giriş

Giriş

Aslı Berksoylu / Sekreter

Emre Şenol / Hayat Teknik

Meral Öter / Hayat Teknik

Bülent Ondur / Aktüerya

Nesrin Koçyiğit / Hayat Teknik

Gülay Doğan / Hayat Teknik

Esra Çuhadar / Sağlık Teknik

Ege YüksSağlık

Marion Hanım / Aktüerya

Nilay Tunç / Sağlık Teknik

Işıl Arıcan / Sağlık

Bur

ak U

ygun

/ Akt

üery

a

Oturma Grubu

Fotokopi Makinası

A. Giriş

Müge Makaroğlu / Hayat Tazminat

Meral Öter / Hayat Teknik

Berkant Dişçigil / Hayat Teknik

Nesrin Gülaydın / Sağlık Tazminat

Ayla Özdemir / Sağlık Tazminat

Gülay Doğan / Hayat Teknik

Şebnem Kaya / Hayat Operasyon

Ege Yükseloğlu / Sağlık Teknik

Alev Önder / Sağlık Teknik

Müşteri İlişkileri

IPA

Muhasebe

Satış

Tazminat

Operasyon

Yönetici

MÜŞTERİ SATIŞ KANALI

Tahsilat

BÖLGE

Taşe

ron

/ MFK

Taşe

ron

/ MFK

Semin D

iren / Sağlık Tam

inat

Şebnem G

ündoğdu / H

ayat Tazminat

Oturma Grubu

• Construct a spaghetti diagram

• draw arrows depicting workflow

• optimize the movement of the product and employee

• revise your layout to minimize unnecessary motionBefore After

Spaghetti diagramming as part of Lean & 5S

Example :Central Processing Area -Before

Example :Central Processing Area -After

Spaghetti Chart Example - “Before”Paint

Final Benches/Inspection

Column Test

Desk

Test Desk

Adhesive

Oven

Drill Press

Alligator

Solder

ExpenseExpense

Tools

‘As-Is’ Product Flow

Incoming Material Racks

Spaghetti Chart Example - “After”

‘To-Be’ Product Flow

Expe

nse

3’ X 8’Bench

Han

d To

ols

Expe

nse

3’ X 8’Bench

Han

d To

ols

Ex pense

3’ X 8’Bench

Hand Tools

Ex pense

3’ X 8’Bench

Hand Tools

Expe

nse

3’ X 8’Bench

Han

d To

ols

Expe

nse

3’ X 8’Bench

Han

d To

ols

Expe

nse

3’ X 8’Bench

Han

d To

ols

RiveterDrillPress

Flam

mab

leCa

bine

t

TestCable/Fixture

Cabinet

Paint Process Station 6 Station 5

Stat

ion

4St

atio

n 3

Station 1 Station 2

Station 7

Oven

IncomingMaterial Cart

Spaghetti Chart Advice

• Don’t 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

ReceivingShipping

Hanging racksOne per store Shelves

Bulk & boxed

Boiler

To store

FG’s

Roll inbasket

DryCleaningMachines

SupplyShelves

WashersDryers

LaundryPrep

Dry CleanSpot

Dry CleanInspect/Sort

LaundryInspect/Sort

LaundryHandfinishLaundry Flat Press

Laundry Press/Hang-shirts

Shirt Racks

Dry CleanPress/Hang

Rac

ks

Racks

Receive

Bag

DC L

What’s 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.