LSS Tool - The Spaghetti Diagram
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LSS Tool – The Spaghetti
DiagramAgenda • 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
ofaaSystem’s
System’sInefficiency
InefficiencySpaghetti 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
MÜŞTERİ SATIŞ KANALI
Nilay Tunç / Işıl Arıcan / Esra Çuhadar / Ege
Ege Yüks
Yükseloğlu / Alev Önder / Sağlık Nesrin Gülaydın / Ayla Özdemir /
Sağlık Teknik Sağlık Sağlık Teknik Sağlık Teknik
Sağlık Teknik Sağlık Tazminat Sağlık Tazminat Muhasebe
Toplantı Odası
BÖLGE
Taşeron / MFK
Yönetici
Fotokopi Makinası
Bülent Ondur / Marion Hanım /
Aktüerya Aktüerya
Oturma
Fotokopi Makinası Nesrin Koçyiğit / Gülay
Gülay Doğan
Doğan // Hayat
Hayat Şebnem Kaya / Grubu
Taşeron / MFK
Operasyon
Hayat Teknik Teknik
Teknik Hayat Operasyon
Burak Uygun /
Sağlık Taminat
Semin Diren /
Aktüerya
Tazminat
Satış
Emre Şenol / Hayat Meral
Meral Öter
Öter // Hayat
Hayat Berkant Dişçigil /
Teknik Teknik
Teknik Hayat Teknik
Aslı Berksoylu /
Tahsilat
Sekreter
Giriş
IPA
Printer
ŞebnemGündoğdu
/ Hayat Tazminat
Olgun Küntay / Genel Müdür Yardımcısı
Oturma
Müge Makaroğlu /
Grubu
Hayat Tazminat
Müşteri İlişkileri
Giriş A. Giriş
Dolap
Sütun
Spaghetti Charts make poor layouts and
wasted motion obvious.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 AfterExample :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
OvenSpaghetti Chart Example - “After”
‘To-Be’ Product Flow
Paint Process Station 6 Station 5
Cab ine t
Hand Tools
Hand Tools
Cab le/F ix ture
Oven
Ex pense
Ex pense
Test
3’ X 8 ’ 3’ X 8 ’
Bench Bench
Ex pens e
Station 4
Station 7
Bench
3’ X8’
Flammable
Hand Tools
Cabinet
Ex pense
Hand Tools
3’ X 8 ’
Bench
Ex pens e
Station 3
Bench
3’ X8’
Hand Tools
Hand Tools
Hand Tools
Ex pense
Ex pense
Drill 3’ X 8 ’ 3’ X 8 ’
Riv eter
Press Bench Bench
In
Ma comin
ter i g
al C
art
Station 1 Station 2Spaghetti 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
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
Hanging racks Boiler
Receiving One per store Shelves
Shipping FG’s Bulk & boxed
Receive
To store
Bag
Dry Clean Dry Clean Dry
Racks
Press/Hang Spot Cleaning
Machines
Dry Clean
Racks
Inspect/Sort
Roll in
basket
Shirt Racks
Laundry
Laundry
Hand
Laundry Flat Press Inspect/Sort
finish
Laundry
Prep Supply
Shelves
Laundry Press/Hang-shirts Washers
Dryers
DC LWhat’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 DiagramNext
•Form teams of 2 – 4 people :
Steps
•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.You can also read
