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

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 SATI KANALI
Toplant Odas Nilay Tun / Salk Teknik Il Arcan / Salk Esra uhadar / Salk Teknik Ege Yks Ege Ykselolu / Salk Salk Teknik

Alev nder / Salk Teknik

Nesrin Glaydn / Salk Tazminat

Ayla zdemir / Salk Tazminat

Muhasebe

Taeron / M FK

BLGE
Ynetici Fotokopi Makinas

Blent Ondur / Akterya

Marion Hanm / Akterya Fotokopi Makinas Nesrin Koyiit / Hayat Teknik Glay Doan // Hayat Glay Doan Hayat Teknik Teknik

Taeron / M FK

ebnem Kaya / Hayat Operasyon

Oturma Grubu

Operasyon

B urak U ygun /

S alk Tam inat

S in D em iren /

A kterya

Tazminat

Emre enol / Hayat Teknik

Meral ter // Hayat Meral ter Hayat Teknik Teknik

Berkant Diigil / Hayat Teknik

Sat

Asl Berksoylu / Sekreter Giri

Tahsilat

IPA
Printer
ebnemG ndodu /H ayat Tazm inat

Olgun Kntay / Genel Mdr Yardmcs

Oturma Grubu

Mge Makarolu / Hayat Tazminat

Mteri likileri

Giri Dolap Stun

A. Giri

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 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 Incoming Material Racks Desk

Column Desk

Test

Final Benches/Inspection

Alligator

Drill Press Paint Oven

Spaghetti Chart Example - After

To-Be Product Flow
Paint Process

Station 6
Hand Tools
Test x re Cab le/F i tu e Cab in t

Station 5
Hand Tools

Ex pe nse

3 X 8 Bench

Ex pe nse

3 X 8 Bench

Oven

Ex pe e ns

Station 7
mable Flam Cabinet
Hand Tools

E pe x nse

3 X 8 Bench

Hand Tools

Ex pe e ns

Hand Tools

Hand Tools

Drill Press
In Ma comin ter i g al C art

3 X 8 Bench

Riv eter

3 X 8 Bench

Station 1

Station 2

Hand Tools

Ex pe nse

Ex pe nse

Station 3

Station 4

3 X8 Bench 3 X8 Bench

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 Long lead times Lost product Defects What else?

The result of these problems may be:

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

Current State Flow Spaghetti Diagram

Receiving Shipping Hanging racks One per store Receive FGs Shelves Bulk & boxed Boiler

To store Bag Dry Clean Press/Hang Racks Racks Dry Clean Inspect/Sort Dry Clean Spot Dry Cleaning Machines

Roll in basket Shirt Racks Laundry Flat Press Laundry Hand finish Laundry Inspect/Sort Laundry Prep Laundry Press/Hang-shirts Dryers Washers

Supply Shelves

DC

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.