the spaghetti diagram
TRANSCRIPT
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.