Using Spaghetti Diagram to Optimize a Process

Spaghetti diagram is a visual representation using a continuous flow line to trace the path of an item or activity through a process. As a process analysis tool, the continuous flow line enables process teams to identify redundancies in the work flow and opportunities to accelerate process flow. It is a quick and easy way to track distances of parts and people on the production floor. It helps to reveal all inefficiencies of a layout.

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Using the Spaghetti Diagram to Improve Work Layout

• The most connected tasks should be placed as much as close to each other, as they are the most frequently used paths.
• The paths with longest distance and longest waiting time also should be relocated to reduce the distance.
• Most of the solutions will appear when the tasks are arranged in ‘C’ shape, ‘U’ shape, Rectangular or Circular shape.
• Depending of the workflow, user can change and choose the appropriate shape. User can also arrive at a customized shape based on his requirement.

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Benefits of the Spaghetti Diagram

1. It helps to identify inefficiencies in Area/Work layout.
2. It helps in identifying the wastes of transportation, motion.
3. It helps in reducing the Non value Added time spent in identifying missed products, confusion in order of processing items etc.
4. It helps to improve the efficiency and reduce the fatigue of employees due to unnecessary movements.
5. It improves Occupational safety of the workers.

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How to draw a spaghetti Diagram

• Plot the physical process flow (Layout) on a paper by approximately scaling down the distance between tasks and their point of operation.
• Team up the workers using the system, asking them to draw.

1. The flow of materials, papers. 
2. The walking pattern of people.
3.  Waiting time and stoppages at different points of the process.

• These should be drawn in different colors to differentiate the exact problem being addressed.
• Lines should be redrawn for every trip or every movement. It should be drawn in such a way that thicker the line, the more complex the process is. Care should be taken not to miss minute tasks, small trips and repeated motions.

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About the Author

Adebayo is a thought leader in continuous process improvement and manufacturing excellence. He is a Certified Six Sigma Master Black Belt (CSSMBB) Professional and Management Systems Lead Auditor (ISO 9001, 45001, ISO 22000/FSSC 22000 etc.) with strong experience leading various continuous improvement initiative in top manufacturing organizations. 

You can reach him here.