Spaghetti Diagrams—

Lean Manufacturing

3 December 2015
Rahul Laxman Iyer
Lean Six Sigma Black Belt
ASQ Certified Quality Engineer
Mesa AZ USA
 Introduction
● What is a Spaghetti Diagram
● Uses of a Spaghetti Diagram
● Benefits of a Spaghetti Diagram
● Developing a Spaghetti Diagram
● Examples of Spaghetti Diagrams (Albeit
Seasonal Examples)
 What is a Spaghetti
Diagram
● 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
– Present State / Current State
– Future State
● It is an illustration of a systems
inefficiency
 What is a Spaghetti
Diagram (Continued)

Current State Spaghetti Diagram of a

Creative Agency
 Uses of a Spaghetti
Diagram
● Identify Waste in a Physical Manner for
a process
● Identify Wasted Motion & Confusing
Flows of Products and Services
● Built around specific work area layouts
– Depicts a Present State / Current State
– Defines Goal Through a Future State
 Benefits of a Spaghetti
Diagram
● 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
 Developing a Spaghetti
Diagram
● 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 Diagrams make poor
layouts and wasted motion obvious
 Spaghetti Diagram
Current State & Future
State
In a Medical X-Ray & Imaging Department
 Examples of Spaghetti
Diagrams
In a Medical Hospital
 Examples of Spaghetti
Diagrams (continued)
In a Manufacturing / Assembly Operation
 Seasonal Example Of A
Spaghetti Diagram
Santa's North Pole Shipping Center
 Conclusion
● What is a Spaghetti Diagram
● Uses of a Spaghetti Diagram
● Benefits of a Spaghetti Diagram
● Developing a Spaghetti Diagram
● Examples of Spaghetti Diagrams
I look forward to helping you to Improve Quality,
Reduce Cost, and Improve Delivery through the
application of Continuous Improvement, Lean, Six
Sigma, and Kaizen in your processes.

Contact me, I am currently looking for new opportunity

in metro Phoenix AZ USA

Rahul Laxman Iyer

http://www.linkedin.com/in/rahuliyer
220 North 22nd Place Unit 1008
Mesa AZ 85213-8380 USA
Tel: +1-623-570-2848
rahulduong@cox.net