Spaghetti Diagram
Trace real movement on a scaled layout, measure distance and frequency, and compare current and proposed routes before changing the workplace.
Purpose and method
Trace movement through a workplace layout and quantify distance, time and unnecessary transport.
When to use it
Use a spaghetti diagram when operators, material, tools or forklifts travel through complex or repetitive routes.
Core principle
The diagram records actual movement of one defined subject during a representative period. The line alone is insufficient without scale, frequency and purpose.
What the interactive module provides
- Movement routes
- Distance calculation
- Before-and-after layout comparison
- visual route, total distance, comparison of alternatives and relocation opportunities
Professional verification: The module supports learning, analysis and documentation. Verify results against actual process conditions, internal standards, safety requirements and competent professional judgement before implementation.
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Recommended workflow
Trace real movement on a scaled layout, measure distance and frequency, and compare current and proposed routes before changing the workplace.
- 1
Choose one subject and representative period
- 2
Set the drawing scale and fixed reference points
- 3
Observe and plot every movement in sequence
- 4
Calculate distance and frequency by purpose
- 5
Test a safer, shorter layout before permanent change
02
Practical example
An operator walks 1.4 km per shift between assembly, printer and material rack. Relocating labels and point-of-use material reduces the route to 480 m.
Calculation or verification principle
Distance per period = route length per cycle × cycle frequency. Saving = current distance − proposed distance; convert walking distance to time only with a justified speed.
Required inputs → Expected outputs
- Required inputs
- scaled layout, tracked person/material, route points, frequency, observation period and movement purpose
- Expected outputs
- visual route, total distance, comparison of alternatives and relocation opportunities
03
Common mistakes to avoid
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Drawing the expected route instead of observing
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Omitting scale or repeated frequency
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Combining several people into one unreadable line
×
Shortening distance while creating ergonomic or safety risk
04
Frequently asked questions
What data do I need to use this tool?
Prepare scaled layout, tracked person/material, route points, frequency, observation period and movement purpose.
What result does the module produce?
The module produces visual route, total distance, comparison of alternatives and relocation opportunities.
Can I implement the result without further review?
No. Treat the output as a structured engineering and improvement aid. Verify source data, assumptions, safety, quality, legal requirements and local process conditions with competent responsible people before implementation.
LEAN Toolbox
Open interactive tool →Spaghetti Diagram
Trace real movement on a scaled layout, measure distance and frequency, and compare current and proposed routes before changing the workplace.