Yamazumi Workload Chart
Stack work elements by station or operator, compare workload with takt time and identify overload, waiting and opportunities to rebalance work.
Purpose and method
Stack work elements by operator or station and compare each load with takt time.
When to use it
Use Yamazumi to reveal overload, idle time, uneven work content and balancing opportunities.
Core principle
Yamazumi visualises element-level workload against demand. It is most useful when standard work elements and observed times are reliable.
What the interactive module provides
- Stacked workload chart
- Takt-time comparison
- Balancing opportunities
- stacked workload chart, overload visibility and alternative balanced assignments
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.
01
Recommended workflow
Stack work elements by station or operator, compare workload with takt time and identify overload, waiting and opportunities to rebalance work.
- 1
Confirm takt and standard work scope
- 2
Break work into observable repeatable elements
- 3
Measure representative element times
- 4
Stack elements by current assignment
- 5
Rebalance within precedence, skill and ergonomic constraints
02
Practical example
Three operators have workloads of 47, 68 and 39 seconds against a 60-second takt. Reassigning inspection and packaging elements creates 52, 53 and 49 seconds.
Calculation or verification principle
Workload per station = sum of assigned element times. Balance loss = 1 − total work content ÷ (number of stations × cycle target).
Required inputs → Expected outputs
- Required inputs
- takt or target cycle, work elements, observed times, station assignment, sequence and constraints
- Expected outputs
- stacked workload chart, overload visibility and alternative balanced assignments
03
Common mistakes to avoid
×
Balancing unstable or undefined work
×
Using averages that hide recurring variation
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Moving tasks without precedence or ergonomic review
×
Treating takt time as a personal performance target
04
Frequently asked questions
What data do I need to use this tool?
Prepare takt or target cycle, work elements, observed times, station assignment, sequence and constraints.
What result does the module produce?
The module produces stacked workload chart, overload visibility and alternative balanced assignments.
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 →Yamazumi Workload Chart
Stack work elements by station or operator, compare workload with takt time and identify overload, waiting and opportunities to rebalance work.