Spaghettidiagram

Spaghettidiagram, also called a spaghetti diagram, is a simple visual tool used to map the physical path of a person, object, or information as it moves through a process. Drawn on a floor plan or process map, movement lines show the actual travel routes and distances involved, helping to reveal how work flows in a space.

The technique emerged from time-and-motion studies and has become common in lean manufacturing and operations improvement. It is used to identify unnecessary motion, back-and-forth travel, and other sources of waste that increase cycle times and handling costs. Spaghetti diagrams are applied in manufacturing, warehousing, healthcare, and service settings to inform layout and workflow changes.

Creating a spaghetti diagram involves selecting a process and a time window, then recording the path of the worker or material across the facility on the plan. Each traversal is drawn as a line, often color-coded for different tasks or shifts. Short, looping lines indicate localized activity, while long, crossing lines point to excessive movement. The diagram is typically used with timing data or other analysis to guide rearrangements of equipment, supplies, or workstations.

Limitations include that it provides a snapshot rather than a complete time-motion study, and lines can clutter the map in complex processes. When used with other data—such as cycle times, distances, and throughput metrics—a spaghetti diagram supports practical workflow optimization without serving as a sole solution.