This document provides instructions for creating and using a spaghetti diagram, a Lean tool that maps the transportation and motion paths in a process to identify waste. It describes how to draw the paths from beginning to end on a scaled layout of the work area. Measuring times and distances helps identify overlapping paths indicating waste. The team then works to redraw an ideal process flow and considers costs versus efficiency gains of potential improvements. Practical application involves mapping three regular processes to find excessive motion or transportation that could be streamlined.

1. Section & Lesson #:
Pre-Requisite Lessons:
Complex Tools + Clear Teaching = Powerful Results
Spaghetti Diagram
Lean – Lesson 9
An introduction to the Spaghetti Diagram, a Lean tool that helps expose
motion and transportation forms of waste.
Lean #05 – 7 Deadly Wastes
Copyright © 2011-2019 by Matthew J. Hansen. All Rights Reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted by any means
(electronic, mechanical, photographic, photocopying, recording or otherwise) without prior permission in writing by the author and/or publisher.

2. o What is a Spaghetti Diagram?
• It visually maps the TRANSPORTATION (path of a product’s movement) or MOTION (path of
equipment or operator movement) in a process in order to expose potential waste.
 It is usually used for mapping the paths of movement within a fixed environment like an office floor, a
warehouse, between multiple buildings on a campus, etc.
o How do you create a spaghetti diagram?
• Map the area on a sheet of paper.
 For example, if it’s for a warehouse, be
sure to draw (close to scale) any walls,
equipment, shelving, etc.
• Draw the path from beginning to end.
 Paths must be drawn continuously from
the beginning of the flow to its end.
 Each movement bouncing multiple times
between the same location should be
individually drawn in order to highlight
that overlapping movement.
 Do not draw through walls, equipment or
shelves; draw actual paths taken.
 Measure time/distance for each path.
• Review with your team
 The team should agree that the paths drawn are accurate; any overlapping path is potential waste.
• Re-draw an ideal state with your team
 When evaluating an ideal state, compare cost to create that ideal state vs. any efficiency gained from it.
Spaghetti Diagram
Copyright © 2011-2019 by Matthew J. Hansen. All Rights Reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted by any means (electronic, mechanical, photographic,
photocopying, recording or otherwise) without prior permission in writing by the author and/or publisher.
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3. Practical Application
o Identify at least three processes you interact with regularly that may involve motion or
transportation types of waste.
• Draw on a sheet of paper the layout of the areas affected by the process.
 Follow from beginning to end an item flowing through the process and map out the motion of the people
involved in the process.
 In addition, separately map out the transportation of the item itself through that same process.
• What areas stand out as having excessive motion or transportation?
 How can the motion or transportation be minimized in the process?
 What costs may be involved for streamlining the process?
 What savings can be expected for streamlining the process?
Copyright © 2011-2019 by Matthew J. Hansen. All Rights Reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted by any means (electronic, mechanical, photographic,
photocopying, recording or otherwise) without prior permission in writing by the author and/or publisher.
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