LEAN Tools 1: the Spaghetti Diagram

IMG_1660The efficiency and effectiveness of a department is impacted by the layout of the work area.  Similarly,  a poorly designed work process can result in wasted movement that wastes time and more importantly, can cause fatigue in staff and residents. When measurements are taken, both before and after modifications are made, the result can be very surprising.

The name Spaghetti Diagram comes from the original drawing where the lines resemble a plate of spaghetti. As a rule of thumb, the more convoluted the diagram, the more opportunity for improvement.

The measurement process is very simple. Staff are observed carrying out their tasks and the path they follow is mapped out on a floor plan. The floor plan does not have to be accurate. A sketch of the area, showing approximate proportional distances will suffice. Each movement is recorded as a separate line. In order to get accurate measurements of distance travelled, staff were asked to wear a simple pedometer. The number of steps were recorded. The time to complete the task, from start to finish was also captured.

Once the initial diagrams are drawn and steps counted, a unit is able to do an analysis. Several questions need to be answered. What is the ideal path for an employee to take to accomplish the task in the least amount of steps? Can the unit be reconfigured? Who will do the reconfiguration? When will it be done? Once the changes have been made, the measurement process is repeated, drawing new spaghetti diagrams, measuring distance travelled and time to complete the task.

What Others Have Said…

Michael developed a LEAN program for our hospital. This involved training both managers and front line staff in LEAN and its application in every department. Two LEAN projects were conducted in an effort to reduce inventory. There was a reduction of $135,000 in pharmacy inventory and $200,000 reduction in OR inventory."
Richard E. D’Alberto, FACHE
President & Chief Executive Officer
Laurens County Hospital

"Michael is a great speaker. He is inspirational and knows his trade."
Lynn Yarbrough
OR, JMRC

"Great quality- appreciate his openness to field question on the spot"
Rita Jones
CEO, Dundy County Hospital

"Michael is an outstanding, knowledgable speaker, keeps the flow going an involve the audience well."
Stephen Stewart
CEO, Artesian Valley Health System

"I like the process in implementation"
Brad Langdorf
VP Clinical Services, Community Hospital

“Michael is an excellent speaker. Content is exciting and educational.”
Mollie Heisel
Human Resource Coordinator
Brown County Regional Health Care
 
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Valerie Gigolyk
Supervisor
Loewen Windows

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Ann Corrigan, RN
VP of Patient Services
Henry County Health Center

“We are utilizing the information on a regular basis. It has been exciting to see this growth.”
Pat Hales , Director of Quality and Educational Services Misericordia Health Center

“Excellent speaker- funny yet seriously important to improve our daily lives.”
Rebecca Ricartti, HR Director
Pacific Alliance Medical Center

“Michael is fantastic. Keeps the learning Entertaining and interesting.”
Stephen Stewart CEO
Artesian Valley Health System

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Curtis Hawkinson CEO
Community Memorial Healthcare

“Very clear and concise presentation. Always includes stories that make you think.”
Heather Greenwood, Med Tech
CHI St. Alexius Health

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Lynne Yarbrough, OR Director
Johnson Regional Medical Center

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Valerie Hangman, QI Coordinator
Providence Medical Center

I was impressed by the content and the clarity of the speaker.”
Jennifer Russell
Government of Manitoba

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Terri Davis, RN
Providence Medical Center

“Dynamic speaker who leads the group to discover the answers for themselves.”
Jeff Dolan
Canada Cases Ltd.

“Mike is inspirational. A Great Motivator.”
Glen W. Buckler
President
Two Small Men with Big Hearts


“You have to see Michael Bayer’s presentation.”
Lois French

Investors Group

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Rob Vineberg
Regional Director General
Citizenship & Immigration Canada

“Excellent speaker- funny yet seriously important to improve our daily lives.”
Rebecca Ricartti,
HR Director
Pacific Alliance Medical Center

“Fantastic! My cheeks hurt from laughing so much, yet I also gained so much knowledge too! Thanks!”
Daiva Griese
One Legacy

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Case Manager, New Directions

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Ron Farmer
Personal Banker, CIBC

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