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Spaghetti diagram template
A spaghetti diagram is a drawing of the path a person, part or document takes through a work area, traced on the layout as it happens. The Lean Lexicon calls it a spaghetti chart, because the route often looks like a plate of spaghetti. Drawn to scale, it turns walking into numbers: trips, distance, walking time and the places where people cross a forklift aisle. This template has a printable sheet (squared paper, a stop list with grid positions and a trip log), a worked example drawn before and after a layout change, and an Excel workbook. In the Excel you set the scale (typed, or worked out from a wall you measured, in feet or meters), give each stop its grid position in the before and after layouts, and log each trip from one stop to the next. It works out the distance and walking time of every trip, flags trips that skip a stop, and compares before with after, per hour and per shift.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for area, what was followed and observer, a squared-paper box to draw the layout and paths with a scale line, a table of stops with grid positions, and a trip log with from, to, squares, distance and aisle crossings.Squared paper and scaleStops with grid positionsTrip logDistance in feet and metersWalking timeAisle crossingsBefore and afterWorked example
When to use it
When to use a spaghetti diagram
- When operators or material handlers seem to walk a lot, or a job takes longer than the work in it.
- Before a layout change, to measure the current paths, and after it, to prove the difference in feet and minutes.
- On a waste walk, to show motion and transport waste with numbers rather than opinion.
- When people or carts cross forklift aisles, to count the crossings a new layout would remove.
How to fill it in
- 1
Choose what to follow
One person, one part or one document, for a whole cycle or a set time such as an hour. Write it and the time on the sheet, and follow the same thing after the change. - 2
Draw the layout to scale
Sketch walls, benches, racks and doors on the squared paper. Measure one wall and count the squares it spans: a 180 ft wall over 60 squares makes 1 square = 3 ft. - 3
Give each stop a grid position
Letter the stops and write their column across and row down, counted in squares from the top left. In the Excel, give the after position too for anything you move. - 4
Trace and log every trip
Walk behind the person and draw each move as it happens. A trip is one move from one stop to the next: log from, to, and whether it crossed an aisle. Do not draw from memory. - 5
Let the grid give the distance
The Excel counts the squares across plus along between the two stops and multiplies by the scale. If the path bends round a rack, type the squares you counted along it instead. - 6
Change the layout and trace again
Move what causes the long or crossing trips, try it, then follow the same person for the same time and compare trips, distance, walking time and crossings.
A filled-in example
Illustrative, not a benchmarkAn example (illustrative): one kitter in a kitting area for one hour, at 1 square = 3 ft, walking at 4 ft/s. The PDF draws both layouts and the Excel Example sheets give the same numbers.
The example kitter's hour, before and after the new layout
Trips in the hour
- Before
- 14
- After
- 6
Feet walked in the hour
- Before
- 1,098 ft
- After
- 378 ft
Minutes walking in the hour
- Before
- 4.6 min
- After
- 1.6 min
Crossings of the forklift aisle
- Before
- 4
- After
- none
Trips fell from 14 to 6, walking from 1,098 to 378 feet in the hour, walking time from 4.6 to 1.6 minutes, and forklift aisle crossings from 4 to none.
- Before: 14 trips covering 366 squares, so 366 × 3 = 1,098 ft (334.7 m). Eight of the trips went to the label printer and the fast parts rack at opposite ends of the area, 30 squares from the kitting bench each way.
- The four trips to the printer crossed the forklift aisle.
- New layout: the printer moved next to the packing bench and the fast parts to a rack beside the kitting bench, so labels and parts no longer need a trip.
- Traced again for an hour: 6 trips, 126 squares, 378 ft (115.2 m), no aisle crossings.
Walking fell by 720 ft, 65.6%, and walking time from 4.6 to 1.6 minutes an hour (1,098 ÷ 4 = 274.5 seconds against 94.5). If the hour is typical of a 7.5-hour shift, that is 5,400 ft and 22.5 minutes of walking saved per shift.
Common mistakes
Drawing from memory
People forget the short trips and the double-backs. Trace it live.
No scale
Without a scale the distances are guesses. Measure one wall and set the squares from it.
Straight lines through racks
People walk along aisles. Use across plus along on the grid, and count the squares along the real path where it bends.
Following something different before and after
Compare the same person or part, the same task and the same length of time. The Excel flags different observation times and compares per hour instead.
Counting distance but not crossings
A short trip across a forklift aisle can matter more than a long one along a walkway. Log the crossings.
Blaming the walker
The paths come from the layout and the process. Change those, not the person.
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Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
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FAQ
Spaghetti diagram template: common questions
A drawing of the path a person, part or document takes through a work area, traced on the layout as it happens. The Lean Lexicon calls it a spaghetti chart because the route often looks like a plate of spaghetti.
Draw the layout to scale on squared paper, count the squares along each trip and multiply by the scale. In the example 1 square is 3 ft, so 366 squares is 1,098 ft. The Excel counts across plus along between the stops' grid positions for you.
Divide the distance by the walking speed. The Excel starts at 4 ft/s (1.22 m/s), the design speed Knoblauch and colleagues recommended in 1996 for adults under 65; time a walk in your own area, because people carrying parts walk slower.
A value stream map shows the flow of material and information across a whole process, with times and inventory. A spaghetti diagram zooms into one area and measures the physical paths people and parts take.
A whole cycle for a long job, or a set time such as an hour for a repetitive one. Use the same length before and after; if they differ, compare the distance per hour.
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- Visual management audit checklist29 checks of whether anyone can tell normal from abnormal at a glance, scored by group, with a trend and actions.
- Quality alert formA quality alert to post at the line, a sign-off sheet for every shift, and a log of open, expired and closed alerts.
- TQM self-assessment templateThe eight TQM principles in 24 statements you can check on the floor, scored 0 to 4 by several people, with the spread, the top 3 gaps and an action plan.
- Employee recognition program templateDesign a recognition program on one page, then run it: points per action, prizes, budget, a points ledger, a monthly leaderboard and a fairness check by team and shift.
- Continuous improvement software evaluation scorecardCompare CI software vendors: a must-have gate, eight weighted criteria scored 1 to 5, points out of 100 and a rank, with a demo script and reference questions.
- Employee engagement survey templateA short anonymous pulse survey for shop floor staff: 14 statements in six drivers, two open questions, results by driver and team, and the actions.
- Hansei reflection sheet (lessons learned)A written look back at one finished project, event or launch: goals against results in numbers, causes rather than blame, lessons to keep or change, and where else they apply.
- Safety cross calendarA month drawn as the green cross, colored each day by the most serious safety event, with totals and days since the last injury.
- Daily kaizen routine boardA team's 10 to 15 minute daily routine at the board: one problem from each person, small fixes with one owner, counted every week.
- Quality circle meeting recordA circle's charter, a one-page record for each meeting and a problem register that follows every problem from selected to closed or escalated.
- Weekly maintenance schedule templateNext week's maintenance jobs, scheduled only when ready, loaded against each craft's hours by day, with schedule compliance and break-ins at week end.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Safety pillar 90-day model area planThirteen weeks from the incident pyramid to safety standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection checklist and logThe 8 monthly checks for each portable extinguisher, plus a log with the hydro test interval from OSHA Table L-1, annual and 6-year due dates and open issues.
- Quad chart templateA project on one page in four boxes: idea and owner, problem, approach, and cost, schedule and result.
- Toolbox talk topics (52 weekly topics)52 weekly toolbox talk topics, each with a one-line key message and a discussion question, and a tracker for the year.
- Loss tree worksheetBreak one big loss number into area, line, machine, loss type and cause, and stop at the cause a team can fix.
- Equipment register templateOne row per asset, with hierarchy, criticality, PM strategy and owner, and a check that flags what is missing.
- Machine history record templateOne record per machine: components and their life, every breakdown and repair with cost, MTBF and MTTR, and a repair-or-extend check.
- Compressed air leak survey logWalk sheet, printable leak tags and a tracker that puts an annual cost on every leak and follows it to a verified fix.
- Defect detection matrix templateMap where each defect is created and where it is found, score the gap and move the check closer to the cause.
- Project savings validation checklistThe gate between a project's claim and a reported saving: 20 checks, a claims register and a six-month sustainment check.
- Life cycle cost analysis templateCompare up to three machines over ten years: price, energy, upkeep, failures and down time, discounted to present value.
- Equipment design review checklistGate reviews for a new machine before order, before build and before start-up, with a safety buy-off and a problems journal.
- Emergency action plan templateA written emergency plan for a plant: site facts, roles and backups, warden coverage, scenario steps and a drill record.
- Preliminary hazard analysis (PHA) worksheetFind and score the hazards of a new line, machine or process before design is fixed, then choose controls and re-score.
- Risk register templateOne scored list of operational risks with owners, actions and dates, a heat map and a review log.
- Hot work permit templateA hot work permit with a precautions checklist, fire watch record and close-out, plus an Excel permit log.
- Confined space entry permit templateA confined space entry permit with checks, an air test log, an entry log and cancellation, plus an Excel register.
- Energy loss matrix templateSeven types of energy loss by six energy sources with a cost in each cell, an action plan and an idle-period shutdown checklist.
- Management safety tour formA leader's scheduled safety walk: observation form, operator interview, tally, actions, rota and a tour log with a dashboard.
- Hazard prediction worksheetA pre-task worksheet: score what could go wrong at each step of a job, add a countermeasure and score again.
- Chemical inventory and SDS register templateA register of every chemical on site with its hazard class, safety data sheet and label, and a check that incompatible products are kept apart.
- Safety committee meeting minutes templateMinutes for a safety committee: attendance, nine agenda items, an action log that carries open actions forward, and monthly numbers.
- Environmental compliance audit checklistAn internal environmental audit: 37 questions with what to look for, a findings log with classes and a score by section.
- APQP checklistThe five APQP phases as a checklist: deliverables, owners, due dates, gate reviews and an issues list.
- Out-of-control action plan (OCAP) templateA reaction plan for a control chart: the steps, what each signal means, who to call and a log of events.
- Quality inspection checklistAn in-process and final inspection record: measured characteristics, visual checks, a decision and first pass yield.
- AQL sampling plan templatePick a sample size, read accept and reject numbers, record the defects and decide on the lot.
- MSA study workbookBias, linearity and stability study sheets for a gauge, with the arithmetic done and a guide to which study when.
- Incoming quality control stage sheetA register that shows how much control each purchased part has and plans the move from your dock to the supplier's process.
- Internal audit schedule templateA year of internal audits planned by risk: the programme, the register, the auditors and the findings.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- Pest control inspection checklistA pest control walk-round for a food plant, with a log of traps and stations and action levels for each type of device.
- Vehicle inspection checklist53 checks for a truck, tractor or trailer, each tied to the federal rule it comes from, with a defect log.
- Pre-trip inspection checklistA driver's 42-check walk-round in order, with the driver vehicle inspection report for the end of the day.
- Cleanroom audit checklist33 cleanroom checks split by how often they run (each shift, weekly, per plan, system), a gowning order to watch against, a differential pressure log and a findings log, with a worked week of readings.
- GMP audit checklist for drug manufacturing42 self-inspection checks ordered by the subparts of 21 CFR 211, each with its section, the matching EU GMP chapter and whether it is seen on the floor or in records, graded critical, major or minor, with a worked audit of a packaging line.
- Line clearance checklist28 line clearance checks in six sections (area, equipment, materials, printed materials, documents, coder and vision settings), cleared by the operator and verified by a second person, with a printed-materials reconciliation and a worked example that does not balance.
- ISO 13485 internal audit checklist38 questions on ISO 13485 clauses 4 to 8, each with the FDA QMSR section that brings it in or adds to it, a production floor tab (records, current instructions, training, nonconforming product, CAPA) and a worked audit of a catheter line.
- ISO 22716 GMP audit checklist for cosmetics25 cosmetic GMP checks following the sections of ISO 22716, split into a floor walk (people, premises, equipment, materials, production) and system checks (lab, out of specification, deviations, complaints, change control, audits, documents), with a worked audit of a filling line.
- SSOP template: sanitation standard operating procedureOne sanitation SOP sheet per area or machine (steps, chemical, contact time, PPE, lockout, owner), a 23-check pre-op inspection and a verification log for visual, ATP and micro checks.
- SQF internal audit checklist for food manufacturing54 questions in the two parts of the SQF manufacturing code (system elements and GMP), each group mapped to BRCGS and FSSC 22000, graded Conforms to Critical, with findings, a score and a yearly plan.
- Injection molding defects chart16 molding defects with causes by machine, material, mold and method, first checks, and an Excel defect log with a Pareto.
- ESD audit checklist29 checks for an ESD protected area, with daily tests split from periodic verification, a measurement log and a worked audit.
- Management of change formA change request and review form for a plant: what changes, the hazard review, approvals, pre-startup review, training and close-out.
- Silica exposure control plan templateA written silica plan for general industry: tasks, controls and housekeeping, plus monitoring, medical surveillance, training and a 31-check plan audit.
- Goods received note templateA one-page goods received note and an Excel register with accepted to date, still to come and an invoice check for each PO line.
- Lessons learned templateA one-page lessons log, a 45 minute session guide and an Excel register that shows which actions are done, open or overdue.
- Packing list templateA one-page packing list with a pack checklist, and an Excel file that works out volume, shipped to date and back order.
- Sign-in sheet templateA training and meeting sign-in sheet, a visitor sign-in and out sheet, and an Excel register of attendance and visitors on site.
- Purchase order templateA one-page purchase order and an Excel version that adds up the lines, checks the approval limit and tracks what is still to come.
- Part submission warrant (PSW) templateA PSW working form plus twelve checks before anyone signs, and an Excel that works out whether the warrant is ready.
- Ballooned drawing and dimensional results templateA ballooning guide and a results sheet for six parts per characteristic, with OK, NEAR LIMIT or NOT OK worked out for each row.
- Attribute agreement analysis templateA 30-part, three-appraiser study sheet for pass or fail decisions, with kappa, effectiveness, miss rate and false alarm rate in Excel.
- DVP&R template (design verification plan and report)A design verification plan and report on one sheet: tests, criteria, owners and dates, with status worked out as of a date.
- Special characteristics matrix templateOne row per special characteristic, followed from drawing to PFMEA, control plan, gauge study and capability, with the first gap named.
- Maintenance request form templateA one-page request form and an Excel log that times each answer against a priority target.
- Maintenance log templateA maintenance log page and an Excel log that totals cost, downtime and planned work and flags repeat breakdowns.
- Preventive maintenance schedule templateA PM schedule with next due dates and status, and an Excel calendar of the jobs and hours in each month.
- Work instruction templateA one-page work instruction with key points and step times, and an Excel training record that flags re-checks.
- Fire drill report templateA report for each fire or mock drill: a timeline from the alarm, the head count, an observer checklist, actions and a yearly log.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.