Use of Spaghetti Diagram for Identification and Elimination of Waste Movements in Shop Floor for OEE Improvement - A Case Study

Oct 26, 2026

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Business objectives depend on sustained growth and profitability achieved through productivity improvement. Frequent machine breakdowns, long changeover times, and high manufacturing costs threaten performance. The research aims to enhance OEE to meet rising customer demands without adding capacity. It addresses equipment unavailability bottlenecks, improves process effectiveness, reduces changeovers and cycle time, and aligns workforce culture with focused improvements, targeting higher productivity, best capacity utilization, and right-quality output at the right time.

LanguageEnglish

CategoryResearch & Report

FormatPDF

Pages5

Reading Time13 min

AccessFree to download

I. INTRODUCTION

Manufacturing challenges and maintenance importance

II. LITERATURE SURVEY

Spaghetti diagram concept

Benefits and author viewpoint

III. IMPROVEMENT OF BANDSAW PRODUCTIVITY

Case organization and TPM/OEE implementation

Improvement of OEE

ABOUT XYZ COMPANY

International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 Vol. 4 Issue 05, May-2015 Use of Spaghetti Diagram for Identification and Elimination of Waste Movements in Shop Floor for OEE Improvement: A Case Study Nagaraj A Raikar Assistant Professor Dept of Mechanical Engineering AITD Assagao, Mapusa, GOA Prasanna Kattimani Assistant Professor Dept of Mechanical Engineering AITD Assagao, Mapusa, GOA Gaurish Walke Assistant Professor Dept of Mechanical Engineering AITD Assagao, Mapusa, GOA Abstract—Business objectives are mainly, long term growth and profitability that can happen only by increasing in the productivity. Frequent machine breakdown, high changeovertime, and high manufacturing cost are becoming great threat. The author’s main aim to keep up the Research is to improve OEE to meet customer’s increasing demands without addition of capacity thus meeting business goals. This document demonstrates the need to overcome most of bottleneck of equipment’s unavailability for resources utilization and to run the process more effectively. Improvement in OEE was possible through reducing the changeovers and cycle time and developing the workforce culture align to the focused improvements. The outcome of this Research may expect to have marked improvement in productivity with best utilization of the capacity along with right quality product, at right time. Keywords—Equipment downtime, Productivity, Losses, Cycle time. I. INTRODUCTION In all the manufacturing industries delivering the quality product at the right time has become more challenging intoday’s market situation . The paper Use of Spaghetti diagram for identification and elimination of waste movements in shop floor for OEE Improvement Maintenance has become more challenging in the current dynamic business environment. The manufacturing sector has been experiencing tremendous challenges in ensuring all products are delivered to customers on time. However, the current business environment and pressures from various parties such as customers, suppliers, governments and so forth have put manufacturing sectors under severe pressure. To operate efficiently and effectively, manufacturing sectors need to ensure no disruption due to equipment breakdown, stoppages and failure. Manufacturing systems in particular often operate at less than full capacity, with low productivity, and the cost of producing products are high. Recent study (Mobley,1990) shows that 25-30% of total production cost is attributed to maintenance activities in the factory. The quality of maintenance significantly affects business profitability. The importance of maintenance functions has increased due to its role in keeping and improving the availability, product quantity, safety requirements, as maintenance costs constitute an important part of the operating budget of manufacturing firms (Al-Najjar and Alsyouf 2003:85-100) . In response to maintenance problems encountered in manufacturing environment, the Japanese developed and introduced the concept of Total Productive Maintenance (TPM), in 1971. TPM is a maintenance system defined by Nakajima (Nakajima 1988) in Japan, which covers the entire life of equipment in every division including planning, manufacturing, and maintenance. It describes a synergistic relationship among all organizational functions, but particularly between production and maintenance, for continuous improvement of product quality, operational efficiency, capacity assurance and safety. II. LITERATURE SURVEY A. SPAGHETTI DIAGRAM: A spaghetti diagram is a visual representation using a continuous flow line tracing the path of an activity through a process. The continuous flow line enables process team to identify redundancies in the work flow and opportunities to expedite process flow. The intent of this in literature review was to identify ways to shorten the walking time from one activity to another for frequently performed tasks

FAQs

What problem does the research focus on regarding shop-floor performance?

The research focuses on productivity threats caused by frequent machine breakdowns, high changeover time, and high manufacturing costs, which reduce overall effectiveness on the shop floor.

How does the spaghetti diagram help improve OEE?

The spaghetti diagram traces continuous paths of activities, helping teams identify wasted work-flow motions, overlapping walk paths that indicate delays, and opportunities to shorten walking time between frequent tasks.

Which improvements are emphasized to increase OEE in the case study?

OEE improvement is pursued by reducing changeovers and cycle time, addressing equipment unavailability bottlenecks, and developing a workforce culture aligned with focused improvements.

Oct 26, 2026

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