# Spaghetti Diagram Distance Calculator (Walking Waste and Layout Savings)

> Source: https://netray.co/tools/spaghetti-diagram-distance-calculator
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

Convert the distance you measured on a spaghetti diagram into walking time and annual cost, and compare it to an improved layout.

## Category

manufacturing

## Industry

Discrete Manufacturing

## Audience

- Lean practitioner
- Industrial engineer
- Plant manager

## Tool

**Kind:** calculator

**Currency:** $

**Inputs:**

#### Walking distance per cycle (current)

**Key:** dist_now

**Type:** number

**Default:** 62

**Min:** 0

**Step:** 1

**Unit:** m

**Help:** Trace the path on a layout and sum the segments.

#### Walking distance per cycle (proposed)

**Key:** dist_new

**Type:** number

**Default:** 28

**Min:** 0

**Step:** 1

**Unit:** m

#### Cycles per shift

**Key:** cycles

**Type:** number

**Default:** 120

**Min:** 0

**Step:** 5

**Unit:** cycles

#### Shifts per day

**Key:** shifts

**Type:** number

**Default:** 2

**Min:** 1

**Max:** 4

**Step:** 1

#### Working days per year

**Key:** days

**Type:** number

**Default:** 250

**Min:** 1

**Max:** 365

**Step:** 1

**Unit:** days

#### Walking speed

**Key:** speed

**Type:** number

**Default:** 1.2

**Min:** 0.5

**Max:** 2

**Step:** 0.1

**Unit:** m/s

**Help:** Typical factory walking pace is about 1.0 to 1.4 m/s.

#### Loaded labor cost

**Key:** rate

**Type:** number

**Default:** 28

**Min:** 0

**Step:** 1

**Unit:** $/hr

**Outputs:**

#### Annual walking distance (current)

**Key:** km_now

**Expr:** dist_now * cycles * shifts * days / 1000

**Format:** number

**Description:** Kilometers walked per year for this task.

#### Annual walking distance (proposed)

**Key:** km_new

**Expr:** dist_new * cycles * shifts * days / 1000

**Format:** number

#### Walking hours per year (current)

**Key:** hours_now

**Expr:** km_now * 1000 / speed / 3600

**Format:** hours

#### Hours saved per year

**Key:** hours_saved

**Expr:** (km_now - km_new) * 1000 / speed / 3600

**Format:** hours

**Primary:** true

#### Labor value of time saved per year

**Key:** cost_saved

**Expr:** hours_saved * rate

**Format:** currency

**Primary:** true

#### Distance reduction

**Key:** reduction

**Expr:** if(gt(dist_now, 0), (dist_now - dist_new) / dist_now * 100, 0)

**Format:** percent

**Chart:**

#### Hours saved per year vs proposed distance

**Type:** line

**X:** dist_new

**From:** 0

**To:** 62

**Steps:** 31

**Series:**

- hours_saved

**Disclaimer:** Time saved only becomes cost savings if the freed capacity is used for value-adding work or overtime is avoided. Treat the labor value as capacity released.

## Content

**Intro:** A spaghetti diagram shows where people and material travel, and the distance numbers make the waste visible. Enter the measured path length before and after a layout change, and this calculator converts it into annual kilometers, walking hours and the labor value released.

**Sections:**

#### How to use the calculator

**Body:** Draw the path of one operator or one part on a to-scale layout for a defined number of cycles, using a different color for each route. Measure the length of the lines with a ruler, a wheel or a floor plan scale. Enter the distance per cycle for the current and proposed layout, the number of cycles per shift, shifts per day and days per year. The tool returns annual walking distance, hours and the labor value. The chart shows how the saving grows as the proposed path shortens.

**Bullets:**

- Observe for a full representative period, not only the best hour
- Include trips for tools, gauges, paperwork and material
- Measure the proposed layout on the same drawing scale
- Keep walking speed realistic: 1.2 m/s is a reasonable default

#### The formula

**Body:** Annual distance equals distance per cycle times cycles per shift times shifts per day times working days per year. Walking time is distance divided by speed, and labor value is the hours multiplied by the loaded hourly cost. The calculation is simple on purpose; its strength lies in showing a large number that people can picture. In the sample, cutting a 62 meter path to 28 meters saves roughly 1,400 hours per year for a two-shift cell, which is close to one full-time person.

#### Using the result

**Body:** The result supports a layout case, for example moving a deburr bench next to a CNC cell or putting a gauge at point of use. Combine it with a standard work combination sheet to show the effect on operator cycle time. Be honest about what the saving is: time is released, and the plant must decide whether to use it for more output, other tasks or reduced overtime. Present both the distance and the hours to the team who walks the route.

#### Common mistakes

**Body:** Measuring one cycle and extrapolating without checking variation, forgetting the return trip, ignoring forklift or tugger paths in the same area, and claiming 100 percent of the freed time as cash savings are the usual errors. Remember also that moving equipment has costs and safety implications, so include those in the business case.

**Cta:** If you want to find the trips that matter in the first place, we can help analyze transaction and move data from your ERP to find the busiest flows.

**Faq:**

#### What is a spaghetti diagram?

**Answer:** It is a drawing of the actual movement paths of people, material or information on a floor layout. The tangled lines show unnecessary travel and help design a more direct flow.

#### How accurate is a typical walking speed?

**Answer:** Factory walking speeds vary with load, floor conditions and traffic, usually between 1.0 and 1.4 meters per second. Measure on your floor if the result drives a large investment.

#### Does saved walking time equal saved money?

**Answer:** Not automatically. It is released capacity. You convert it to savings only if you reduce overtime, avoid hiring or use the time for work that adds value.

#### How many cycles should I observe?

**Answer:** Observe enough cycles to see variation, often 10 to 20 for a short cycle task. For infrequent trips, use logs or a time-sample over a full shift.

## Search terms

spaghetti diagram calculator, spaghetti diagram distance calculation, walking waste calculator, layout improvement savings, motion waste cost calculator, spaghetti chart lean, travel distance reduction calculator, cell layout walking time

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