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Yamazumi Line Balancing Worksheet

A Yamazumi chart stacks each operator's time into value-add, necessary non-value-add and waste, then compares the stack to takt. This worksheet gives you the data table and the balance numbers, ready to paste into a stacked bar chart.

Download:

Total cycle (s)	Load vs takt	Spare time to takt (s)
46	76.7%	14
58	96.7%	2
65	108.3%	-5
48	80%	12
41	68.3%	19

Total value-add

151

Total necessary NVA

Total waste

Total work content

258

Line balance efficiency

79.4%

Total work content divided by stations times the slowest station.

Waste share of work content

14.7%

Theoretical minimum stations at takt

Time each station over several cycles and use the repeatable value. Takt time is the same for every station on a single line; keep the column to allow different products.

Baseline line balance from ERP labor data

Optional review of how routing and labor reporting data could seed a balance study.

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How to use the worksheet

Observe each station for at least ten cycles with a stopwatch. For every element classify the seconds as value-add (the customer would pay for it), necessary non-value-add (walking to get a part, scanning, a required inspection) or waste (waiting, rework, searching). Enter the three numbers per station and the takt time. The sheet adds the total cycle, the load as a percentage of takt and the spare time. Any station above 100 percent will cause a bottleneck, and one far below takt is a candidate for absorbing work from its neighbors.

Observe real work, not the standard on the routing
Classify every second, even tiny walks
Run the worksheet again after each rebalancing trial

Balance efficiency explained

Balance efficiency is total work content divided by the number of stations times the longest station time. A perfectly balanced line scores 100 percent. The theoretical minimum number of stations is total work content divided by takt, rounded up. If you have more stations than that figure, you may be able to rebalance rather than add people. Removing waste first, then moving the necessary non-value-add work, is usually better than simply moving all elements around.

Common mistakes

Do not average one slow and one fast cycle and call it the station time; use the repeatable, achievable time. Do not hide waste inside value-add to make the chart look better. Remember that takt comes from demand and available time, not from what the line can do today. Feed the new work content and station assignments back to your ERP routing only after the change has been validated for stability and quality.

Frequently Asked Questions

What does a Yamazumi chart show?

It is a stacked bar chart of each operator's or station's cycle time, split into value-add, necessary non-value-add and waste, with takt time drawn as a line. It shows who is over takt, who has spare time and how much of the work is waste.

How is it different from a line balance chart?

A basic line balance chart shows total time per station against takt. A Yamazumi adds the split by work type, so you can see whether a station is slow because of real work or because of waste that can be removed.

What takt time should I enter?

Use available production time per shift divided by customer demand per shift. Do not use the current cycle time of the line. If demand varies, balance for the planned rate and recheck when the rate changes.

Can I chart this in Excel?

Yes. Export the table to Excel, select the station, value-add, necessary and waste columns and insert a stacked column chart. Add takt as a line series for the usual Yamazumi view.

Netray can pull routing times and actual labor reporting from your ERP so the Yamazumi baseline starts from data rather than a stopwatch alone.

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