Yamazumi Chart Template
Stack each operator's work elements against takt and see the balance.
Example loaded: gearbox assembly, 4 operators at a 60 s takt.
- Takt time
- -
- Total work content
- -
- Operators needed
- -
- Balance efficiency
- -
Filled boxes are tinted. Click a box to go to it.
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How to make a yamazumi chart
- Set takt. Enter available working time per shift and demand per shift. The takt time calculator shows the formula in more detail.
- Time each work element. Break each operator's job into elements of a few seconds each and time several cycles. Use the typical repeatable time, not the best one.
- Enter the elements by operator. One row per element, with the operator or station, the element, its seconds and its type.
- Mark the type. Value-added changes the product. Necessary non-value-added is required today but adds nothing, like loading a fixture or a required test. Waste can go: walking to fetch, searching, rework, waiting.
- Read the chart. Bars over the takt line are the problem. Remove waste first, then move elements from the tallest bars to the shortest ones.
- Rebalance and check the count. Compare total work content with takt to see how many operators the line needs, and update the chart after each change.
Yamazumi chart example: gearbox assembly
A four-operator assembly line. Available time is 450 minutes a shift and demand is 450 units a shift, so takt is 450 × 60 ÷ 450 = 60 seconds.
| Operator | Element | Seconds | Type |
|---|---|---|---|
| Op 1 | Pick housing from rack | 5 | NVA |
| Op 1 | Press bearing | 18 | VA |
| Op 1 | Insert seal | 12 | VA |
| Op 1 | Walk to cart for seals | 8 | Waste |
| Op 1 | Inspect bore | 6 | NVA |
| Op 2 | Fit shaft | 20 | VA |
| Op 2 | Fasten 4 bolts | 24 | VA |
| Op 2 | Search for driver bit | 6 | Waste |
| Op 2 | Torque check | 8 | NVA |
| Op 2 | Move unit to next station | 4 | NVA |
| Op 3 | Fit cover | 15 | VA |
| Op 3 | Fasten cover | 16 | VA |
| Op 3 | Apply label | 5 | NVA |
| Op 4 | Leak test | 22 | NVA |
| Op 4 | Pack | 14 | NVA |
| Op 4 | Fill in paperwork | 7 | Waste |
The math
Op 2 = 20 + 24 + 6 + 8 + 4 = 62 s (over the 60 s takt)
Op 3 = 15 + 16 + 5 = 36 s
Op 4 = 22 + 14 + 7 = 43 s
Total work content = 190 s; operators needed = 190 ÷ 60 = 3.17, so 4
Balance efficiency = 190 ÷ (4 × 62) = 76.6%
Rebalance: remove the three waste elements (walk for seals 8 s, search for bit 6 s, paperwork 7 s) and move the 8 s torque check from Op 2 to Op 3. The bars become 41, 48, 44 and 36 s, all under takt. Total work is now 169 s, and efficiency is 169 ÷ (4 × 48) = 88.0%. At 169 ÷ 60 = 2.82, the line could run with 3 operators if the elements can be split into three bars of 60 s or less.
Press Load the filled example above to see these bars against the takt line. For line and shop versions with before and after tabs, see the Yamazumi Balancer, and read how to make a yamazumi chart for the method in depth.
Why this tool matters
Averages hide imbalance. A line can look fine on paper while one operator is over takt every cycle and two others wait. The yamazumi chart shows every operator's work against takt, and the colors show which seconds are waste, so you rebalance by removing work first instead of just moving it around.
Facilitator tip
Remove waste before you rebalance. Moving a walk or a search to another operator only moves the problem. Take it out, then shift value-added and necessary elements to level the bars.
Frequently asked questions
What is a yamazumi chart?
A stacked bar chart of work content by operator or station. Each bar is one operator, built from the work elements they do, stacked by time and colored by type. A horizontal line marks takt time, so you can see at a glance who is over takt and who has spare time.
How do you read a yamazumi chart?
Compare each bar with the takt line. A bar above takt cannot keep pace with demand. Bars well below takt are waiting time. The colors show how much of each bar is value-added work, necessary non-value-added work, and waste you can remove.
How many operators do I need?
Divide the total work content by takt and round up. 190 seconds of work at a 60-second takt is 190 ÷ 60 = 3.17, so 4 operators unless you remove at least 10 seconds of work (3 × 60 = 180).
What is line balance efficiency?
Total work content divided by the number of operators times the longest bar. 190 s on 4 operators with a longest bar of 62 s is 190 ÷ (4 × 62) = 76.6%. The gap is time operators spend waiting for the slowest station.
What is the difference between a yamazumi chart and a line balance chart?
A line balance chart shows one bar per station with its total time. A yamazumi chart breaks each bar into its work elements and colors them by value, so it also shows what to remove or move when you rebalance.
How do I make a yamazumi chart in Excel?
Use a stacked column chart with one series per element and add takt as a line series, which takes a while to set up and to keep up to date. This template draws the chart from the element list and exports the list as CSV for Excel.