How to Create a Yamazumi Chart | Geneo

latestbusinessoffe
Jul 1
2 min read

How to Create a Yamazumi Chart by Geneo

Creating a Yamazumi chart starts with one clear objective: to visualise and balance work across a one-piece flow process. When each operator performs a defined sequence of tasks in a continuous line, any imbalance, whether it’s an overloaded station, an idle operator, or hidden waste, disrupts the flow and creates delays. A Yamazumi chart helps teams see those issues clearly so they can optimise the line for smooth, consistent output.

Most teams begin by gathering task-level data, which involves listing the steps in the process, timing each one, and noting whether it adds value. Then, they stack these tasks as coloured bars, typically in Excel, with one bar per operator or station. It’s a quick way to visualise cycle time vs. takt time, identify bottlenecks, and begin rebalancing work.

And it works - until it doesn’t.

Manual Yamazumi charts are snapshots. They’re static, disconnected from actual work instructions, and quickly become outdated as standards evolve. Each update requires someone to dig into spreadsheets, cut, paste, and recalculate, which makes ongoing use difficult and continuous improvement slower than it should be.

That’s precisely what GEN-OPS was designed to solve.

With GEN-OPS, Yamazumi charts are built directly from the actual standard work being performed by operators. Each task is structured, timed, and categorised within the system. When the standard is revised, whether it’s a process improvement, a customer-specific variation, or a quality-driven change, the Yamazumi chart updates automatically. There’s no duplication of effort, no delay, and no risk of misalignment.

You get a real-time, living view of your one-piece flow — ready to support faster rebalancing, better team planning, and more effective improvement cycles. You can even simulate changes in production mix or team size to see the impact before anything hits the line.

So yes, you can build a Yamazumi chart manually.

But if you want one that stays accurate, evolves with your operation, and helps you improve, that’s where GEN-OPS comes in.