What is the difference between a Yamazumi chart and a cycle time bar chart?

A standard cycle time bar chart shows total time per station as a single bar. A Yamazumi chart breaks that bar into stacked segments representing individual work elements, classified by type (VA, IWA, MUDA). This additional detail reveals not just where imbalances exist, but what types of work are causing them.

What software can generate Yamazumi charts automatically?

Yamazo VAS generates Yamazumi charts automatically from video time study data. You tag work elements in the video, and the software creates the chart instantly, grouped by station, operator, or process. Other methods include manual creation in Excel or using specialized lean manufacturing tools.

How often should Yamazumi charts be updated?

Yamazumi charts should be updated whenever there is a significant change to the production line: new product introduction, cycle time changes, staffing adjustments, or after kaizen improvement events. In continuous improvement environments, regular re-analysis (monthly or quarterly) is recommended.

Can Yamazumi charts be used outside manufacturing?

Yes. While Yamazumi charts originated in manufacturing, they can be applied to any process with sequential or parallel workstations: logistics, healthcare workflows, software development pipelines, and administrative processes.

What is a Yamazumi Chart? | Definition, Examples & Software

A Yamazumi chart (also called a Yamazumi board) is a stacked bar chart used in lean manufacturing to visualize the workload distribution across stations or operators on a production line. Each bar represents a workstation, with segments showing individual work elements stacked by time. The chart makes it immediately visible which stations are overloaded, underutilized, or balanced against the takt time.

How to Create

To create a Yamazumi chart: (1) Identify all workstations on your line. (2) Measure the cycle time of each work element at each station using time study or video analysis. (3) Classify each element as Value-Added (VA), Incidental Work (IWA/IWR), or Waste (MUDA). (4) Stack the elements for each station in a bar chart. (5) Overlay the takt time line to identify stations that exceed the target. (6) Use the visual to redistribute work elements and balance the line. Modern tools like Yamazo VAS generate Yamazumi charts automatically from video analysis data.

Example

Consider a 5-station assembly line with a takt time of 60 seconds. Station 3 shows a total cycle time of 78 seconds (30% over takt), while Station 1 is at only 42 seconds. The Yamazumi chart makes this imbalance immediately visible. By moving two work elements (totaling 18 seconds) from Station 3 to Station 1, you can bring all stations within takt time and improve line efficiency from 72% to 91%.

What is a Yamazumi Chart? | Definition, Examples & Software

How to Create

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