PART III | LESSON 9: THE LAYERED FLOW DIAGRAM MATERIAL HANDLING ACADEMY
DRIVING QUESTION How does a flow diagram grow into the design map?
The same Riverside flow shown in four rounds. Layer 1 is blocks and arrows. Layer 2 adds 20 CPM combined and the 55, 35, 10 split. Layer 3 highlights the sort decision in blue and tags the three data questions. Layer 4 adds a buffer note, the mezzanine landing, a red forklift crossing, and an operator symbol.

The same flow, developed in four rounds. The design matures; the format never changes.

The Four Layers

Layer 1: Flow

Blocks and arrows, confirmed with the customer as a story.

Layer 2: Rate

Volume and rate at each stage. Where the system works hardest.

Layer 3: Decisions

Delays, assumptions as open items, and every smart decision point.

Layer 4: Buffers & People

Buffer requirements, operator and maintenance access, the crossing.

THE THREE DATA QUESTIONS
  1. What decision gets made here, and what does the system need to know to make it?
  2. Who or what makes it, and where does that information come from?
  3. What happens if the answer does not arrive in time?