How to Elevate Construction Superintendents

Read 11 min
Imagine you just came back from an LCI Congress, or a Lean Construction Blog Webinar, or some other lean training. You are excited, energetic, and hopeful for the future. Finally, you will be able to take that next step, improve your project, and reduce waste. Nothing can stop you now. Until you head back to the project the next day… You begin to realize you’ll have to get this past your Super. He is good, but not always open to new ideas. You begin to realize this will be harder than you thought, simply because it starts with people. The frustration begins to build as the first answers to your suggestions are, “We don’t need that,” and, “That won’t work here.”

Now, let’s change seats. Pretend you are the Superintendent. You have been doing this for years, and maybe even for decades, you always bring the project in on time somehow, and you always have control. Now, someone on your team, after one training, is telling you in mild tones that you are doing it wrong, and that command and control is bad. “What in the world just happened?” you think to yourself. “Why would having control of the project be bad?” The fact is that Supers are placed into difficult, if not brutal situations with unruly trades, insufficient project budgets, unrealistic deadlines, and a lack of resources. They not only have to keep control; they are incentivized financially to do so. No one will ever know the stress of being a Super unless they have been one.

So, here is our problem. Supers must maintain control to survive, and everyone else wants them to give it up. What is to be done? That answer is two-fold. More training for Superintendents who have been largely ignored for a century now, and using and having a better understanding of the right system on site. What is needed is an Integrated Control System, not command and control. Integrated Control is the collaboration and decision making of an integrated team who then acts with total participation to create control, stability, and flow on the project. This is the way! One person deciding and controlling is not the way, and neither is team collaboration with chaos in the field because there is no control. A good job is a clean job. A good job is organized. A good job is safe, lean, and stable, and a good job has total participation. Yes, a Super must have control of his project, but must do it with the team, and through the team.

To do this, we must have training and awareness. There is little or no training, at least in book form, for Superintendents, and yet there are countless books and trainings for project managers of all types. There are even books for field engineers, the position just before getting to a Super role, but still, nothing remains for the career Superintendent. Until Now! Elevating Construction Superintendents was written as a first in a series of books titled, “The Art of the Builder.” The first book, which is out now on Audible, Amazon, and Kindle, provides fundamental training for Superintendents. Other books now available:

-Elevating Construction Takt Planning

-Elevating Construction Field Engineers

-Elevating Construction Senior Superintendents

-Elevating Construction Foremen

-Elevating Construction Surveyors

To name a few. The concepts in the first book will teach and enable Supers to respect people and resources, create stability on their projects, successfully work with an integrated team, and to continuously improve. Builders who have read and implemented this have cleaner, safer, and more organized projects, with better schedules, and healthier and happier environments and cultures. This comes from a fundament understanding of builder principles, and the ability to implement step-by-step on their project as guided by the book.

Supers will be taught to:

  1. Be Involved with Intentional Pre-construction Efforts

  2. Write Lean into Contracts

  3. Win over the Workforce

  4. Build the Project Management Team First

  5. Orient People Well

  6. Design Remarkable Interaction Spaces

  7. Create Self-sustaining Logistics Systems

  8. Use the Meeting Systems to Scale Communication

  9. Stabilized Procurement & Deliveries

  10. Implement an Effective Quality Program

  11. Being a Daily Issue Correction System

  12. Manage a Roadblock Removal System

  13. Implement Zero Tolerance

  14. And, Grade contractors

The Integrated Control System presumes that the project team’s first priority is to create respect and stability for the workers, and that from there, they can then continuously improve.

Workers need to know/have:

  1. What s/he is building

  2. How to install it

  3. Where to put it

  4. The materials

  5. The equipment

  6. A clean environment

  7. A safe environment

In order to succeed.

The Last Planner System has changed the industry for the better. What kind of builders will enter and use that system? The answer is Lean Builders that know The Art of the Builder. Take this journey with us as we prepare the next generation to lead remarkably in construction.

About:

 

Jason Schroeder is a former Field Operations and Project Director. He has worked as a construction leader for 22 years through positions that range from field engineer, to project superintendent, general superintendent, and field operations director. He is the Owner and Lead Consultant at Elevate Construction IST, a company focused on elevating construction from coast to coast by providing insights, solutions, and training that create respect in the field, through trained leaders, which ultimately preserves and protects families in construction. He is the creator of the Field Engineer Boot Camp and Superintendent Boot Camp, which are immersive courses that train field leadership. He is a husband, and a father of eleven. Their family has focused their finances, time, and future to serving others in construction through their business.

Jason has been involved with Lean since 2011 when he was introduced to it through Paul Aker’s book, 2 Second Lean. Since then, he has experimented with lean as a superintendent, general super, and director on multiple projects. His training includes a DBIA certification, CM-BIM certification, CM-Leancertification, Lean Leader Certification through Leancor, and multiple training courses for professional development. Hundreds of books later, and through practical implementation, Jason has been able to scale operational excellence from project to project, and throughout entire companies. Jason is an expert on Takt Planning, Team Balance & Health, Personal Organization, Field Engineering, and what he calls The Integrated Control System. Jason hosts a podcast, The Elevate Construction Podcast, a blog through elevateconstructionist.com, and trains, consults, and coaches throughout the country.

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here) 
-Listen to the Elevate Construction podcast: (Click here) 
-Check out our training programs and certifications: (Click here)
The Takt Book: (Click here)

On we go!

Start with Takt

Read 5 min

CPM is a requirement for most construction projects. That’s fine, we can make that work… If  you start your plan with a Takt plan and create flow. When projects are created in CPM flow is not naturally created in the system.

The picture below shows an analysis of a project created in CPM.

 
 

You may notice some of the activity colors have flow, and others stack, and others actually go backward. This is a common finding when doing a flow analysis on CPM schedules across the country. This is why projects crash land, crew counts increase, material inventory becomes unmanageable, and we do not have flow. The only way to fix this is to structure a schedule with flow. The graphic below shows this effort based on the example above.

 
 

What do you see? You see a better flow, you see there is a need for separate crews in the second area, and you see the path to completion. This approach will finish the project on time. Once this analysis is done, it is time to format this into a Takt plan for the project to follow:

 
 
 

Now we have a plan the entire project can follow. But! And this is the inspired part… All of this would have been easier if we would have started with Takt, and then built a CPM schedule from it if the Owner requires it.

Our plea is to please start with Takt planning. Please design flow into your system. Please set yourself up for success. If you start with Takt planning, you will have a more correct overall project duration, a steady flow, reduced chances of a crash landing at the end,  reduced crew counts, material inventory and costs. This is what winning looks like!

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here) 
-Listen to the Elevate Construction podcast: (Click here) 
-Check out our training programs and certifications: (Click here)
The Takt Book: (Click here)

Discover Jason’s Expertise:

Meet Jason Schroeder, the driving force behind Elevate Construction IST. As the company’s owner and principal consultant, he’s dedicated to taking construction to new heights. With a wealth of industry experience, he’s crafted the Field Engineer Boot Camp and Superintendent Boot Camp – intensive training programs engineered to cultivate top-tier leaders capable of steering their teams towards success. Jason’s vision? To expand his training initiatives across the nation, empowering construction firms to soar to unprecedented levels of excellence.

On we go!

Remarkable Field Operations

Read 4 min

Do you want a strong Field Ops group in your organization? If so, where is the list? Where is the checklist for you to get started? Well, the wait is over. Check out the checklist below and get started on your journey with strong Field Operations:

 
 
 

First Step:

  • Align expectations of all field positions levels

  • Align pay structures

  • Align goal setting and performance reviews

  • Align incentive programs

  • Create a monthly Super meeting where top leaders are trained, and all leaders are trained

Second Step:

  • Create a field leadership group

  • Start Bi-monthly Craft training

  • Create a Craft progression program that allows Craft to learn in the field engineering role (builder) as they head toward becoming Supers

  • Focus field leadership around the following focuses:

  • Safety

  • Self-perform

  • Planning & Scheduling

  • Survey

  • Quality

Third Step:

  • Standardize all processes and systems

  • Deploy standardized signage

  • Brand and package safety program to align with new systems

  • Deploy Builder & Super Boot Camps

Fourth Step:

 
  • Designate General Superintendents

  • Have field representation on the leadership team

  • Implement a 2 second lean continuous improvement system

  • Begin a monthly field builder professional development effort

  • Create leads for Safety, Survey, Quality, Scheduling, and Self Perform

Whatever your approach is to strengthening your field operations, you will be benefited. Every business must focus on marketing, finances, legal, operations, and the product. Please remember what is built in the field is the product, and there must be product representation within your leadership.

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here) 
-Listen to the Elevate Construction podcast: (Click here) 
-Check out our training programs and certifications: (Click here)
The Takt Book: (Click here)

Discover Jason’s Expertise:

Meet Jason Schroeder, the driving force behind Elevate Construction IST. As the company’s owner and principal consultant, he’s dedicated to taking construction to new heights. With a wealth of industry experience, he’s crafted the Field Engineer Boot Camp and Superintendent Boot Camp – intensive training programs engineered to cultivate top-tier leaders capable of steering their teams towards success. Jason’s vision? To expand his training initiatives across the nation, empowering construction firms to soar to unprecedented levels of excellence.

On we go!

Upcoming Super Boot Camp

Read 2 min

Are you ready to take your next step as a Superintendent? Join us for our next Super Boot Camp. If you are interested, please send an email to Jason at jasons@elevateconstructionist.com or text at 602.571.8987.

 
 
 
 
 
 
 
 

 

 
 

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here) 
-Listen to the Elevate Construction podcast: (Click here) 
-Check out our training programs and certifications: (Click here)
The Takt Book: (Click here)

Discover Jason’s Expertise:

Meet Jason Schroeder, the driving force behind Elevate Construction IST. As the company’s owner and principal consultant, he’s dedicated to taking construction to new heights. With a wealth of industry experience, he’s crafted the Field Engineer Boot Camp and Superintendent Boot Camp – intensive training programs engineered to cultivate top-tier leaders capable of steering their teams towards success. Jason’s vision? To expand his training initiatives across the nation, empowering construction firms to soar to unprecedented levels of excellence.

On we go!

Great Guides for Supers

Read 2 min

We have distilled some of the best wisdom from history into a few key graphics that will help Superintendents in their role. Check them out below:

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

 

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here) 
-Listen to the Elevate Construction podcast: (Click here) 
-Check out our training programs and certifications: (Click here)
The Takt Book: (Click here)

Discover Jason’s Expertise:

Meet Jason Schroeder, the driving force behind Elevate Construction IST. As the company’s owner and principal consultant, he’s dedicated to taking construction to new heights. With a wealth of industry experience, he’s crafted the Field Engineer Boot Camp and Superintendent Boot Camp – intensive training programs engineered to cultivate top-tier leaders capable of steering their teams towards success. Jason’s vision? To expand his training initiatives across the nation, empowering construction firms to soar to unprecedented levels of excellence.

On we go!

Takt Process Resource

Read 3 min

Takt planning is like a super helpful tool for construction projects. It’s a way to spot problems quickly and make everything run smoother. Imagine it as a map that shows where things might go wrong on a construction site. This map is easy to understand, even if you’re not an expert. It helps people in charge make better decisions by letting them see potential issues ahead of time.

The main goal is to keep the work moving steadily, so projects get done on time and on budget. Takt planning is a real game-changer in construction management, all about spotting problems and making things flow better, just like we mentioned: A system that can show us our problems so that we can fix them and increase flow on our construction projects.

The attached excel sheet can be used as a source for Takt Dials and Value Progression Options.

 

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here) 
-Listen to the Elevate Construction podcast: (Click here) 
-Check out our training programs and certifications: (Click here)
The Takt Book: (Click here)

Discover Jason’s Expertise:

Meet Jason Schroeder, the driving force behind Elevate Construction IST. As the company’s owner and principal consultant, he’s dedicated to taking construction to new heights. With a wealth of industry experience, he’s crafted the Field Engineer Boot Camp and Superintendent Boot Camp – intensive training programs engineered to cultivate top-tier leaders capable of steering their teams towards success. Jason’s vision? To expand his training initiatives across the nation, empowering construction firms to soar to unprecedented levels of excellence.

On we go!

Takt Leveling Production

Read 8 min

The key to the future of construction is Takt planning & control that we like to call the Takt Production System. This system works seamlessly in concert with The Last Planner® System & Scrum to be the only three planning and scheduling systems and tools needed for construction. All three are focused on the right things, flow and value.

 
 

Above are three separate options for a large civil project from an awesome contractor Petticoat-Schmitt that we created in about a half hour. We looked at only what we can do with leveling production to find the common rhythm we found a way to cut 40-25% of the overall duration while also including in that cut an additional 8% buffer into the plan making this not only exponentially better but more likely to be archived.

Option 1 you will see how each scope of work is working at their own capacity, this takt simulation is 15-20% better than the CMP, This duration comes in around 75 days total duration.

Option 2 we realized we could increase our throughput if we cut the zones in half with our crew we have available (there are three crews to achieve Takt wagons A-E). When we found this optimization we added in some buffers and held the date around 75 days giving us that more likelihood to be able to achieve this schedule. This one is more than 15-20% better than the CPM because we added more buffer time into the plan as we didn’t have very much in Option 1.

Option 3 This is the best duration we found coming in at 60 days but with the most buffers (10 days of buffer throughout this schedule). This option is 40% better than the original CPM schedule. We did have a question about if Trade H with their equipment would be able to adjust to the rhythm that we have in Option 3 so we made……

Option 4 where we took away a buffer day and we back to the original production for H and changed J a bit because we could with these changes this making our cost decrease too. Our final two options are the ones we are looking into to see which one will work per the systems constraints, resources, work force and trades. This means we will for sure cut our overall project duration by 40-38% and still be giving each trade the same about of time….

Yes this is achievable, and no this is not a trick, it is what we have all been wishing for. A system that can show us our problems so that we can fix them and increase flow on our construction projects. This is available to you right now, We are not selling software and do not believe that you need anything other than excel to start. In fact if you want, we have a book that you can listen to for free right now to understand these principles to learn what we call “The Takt Production System”.

At Elevate Construction and leanTakt we believe Takt is the key to alleviating the issues in construction like the high statistics we have in the construction industry such as: work life balance, alcoholism, divorce, stress, safety incidences & deaths and even worse suicide. We do not want to be what holds back Takt from taking hold in our industry so we believe in making this tool as free as possible.

After helping hundreds of projects use Takt I have personally seen some projects cut schedule by more than half using Takt. This does not mean that every project type can be cut by this much but simply a data point to convey the possibilities with this system. not to mention that everyone can read it and that it will allow you to be able to achieve flow and focus most of your time finding and removing roadblocks.

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here) 
-Listen to the Elevate Construction podcast: (Click here) 
-Check out our training programs and certifications: (Click here)
The Takt Book: (Click here)

Discover Jason’s Expertise:

Meet Jason Schroeder, the driving force behind Elevate Construction IST. As the company’s owner and principal consultant, he’s dedicated to taking construction to new heights. With a wealth of industry experience, he’s crafted the Field Engineer Boot Camp and Superintendent Boot Camp – intensive training programs engineered to cultivate top-tier leaders capable of steering their teams towards success. Jason’s vision? To expand his training initiatives across the nation, empowering construction firms to soar to unprecedented levels of excellence.

On we go!

Is Takt Really Magic?

Read 7 min

By: Kevin Rice

Something I asked my self as I started researching Takt and its benefits. Like you; I am newer to Takt planning and thought I would take a concept that intrigued me and start to explore my findings.

 
 
 

Scheduling with Takt allows you to take a project with a linear schedule and implement strategic overlapping. This leads to shorter project duration and more buffer time, but how is this possible?

Today I’d like to dive deeper into Little’s “Takt” Law, also called Dlouhy & Binninger’s Law. This law describes the relationship between inputs in a Takt plan. It goes something like this:

(Takt Wagons + Takt Zones – 1) x Takt Time = Total Duration

(TW + TZ – 1) x TT = TD

I’m sure that most of you are familiar with this idea, but I wanted to dive into the math and really understand how this works, so I turned to one of my best friends, Excel. Yeah, I’m weird like that.

 

I started by building a simple matrix that showed a few of the possible Takt plans for a given set of inputs and the actual Takt flow diagram for each one. It looked like this:

 
 
 

Once I built the matrix I found I had more questions than I did when I started. Questions like:

  • What is the “best” Takt plan for this set of inputs?

  • Why does each trade get 2 extra days when going from 2 sequences to 4 sequences? And why do they get 6 extra days when going to 8 sequences?

  • What about other numbers of sequences?

To answer these questions I turned back to my friend Excel and graphed out what the theoretical lower limit for this set of inputs ranging from 1 and 10 sequences.

 
 
 
 
 

This shows the Law of Diminishing Returns when Takt planning. This graph is great, but it is theoretical and I wanted to see what happens when you take it to the real world. We don’t often work in half day increments and it is common to round these up to the nearest day or week. Adding this real life constraint of rounding each Takt time up to the nearest unit changes things significantly. So back to excel I went and here is what happens.

 

 
 
 
 

Crazy stuff right! Rounding changes everything! You can see how important it is to know some of this information up front during the planning phases of your project. Understanding how it affects duration is critically important to formulate the best Takt plan. Notice that the theoretical lower limit intersects with certain numbers of sequences or zones. These Takt plans will be lean and mean, but not always possible, or desired. Sometimes a certain number of sequences or zones is better for a particular project, but it is important to know how this affects the Takt plan relative to possibilities. This way a more informed decision can be made to balance all of the factors involved in completing large scale projects.

Rounding is also where the extra 2 days and 6 days of trade work come from. Rounding each Takt time up accrues over the project. This gives each trade more time on the project and still reduces the overall project duration. It became obvious that the utility of a tool that would model all the different possible Takt plans for any given set of inputs would really help to optimize Takt planning and allow for a more efficient and strategic overall plan.  

 

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here) 
-Listen to the Elevate Construction podcast: (Click here) 
-Check out our training programs and certifications: (Click here)
The Takt Book: (Click here)

Discover Jason’s Expertise:

Meet Jason Schroeder, the driving force behind Elevate Construction IST. As the company’s owner and principal consultant, he’s dedicated to taking construction to new heights. With a wealth of industry experience, he’s crafted the Field Engineer Boot Camp and Superintendent Boot Camp – intensive training programs engineered to cultivate top-tier leaders capable of steering their teams towards success. Jason’s vision? To expand his training initiatives across the nation, empowering construction firms to soar to unprecedented levels of excellence.

On we go!

Why Huddle Boards?

Read 12 min

What is the purpose of a huddle board?

A huddle board should let us see if we are winning daily. It allows everyone on the project site to see as a group, know things as a group, and act together as a group. The purpose is to run the project, and not let it run us. We cannot manage what we cannot measure, and we cannot measure what we cannot see. Huddle boards are for helping us see what winning looks like, so we can own the gap between where we are and where we want to go.

 
 

Here are some guidelines:

1. Everything should be out of our heads. The schedule, the logistics, the strategy, and the problems. None of it belongs in our head or the head of the superintendent. Your mind is for having ideas, not holding them. Huddle boards are supposed to hold them. The reason an inexperienced superintendent is constantly fighting fires and on the phone is because the visual huddle board for the project is in their head. Get it out of your head, and the people will begin interacting with the information and figuring things out for themselves.

2. Everyone every day should be able to see what winning looks like

 

How do you use your huddle board?

Here are some helpful guidelines for using a huddle board:

1. Keep it shut overnight and when not in use.

2. Lock it.

3. Use the newer versions that are moisture tight and don’t ruin the papers inside.

4. Use a squeegee to clean off the face of the huddle board in the morning when presenting to the workers.

5. Keep a rag on hand to finish cleaning the face of the glass off.

6. Use large dry-erase markers on the front to communicate with workers.

7. The idea is to keep the schedule updated weekly, open the front screen to edit the materials inside with the foremen, and then to close the front screen ahead of the worker huddle so you can use the markers to communicate the plan the next day.

 
 
 

Why do we have a Takt plan?

The Takt plan shows where we are, where we are going, and how delays impact our milestones and deadlines. Without knowing the overall plan we cannot strategize and make corrections to the project plan. We should be able to see flow, target dates, buffers, and deadlines. Without this, there is no way to see the impacts of changes, get help, and request needed funds or time from the owner. The superintendent must keep this plan up to date personally every week if not every day.

 

Why do we have a Logistics Plan?

To win on our projects we must only handle things once. That means materials, stock piles, installations, and routes. We need to play the staging of all these things before they arrive on site or show up. If we do that, we will reduce waste, respect people, and make money. We can coordinate this as we visually show the plan for the day on the logistics plan to the entire team.

 

Why do we track roadblocks?

The super, PM, PX, and company leaders are all professional roadblock removers. The two main rules in construction are: Keep the flow, and keep the team balanced. We keep the flow by seeing and removing roadblocks before they affect the work, and we keep the team balanced by sharing the load and working together. Every day a superintendent needs to gather information about roadblocks from the team so s/he can work with the PM in the team daily huddle to remove roadblocks together, and keep work moving forward.

 

Why do we target certain codes for production by foreman?

If we bid a project at 8%, our estimate shows 8%, our budget meetings show 8%, our schedule shows 8%, and our production trackers show 8%. But we want a higher % to fund bonuses. So, what do we do? Great question! We show key production codes that we can use to do better than the estimate, and we visually show that production rate for everyone to see. That way, the team can track daily progress to hitting those targets. We will never get higher than our estimate % gross margin unless we target that number. These code trackers target that number.

 

What meetings do you host?

There are two meeting we must host. The afternoon foreman huddle, and the morning worker huddle.

The purpose of the Afternoon Foreman Huddle is to do the following in addition to the normal agenda:

1. Mark what activities were and were not completed the day before.

2. What activities have to be done tomorrow to keep schedule.

3. Where deliveries, staging, and stock piles will be located.

4. Prepare work and find roadblocks for the super and PM to remove.

5. Discuss production targets and make plans to do better.

6. Make a plan for the next day.

 

The purpose of the Morning Worker Huddle is to communicate the plan for the day to the workers. It is crucial to show in red where we are not winning according to our plan and to engage the minds of all workers and foremen in solving the problems and improving each day.

Here are some questions for us:

 

1. How can we manage the schedule without a visual schedule?

2. How can we only handle things once if we do not all know where things go?

3. How can we create flow unless we see and remove roadblocks together?

4. How can we get to a higher % unless we know what key scopes will get us there and what production rate we need to hit to get there?

The answers are obvious.

We use huddle boards because we only win as a team. Navy seals win as a team. Olympic champions win as a team. Race car drivers win in a team. Companies win a as a team, and to win as a team, we must see as a team, know the status of the project as a team, and act together to improve it.

 

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here) 
-Listen to the Elevate Construction podcast: (Click here) 
-Check out our training programs and certifications: (Click here)
The Takt Book: (Click here)

Discover Jason’s Expertise:

Meet Jason Schroeder, the driving force behind Elevate Construction IST. As the company’s owner and principal consultant, he’s dedicated to taking construction to new heights. With a wealth of industry experience, he’s crafted the Field Engineer Boot Camp and Superintendent Boot Camp – intensive training programs engineered to cultivate top-tier leaders capable of steering their teams towards success. Jason’s vision? To expand his training initiatives across the nation, empowering construction firms to soar to unprecedented levels of excellence.

On we go!

How do you Apply Kingman’s Formula?

Read 13 min

THEORETICALLY

I will preface my comments and say we are all at different stages in our LeanTakt journey in the construction industry; and the fact that the US market is still clinging to the CPM tools of yesteryear makes this question problematic to answer generally. So I am choosing to refer my comments mainly for the US market even though we have a broad coalition of international leanTakt folks that might disagree with some of my generalities. (for instance in Germany over 50% of construction projects are planned and executed using Takt, according to experts from the region).

The sooner we can understand (and help our clients understand) that we will encounter variation on our projects; the better off we will be. Because we will encounter and have to deal with variation on every single project that we will ever be a part of.

In the amazing book The Goal (which is a must read for everyone in construction!). The Author Eli Goldratt wrote about an issue that is near impossible to predict 100% but needs to be accounted for. He called this Statistical Fluctuation because of this what I call “variation”the straight production math does not work out. Mike Tyson’s famous quote applies here: “everyone has a plan until they get punched in the face”.

in the book Alex Bogo (main character) also figured out that only a few processes in his manufacturing plant need to be working at a high utilization or capacity. These are the systems bottlenecks. Again if you have yet to read this book you are missing out on why construction production has been stagnating for decades (see chart Below).

 

 

So when planning and you are new to takt planning the easy thing to remember is what Katherine said, we know about this and need to account for it….. But hold on I have some great value on a process on how to do this today right now that will help you even if you have not found a way to capture either the variation or utilization. It is called work packaging and buffer management.

Work Packaging

When you know your sequential work flow in a production area that I would call a takt zone

 
 

from say a phase pull plan (see Last Planner® System)

 
 

you now have the opportunity to systematize your production line into Takt wagons that are aligned to your bottlenecks production, the rule of thumb we follow when doing this is that the Takt time should be aligned with the bottleneck in some form (there are various ways of doing this). Next you “package” the work packages (the individual sticky notes from the pull plan) together into groups that can be in the same zone at the same time. These are called Takt Wagons.

 

You will add in integrated buffer to account for some of these effects mostly for the non bottleneck work packages. For the bottlenecks we use Buffer Management in the next section. Again this is where you would theoretically just add in some buffer to account for our variation and utilization.

A=VUT

T is identified primarily from the phase pull plan above

V&U are accounted for with work-packaging and buffer management

 

Buffer Mangement

From the Optimization step you will usually find time you can save with changing batch sizes and limiting work in process (WIP). From that time saved it allows you the ability to add the needed buffer into the plan to achieve flow. This is what CPM doesn’t do for us, since its primary focus is resource efficiency it inadvertently has us max our utilization of resources all as much as we can which just creates busy people working on a ton of non value add stuff and increases WIP elongating our overall duration.

 
 
 
 

Just like the image above a freeway with 100% utilization is a parking lot! So obviously adding in the buffer makes sense because the likelihood of everything going to plan with no variation is 0% meaning we have to have it in our plan and understand where it is. Either just the CPM expert knows where this is or its thrown in as larger activity durations and weird logic ties that end up making the plan not useful in the first place.

So when bottleneck has been established and is driving your takt time there are a myriad of ways to add in “visible” buffer. These buffers should account for two things, if we understand that the bottleneck is going to be the most utilized resource then we need to allow it some buffer so it is not planned at 100% utilization. It is also added in to account for variation that will occur just like was mentioned above.

 
At first you need to make educated guesses on these other than some basic rules of thumb that can help you:
 
  1. 5% integrated buffer for non bottleneck work packages

  2. use the remaining buffer to systemically support the bottleneck

  3. Use Stability Parametric to know if you have the right Bottleneck buffers vs calculated end buffers.

I am sure there might be more questions and It also happens that we cover these topics in our upcoming class on Takt in construction and we only have a few more spots open so jump in and sign up if you are interested. (Click Here)

 

LITERALLY

The best way to identify your variation and account for it in your work packages is to track this with your roadblock tracking maps and gather data on variation that you caught ahead of time. Also if you are using the Last Planner® System and are tracking PPC & Variances this is the data on items you didn’t resolve and did effect you. With This information you can calculate how much variation you should encounter. It is different for each type of work in construction (health care, industrial, high rise). Thus tracking and accounting for it will be at the company or department level. When you have tracked this historical variation you can use that as a percentage for integrated buffer in work packaging and buffer management.

Here is a video where tracking historical information can help you with planning the same work in the future because the sequence.

 

By now you can see that there is a process and method for accounting for real life (Variation x Utilization x Cycle Time). The more our systems drive less WIP, account for variation, keep us from 100% utilization and standardize these processes we will increase flow and decrease our overall durations of our construction projects.

 
 
 
 

The author of a great article that some of these graphics are from is an Agile Guru from the software side of industry; his name is Adrian Liard and you can check out his original post which is amazing here: https://medium.com/@Adrien_Liard/why-you-should-limit-work-in-progress-and-stop-multitasking-ba7ecd4670f

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here) 
-Listen to the Elevate Construction podcast: (Click here) 
-Check out our training programs and certifications: (Click here)
The Takt Book: (Click here)

Discover Jason’s Expertise:

Meet Jason Schroeder, the driving force behind Elevate Construction IST. As the company’s owner and principal consultant, he’s dedicated to taking construction to new heights. With a wealth of industry experience, he’s crafted the Field Engineer Boot Camp and Superintendent Boot Camp – intensive training programs engineered to cultivate top-tier leaders capable of steering their teams towards success. Jason’s vision? To expand his training initiatives across the nation, empowering construction firms to soar to unprecedented levels of excellence.

On we go!

    faq

    General Training Overview

    What construction leadership training programs does LeanTakt offer?
    LeanTakt offers Superintendent/PM Boot Camps, Virtual Takt Production System® Training, Onsite Takt Simulations, and Foreman & Field Engineer Training. Each program is tailored to different leadership levels in construction.
    Who should attend LeanTakt’s training programs?
    Superintendents, Project Managers, Foremen, Field Engineers, and trade partners who want to improve planning, communication, and execution on projects.
    How do these training programs improve project performance?
    They provide proven Lean and Takt systems that reduce chaos, improve reliability, strengthen collaboration, and accelerate project delivery.
    What makes LeanTakt’s training different from other construction courses?
    Our programs are hands-on, field-tested, and focused on practical application—not just classroom theory.
    Do I need prior Lean or takt planning experience to attend?
    No. Our programs cover foundational principles before moving into advanced applications.
    How quickly can I apply what I learn on real projects?
    Most participants begin applying new skills immediately, often the same week they complete the program.
    Are these trainings designed for both office and field leaders?
    Yes. We equip both project managers and superintendents with tools that connect field and office operations.
    What industries benefit most from LeanTakt training?
    Commercial, multifamily, residential, industrial, and infrastructure projects all benefit from flow-based planning.
    Do participants receive certificates after completing training?
    Yes. Every participant receives a LeanTakt Certificate of Completion.
    Is LeanTakt training recognized in the construction industry?
    Yes. Our programs are widely respected among leading GCs, subcontractors, and construction professionals.

    Superintendent / PM Boot Camp

    What is the Superintendent & Project Manager Boot Camp?
    It’s a 5-day immersive training for superintendents and PMs to master Lean leadership, takt planning, and project flow.
    How long does the Superintendent/PM Boot Camp last?
    Five full days of hands-on training.
    What topics are covered in the Boot Camp curriculum?
    Lean leadership, Takt Planning, logistics, daily planning, field-office communication, and team health.
    How does the Boot Camp improve leadership and scheduling skills?
    Yes. You’ll learn how to run day huddles, team meetings, worker huddles, and Lean coordination processes.
    Who is the Boot Camp best suited for?
    Construction leaders responsible for delivering projects, including Superintendents, PMs, and Field Leaders.
    What real-world challenges are simulated during the Boot Camp?
    Schedule breakdowns, trade conflicts, logistics issues, and communication gaps.
    Will I learn Takt Planning at the Boot Camp?
    Yes. Takt Planning is a core focus of the Boot Camp.
    How does this Boot Camp compare to traditional PM certification?
    It’s practical and execution-based rather than exam-based. You learn by doing, not just studying theory.
    Can my entire project team attend the Boot Camp together?
    Yes. Teams attending together often see the greatest results.
    What kind of real-world challenges do we simulate?
    Improved project flow, fewer delays, better team communication, and stronger leadership confidence.

    Takt Production System® Virtual Training

    What is the Virtual Takt Production System® Training?
    It’s an expert-led online program that teaches Lean construction teams how to implement takt planning.
    How does virtual takt training work?
    Delivered online via live sessions, interactive discussions, and digital tools.
    What are the benefits of online takt planning training?
    Convenience, global accessibility, real-time learning, and immediate application.
    Can I access the virtual training from anywhere?
    Yes. It’s fully web-based and accessible worldwide.
    Can I access the virtual training from anywhere?
    Yes. It’s fully web-based and accessible worldwide.
    What skills will I gain from the Virtual TPS® Training?
    Macro and micro Takt planning, weekly updates, flow management, and CPM integration.
    How long does the virtual training program take?
    The program is typically completed in multiple live sessions across several days.
    Can I watch recordings if I miss a session?
    Yes. Recordings are available to all participants.
    Do you offer group access or company licenses for the virtual training?
    Yes. Teams and companies can enroll together at discounted rates.
    How does the Virtual TPS® Training integrate with CPM tools?
    We show how to align Takt with CPM schedules like Primavera P6 or MS Project.

    Onsite Takt Simulation

    What is a Takt Simulation in construction training?
    It’s a live, interactive workshop that demonstrates takt planning on-site.
    How does the Takt Simulation workshop work?
    Teams participate in hands-on exercises to learn the flow and rhythm of a Takt-based project.
    Can I choose between a 1-day or 2-day Takt Simulation?
    Yes. We offer flexible formats to fit your team’s schedule and needs.
    Who should participate in the Takt Simulation workshop?
    Superintendents, PMs, site supervisors, contractors, and engineers.
    How does a Takt Simulation improve project planning?
    It shows teams how to structure zones, manage flow, and coordinate trades in real time.
    What will my team learn from the onsite simulation?
    How to build and maintain takt plans, manage buffers, and align trade partners.
    Is the simulation tailored to my specific project type?
    Yes. Scenarios can be customized to match your project.
    How do Takt Simulations improve trade partner coordination?
    They strengthen collaboration by making handoffs visible and predictable.
    What results can I expect from an onsite Takt Simulation?
    Improved schedule reliability, better trade collaboration, and reduced rework.
    How many people can join a Takt Simulation session?
    Group sizes are flexible, but typically 15–30 participants per session.

    Foreman & Field Engineer Training

    What is Foreman & Field Engineer Training?
    It’s an on-demand, practical program that equips foremen and engineers with leadership and planning skills.
    How does this training prepare emerging leaders?
    By teaching communication, crew management, and execution strategies.
    Is the training on-demand or scheduled?
    On-demand, tailored to your team’s timing and needs.
    What skills do foremen and engineers gain from this training?
    Planning, safety leadership, coordination, and communication.
    How does the training improve communication between field and office?
    It builds shared systems that align superintendents, engineers, and managers.
    Can the training be customized for my team’s needs?
    Yes. Programs are tailored for your project or company.
    What makes this program different from generic leadership courses?
    It’s construction-specific, field-tested, and focused on real project application.
    How do foremen and field engineers apply this training immediately?
    They can use new systems for planning, coordination, and daily crew management right away.
    Is the training suitable for small construction companies?
    Yes. Small and large teams alike benefit from building flow-based leadership skills.

    Testimonials

    Testimonials

    "The bootcamp I was apart of was amazing. Its was great while it was happening but also had a very profound long-term motivation that is still pushing me to do more, be more. It sounds a little strange to say that a construction bootcamp changed my life, but it has. It has opened my eyes to many possibilities on how a project can be successfully run. It’s also provided some very positive ideas on how people can and should be treated in construction.

    I am a hungry person by nature, so it doesn’t take a lot to get to participate. I loved the way it was not just about participating, it was also about doing it with conviction, passion, humility and if it wasn’t portrayed that way you had to do it again."

    "It's great to be a part of a company that has similar values to my own, especially regarding how we treat our trade partners. The idea of "you gotta make them feel worse to make them do better" has been preached at me for years. I struggled with this as you will not find a single psychology textbook stating these beliefs. In fact it is quite the opposite, and causing conflict is a recipe for disaster. I'm still honestly in shock I have found a company that has based its values on scientific facts based on human nature. That along with the Takt scheduling system makes everything even better. I am happy to be a part of a change that has been long overdue in our industry!"

    "Wicked team building, so valuable for the forehumans of the sub trades to know the how and why. Great tools and resources. Even though I am involved and use the tools every day, I feel like everything is fresh and at the forefront to use"

    "Jason and his team did an incredible job passing on the overall theory of what they do. After 3 days of running through the course I cannot see any holes in their concept. It works. it's proven to work and I am on board!"

    "Loved the pull planning, Takt planning, and logistic model planning. Well thought out and professional"

    "The Super/PM Boot Camp was an excellent experience that furthered my understanding of Lean Practices. The collaboration, group involvement, passion about real project site experiences, and POSITIVE ENERGY. There are no dull moments when you head into this training. Jason and Mr. Montero were always on point and available to help in the break outs sessions. Easily approachable to talk too during breaks and YES, it was fun. I recommend this training for any PM or Superintendent that wants to further their career."

    agenda

    Day 1

    Foundations & Macro Planning

    day2

    Norm Planning & Flow Optimization

    day3

    Advanced Tools & Comparisons

    day4

    Buffers, Controls & Finalization

    day5

    Control Systems & Presentations

    faq

    UNDERSTANDING THE TRAINING

    What is the Virtual Takt Production System® Training by LeanTakt?
    It’s an expert-led online program designed to teach construction professionals how to implement Takt Planning to create flow, eliminate chaos, and align teams across the project lifecycle.
    Who should take the LeanTakt virtual training?
    This training is ideal for Superintendents, Project Managers, Engineers, Schedulers, Trade Partners, and Lean Champions looking to improve planning and execution.
    What topics are covered in the online Takt Production System® course?
    The course covers macro and micro Takt planning, zone creation, buffers, weekly updates, flow management, trade coordination, and integration with CPM tools.
    What makes LeanTakt’s virtual training different from other Lean construction courses?
    Unlike theory-based courses, this training is hands-on, practical, field-tested, and includes live coaching tailored to your actual projects.
    Do I get a certificate after completing the online training?
    Yes. Upon successful completion, participants receive a LeanTakt Certificate of Completion, which validates your knowledge and readiness to implement Takt.

    VALUE AND RESULTS

    What are the benefits of Takt Production System® training for my team?
    It helps teams eliminate bottlenecks, improve planning reliability, align trades, and reduce the chaos typically seen in traditional construction schedules.
    How much time and money can I save with Takt Planning?
    Many projects using Takt see 15–30% reductions in time and cost due to better coordination, fewer delays, and increased team accountability.
    What’s the ROI of virtual Takt training for construction teams?
    The ROI comes from faster project delivery, reduced rework, improved communication, and better resource utilization — often 10x the investment.
    Will this training reduce project delays or rework?
    Yes. By visualizing flow and aligning trades, Takt Planning reduces miscommunication and late handoffs — major causes of delay and rework.
    How soon can I expect to see results on my projects?
    Most teams report seeing improvement in coordination and productivity within the first 2–4 weeks of implementation.

    PLANNING AND SCHEDULING TOPICS

    What is Takt Planning and how is it used in construction?
    Takt Planning is a Lean scheduling method that creates flow by aligning work with time and space, using rhythm-based planning to coordinate teams and reduce waste.
    What’s the difference between macro and micro Takt plans?
    Macro Takt plans focus on the overall project flow and phase durations, while micro Takt plans break down detailed weekly tasks by zone and crew.
    Will I learn how to build a complete Takt plan from scratch?
    Yes. The training teaches you how to build both macro and micro Takt plans tailored to your project, including workflows, buffers, and sequencing.
    How do I update and maintain a Takt schedule each week?
    You’ll learn how to conduct weekly updates using lookaheads, trade feedback, zone progress, and digital tools to maintain schedule reliability.
    Can I integrate Takt Planning with CPM or Primavera P6?
    Yes. The training includes guidance on aligning Takt plans with CPM logic, showing how both systems can work together effectively.
    Will I have access to the instructors during the training?
    Yes. You’ll have opportunities to ask questions, share challenges, and get real-time feedback from LeanTakt coaches.
    Can I ask questions specific to my current project?
    Absolutely. In fact, we encourage it — the training is designed to help you apply Takt to your active jobs.
    Is support available after the training ends?
    Yes. You can access follow-up support, coaching, and community forums to help reinforce implementation.
    Can your tools be customized to my project or team?
    Yes. We offer customizable templates and implementation options to fit different project types, teams, and tech stacks.
    When is the best time in a project lifecycle to take this training?
    Ideally before or during preconstruction, but teams have seen success implementing it mid-project as well.

    APPLICATION & TEAM ADOPTION

    What changes does my team need to adopt Takt Planning?
    Teams must shift from reactive scheduling to proactive, flow-based planning with clear commitments, reliable handoffs, and a visual management mindset.
    Do I need any prior Lean or scheduling experience?
    No prior Lean experience is required. The course is structured to take you from foundational principles to advanced application.
    How long does it take for teams to adapt to Takt Planning?
    Most teams adapt within 2–6 weeks, depending on project size and how fully the system is adopted across roles.
    Can this training work for smaller companies or projects?
    Absolutely. Takt is scalable and especially powerful for small teams seeking better structure and predictability.
    What role do trade partners play in using Takt successfully?
    Trade partners are key collaborators. They help shape realistic flow, manage buffers, and provide feedback during weekly updates.

    VIRTUAL FORMAT & ACCESSIBILITY

    Can I access the virtual training from anywhere?
    Yes. The training is fully accessible online, making it ideal for distributed teams across regions or countries.
    Is this training available internationally?
    Yes. LeanTakt trains teams around the world and supports global implementations.
    Can I watch recordings if I miss a session?
    Yes. All sessions are recorded and made available for later viewing through your training portal.
    Do you offer group access or company licenses?
    Yes. Teams can enroll together at discounted rates, and we offer licenses for enterprise rollouts.
    What technology or setup do I need to join the virtual training?
    A reliable internet connection, webcam, Miro, Spreadsheets, and access to Zoom.

    faq

    GENERAL FAQS

    What is the Superintendent / PM Boot Camp?
    It’s a hands-on leadership training for Superintendents and Project Managers in the construction industry focused on Lean systems, planning, and communication.
    Who is this Boot Camp for?
    Construction professionals including Superintendents, Project Managers, Field Engineers, and Foremen looking to improve planning, leadership, and project flow.
    What makes this construction boot camp different?
    Real-world project simulations, expert coaching, Lean principles, team-based learning, and post-camp support — all built for field leaders.
    Is this just a seminar or classroom training?
    No. It’s a hands-on, immersive experience. You’ll plan, simulate, collaborate, and get feedback — not sit through lectures.
    What is the focus of the training?
    Leadership, project planning, communication, Lean systems, and integrating office-field coordination.

    CURRICULUM & OUTCOMES

    What topics are covered in the Boot Camp?
    Takt planning, day planning, logistics, pre-construction, team health, communication systems, and more.
    What is Takt Planning and why is it taught?
    Takt is a Lean planning method that creates flow and removes chaos. It helps teams deliver projects on time with less stress.
    Will I learn how to lead field teams more effectively?
    Yes. This boot camp focuses on real leadership challenges and gives you systems and strategies to lead high-performing teams.
    Do you cover daily huddles and meeting systems?
    Yes. You’ll learn how to run day huddles, team meetings, worker huddles, and Lean coordination processes.
    What kind of real-world challenges do we simulate?
    You’ll work through real project schedules, logistical constraints, leadership decisions, and field-office communication breakdowns.

    LOGISTICS & FORMAT

    Is the training in-person or virtual?
    It’s 100% in-person to maximize learning, feedback, and team-based interaction.
    How long is the Boot Camp?
    It runs for 5 full days.
    Where is the Boot Camp held?
    Locations vary — typically hosted in a professional training center or project setting. Contact us for the next available city/date.
    Do you offer follow-up coaching after the Boot Camp?
    Yes. Post-camp support is included so you can apply what you’ve learned on your projects.
    Can I ask questions about my actual project?
    Absolutely. That’s encouraged — bring your current challenges.

    PRICING & VALUE

    How much does the Boot Camp cost?
    $5,000 per person.
    Are there any group discounts?
    Yes — get 10% off when 4 or more people from the same company attend.
    What’s the ROI for sending my team?
    Better planning = fewer delays, smoother coordination, and higher team morale — all of which boost productivity and reduce costs.
    Will I see results immediately?
    Most participants apply what they’ve learned as soon as they return to the jobsite — especially with follow-up support.
    Can this replace other leadership training?
    In many cases, yes. This Boot Camp is tailored to construction professionals, unlike generic leadership seminars.

    SEO-BASED / HIGH-INTENT SEARCH QUESTIONS

    What is the best leadership training for construction Superintendents?
    Our Boot Camp offers real-world, field-focused leadership training tailored for construction leaders.
    What’s included in a Superintendent Boot Camp?
    Takt planning, day planning, logistics, pre-construction systems, huddles, simulations, and more.
    Where can I find Lean construction training near me?
    Check our upcoming in-person sessions or request a private boot camp in your city.
    How can I improve field and office communication on a project?
    This Boot Camp teaches you tools and systems to connect field and office workflows seamlessly.
    Is there a training to help reduce chaos on construction sites?
    Yes — this program is built specifically to turn project chaos into flow through structured leadership.

    agenda

    Day 1

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    Outcomes

    Day 2

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    Day 3

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    Day 4

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    Day 5

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