Probably one of the most useful outlines we can provide for Takt is the step by step outline for how to create one. We hope to help you visualize the process in this blog post. But first, here is the list of steps in summary:
· Identify your start and end date.
· Research your drawings.
· Identify the general flow of the project based on known constraints.
· Identify preliminary Takt zones.
· Identify preliminary Takt time.
· Pull plan a typical sequence to start.
· Create the Takt sequence.
· Create the Takt phase.
· Identify logistics flow.
· Optimize the throughput with Little’s Law.
· Network phases together.
· Develop work steps.
· Trigger planning buffers in the system.
· Add buffers.
· Create standard work.
· Identify bottlenecks.
· Verify with trade partners.
· Create logistics plan/drawings.
· Create Takt zone maps.
· Perform a risk analysis.
· Create a Basis of Schedule (BOS).
· Align procurement.
· Review in a “fresh eyes” meeting.
· Create roadblock tracking maps.
· Track historical production.
· Add a TPNR.
One of the best ways to get into this system is to create your first Takt plan, so let’s get started. But first, we want to explain a few concepts of overall structure.
There are three levels of Takt plan development:
● Macro level, the process analysis – In the macro-level, the overall Takt plan is created.
● Norm-level Takt planning – In the norm-level, the Takt plan harmonization takes place.
● Micro level – This level of Takt planning is crucial to the system and cannot be omitted. In this step, the management of Takt control takes place.
Identify Your Start and End Date
Some projects come with a stipulated start and end date. Some projects’ start and end dates need to be identified through your efforts of creating a Takt plan. To be successful in creating your plan, you will start here and know what constraints you have as you begin the planning process. Then you can begin to…
Research Your Drawings
This step may seem like a given, but it needs to be said. One of the geniuses of Takt is that it gives our builders back the time they need to carry out the basics of a builder which means studying the drawings each day, forward planning in the schedule, and reflecting daily. As the builder studies the design and gets a feel for the flow, the sequence, and the general strategic approach for the project with others, he/she will immediately see and identify the flow of the project. This is to start to…
Builders can get a feel for the general flow of the project after digging into the drawings. Constraints like staging, material flow, material access, adjacent structures, hoisting, and project access will begin to form a picture of how the project will need to generally flow. Does the construction begin from east to west, or west to east? Does the interior run from top down or bottom up? This general idea of how the project will flow as the builder visualizes construction will begin…
Identifying Preliminary Takt Zones
Takt zones, sometimes known as geographical areas, production areas, or sequences, are the areas defined within the phase to identify work that will be scheduled on a rhythm per the Takt time. To get portions of work broken down to fit within a drumbeat, we must break the work up into zones that can be completed according to that drumbeat. This is easy to do, especially if the first planners know the general direction of the flow and how much area can be completed within the Takt time. So, the first planners literally guessed-and yes, I said guess-on the right size areas needed to break up the floor, exterior, or general work area. Once we do that, we can…
Pull Plan the Representative Zone
Now that we have a preliminary Takt zone size, we can outline the sequence of one representative Takt zone. Before you begin the pull plan, you may want to consider getting quantities for the representative area to better help trades visualize the commitments they are making.
The team will collaboratively pull the sequence inside the first representative Takt zone by following these steps:
Ask trades to come prepared with their activities, tags, or Sticky Notes ahead of the meeting and to think about what each activity needs for them to begin.
When opening the meeting establish the following:
1. The Time Frame
2. The trade colors
3. The Sticky Note format
4. The parking lot
5. The rules of the meeting—we recommend asking the group to make the rules of the pull plan together. Common rules teams list are:
1. No one touches each other’s tags
2. Make commitments to each other
3. Work from the milestone back
4. Turn the sticky to a diagonal if it has an unmet constraint
5. Sidebar non-pertinent conversations
6. Each trade will ask for the preceding tasks to be placed on the board
7. And so on…
Begin building the sequence of the pull plan until there are no more predecessors or needed activities
When the sequence is done, the team can work the plan forward to ensure it fits within the target duration and also to introduce parallelization of activities. The team will ensure the activity sequence is optimized.