Patterns in Planning, Constraints, and Prefabrication
In this blog, I want to share two patterns that will really help when you’re thinking about planning, along with one key concept related to prefabrication. These ideas came out of recent conversations with Kevin and from feedback during the Foreman Boot Camp in Kelowna, which was a huge success.
Optimizing Crews and Bottlenecks
Joel shared an interesting perspective on ironworking. He explained how erection crews focus on getting steel in the air quickly while secondary crews follow behind to plumb, torque, and finish. This approach avoids slowing down the crane the most expensive resource on site.
It’s a powerful reminder, sometimes it makes sense to structure work in waves, not because of rework or cleanup, but because of resource optimization. Running tasks in parallel without considering bottlenecks can actually hurt production and cost more.
The key is to distinguish between “cleanup crews” fixing mistakes versus specialized crews designed to keep bottlenecks flowing efficiently. That distinction matters.
The Three Major Constraints
Kevin highlighted a brilliant pattern that applies to almost any construction scenario:
Every project faces three primary constraints:
- Resources: Can the people, tools, and equipment actually perform the work?
- Supply Chain: Are the materials and supplies arriving in time to feed production?
- Spatial/Geographical: Is there enough physical space to complete the work effectively?
Balancing these constraints is essential. Over-utilizing resources leads to burnout and chaos. Underutilizing them means wasted time and missed opportunities. The goal is alignment matching work in process to system capacity with the right buffers to keep flow steady.
As Kevin put it, it’s not about limiting work in process. It’s about aligning work and process with the capacity of the system. That shift in perspective makes all the difference.
Prefabrication and Zone Sizes
The discussion also connected to prefabrication. A common question is: how big should your zones be? The answer depends on three things:
- Building type (multifamily, laboratory, hospital, etc.)
- Level of prefabrication (small unitized elements vs. large prefabricated spools)
- Capability of the contractors (experienced with takt time or still learning)
Smaller zones and shorter takt times may work for multifamily projects, while larger, more complex projects may require bigger zones and longer takt times. There’s no one-size-fits-all. The right approach depends on the patterns within the project itself.
Final Thoughts
Construction is full of variables, but when we look through the lens of patterns—whether in sequencing, constraints, or prefabrication we can make smarter planning decisions. Aligning work with true capacity, respecting constraints, and adapting zone strategies to the project at hand are what elevate outcomes in the field.
Key Takeaway
Great planning in construction comes down to recognizing patterns. By aligning work with capacity, balancing constraints, and tailoring prefabrication strategies, we create flow that drives efficiency and reduces chaos
If you want to learn more we have:
-Takt Virtual Training: (Click here)
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-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
