Rules of Flow in Construction: Synchronization Is Key
Synchronization is a fascinating topic that lies at the heart of efficient construction projects. While achieving one-piece or one-process flow is commendable, the reality of construction involves managing multiple trade partners. Success depends on all these trades working together, with the same timing, intersections, and proper overlaps. That’s the essence of synchronization.
A little-known secret: a project will only go as well as its trades perform together. When trades succeed, the project succeeds. It’s easy to be good individually, but being good collectively—that’s the challenge. This blog dives deep into what synchronization means in construction and how it can transform projects.
What Is Synchronization in Construction?
Synchronization in construction means aligning tasks so they flow seamlessly together. Imagine using a Time-by-Location Takt Plan:
- Trade Rhythm: A trade moves from Zone 1 to Zone 2 to Zone 3, and so on. The question is, can subsequent trades maintain the same speed and flow?
- Consistent Line of Balance: Synchronization ensures trades progress at relatively close speeds, avoiding gaps or inefficiencies.
Even with multiple lines of balance, intersections must be managed. Synchronization is not just about flow but also about timing, rhythm, and interconnections—ensuring trades meet at the right points without disruption.
How Synchronization Works: A Real-World Example
Let’s consider erecting air handlers on a building’s roof. Synchronization here involves aligning several components:
- Start Date for the Crane.
- Delivery of Air Handlers.
- Installation Crew.
- Manufacturers’ Representatives for Assembly.
- Chilled Water, Heating Hot Water, and Permanent Power Availability.
All these activities must converge at a specific milestone. Any delays—like late air handler delivery—can ripple across the project, delaying the crane, crew, and more. That’s why buffer planning is essential to account for uncertainties and maintain synchronization.
The Turkey Dinner Analogy for Synchronization:
The Goldratt family explains synchronization beautifully using the analogy of preparing a turkey dinner. Imagine the family plans to eat at 7 PM:
- The turkey, gravy, stuffing, drinks, and more all need to be ready at the same time.
- Tasks in the kitchen must flow in rhythm, without overburdening anyone.
Similarly, in construction, rhythm, interconnections, and task convergence are crucial for synchronization.
How Synchronization Aligns with Lean Construction:
Lean construction emphasizes:
- Respect for People.
- Stability.
- One-Piece Flow.
- Flowing Together.
Synchronization ties directly to the fourth principle: flowing together. Multiple value-adding and value-receiving units in a system must work in harmony. This requires precise planning, visual systems, and continuous improvement. Without synchronization, inefficiencies arise, resulting in extended project timelines and wasted resources.
What Happens If You Don’t Synchronize?
When tasks are out of sync:
- Gaps and inefficiencies appear between activities.
- Milestones are delayed, extending project durations.
- Delayed components affect others downstream, compounding issues.
Proper synchronization avoids these pitfalls, ensuring every trade flows in harmony and meets milestones effectively.
Real-Life Synchronization Success:
In one project—a cancer center—we had to coordinate chilled water, permanent power, air handlers, the crane, and traffic control. By adding strategic buffers (e.g., a 5-week buffer for chilled water), releasing tasks at the right time, and aligning everything with full kits, we achieved seamless synchronization. The result? Air handlers were operational on time, cooling the building as planned.
Key Takeaways for GCs and Superintendents:
Being good individually is easy; being good together is hard. For general contractors and superintendents, synchronization is their primary job. Think of the superintendent as a choir conductor, coordinating musicians (trades) to play in rhythm. Without synchronization, the project will falter.
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