Understanding Construction Constraints: What You Need to Know
In this blog, I’ll Walk you through the key differences between constraints and roadblocks in construction, explain why these concepts are critical to lean thinking, and break down the types of constraints you’ll likely encounter on a project. If you’re looking to take your project management skills to the next level, you’ve come to the right place. Let’s dive in.
Roadblocks vs. Constraints
First, let’s clarify the difference between roadblocks and constraints:
- Roadblocks are external obstacles that block progress.
- Constraints, on the other hand, are internal—how you’ve sequenced your trades and organized your work zones.
Think of your project like a train moving through stations (zones). If something is ahead of the train and stops it, that’s a roadblock. But if the train’s track design—how trades are sequenced or how the zones are set up—is inefficient, then that’s a constraint. Now, let’s look at some common constraints in construction.
Common Construction Constraints
- Lack of Preparation
A major constraint arises when trades are not properly prepared. Imagine your production plan as a time-by-location chart. If the first trade wagon in your sequence isn’t ready due to poor planning or preparation (no pull plan, no pre-construction meeting), everything slows down. This lack of preparation will cause delays throughout the project, extending timelines unnecessarily.
- Varying Speeds Among Trades
When different trades operate at different speeds, it creates system constraints. Picture a line of trades moving through zones. If the second trade in the sequence is significantly slower than the first, it holds up the entire flow. This constraint limits the pace of your project, as everything moves at the speed of the slowest trade.
- Improper Takt Time
Takt time is the rhythm at which tasks are completed. If the takt time is too long, your project will move too slowly, wasting time. If it’s too short, there won’t be enough buffer time to absorb variation and delays, causing the entire project to start lagging behind. Both scenarios create system constraints that slow overall progress.
- Incorrect Sequence of Activities
Sometimes, constraints occur because activities aren’t sequenced correctly. Let’s say your project plan skips key steps in the process. When the train (your trades) reaches the site, missing activities will hold everything up, causing delays that impact the entire sequence.
- Missing Resources
When your trades lack the necessary resources—be it labor, tools, or equipment—this can become a significant constraint. The missing resource stalls the process, causing all other activities to grind to a halt. Without what’s needed to move forward, your project will come to a standstill.
- Lack of Buffers
A lack of buffers—time built into your schedule to handle unforeseen issues—can also become a system constraint. Without these buffers, you may be forced into trade stacking or trade burdening, which leads to a downward productivity spiral. This will ultimately extend your project’s duration.
Advanced Construction Constraints
Here are three additional common constraints to watch out for:
- Wrong Number of Zones
The number of zones in your project directly affects how long the project will take. If you have fewer, larger zones, the project will move slower. By increasing the number of smaller zones, you can speed up the process.
- Not Planning for Physical Constraints
Physical limitations, like an elevator or hoist, can slow down your trades if not accounted for properly. You should plan around these obstacles to keep the flow of trades uninterrupted.
- Misshaped or Too-Large Zones
If a zone is too large or complex, it can cause delays. Trades may flow easily through some areas, but bottleneck in others, causing the entire sequence to fall apart.
Conclusion
Constraints are an integral part of system design in construction. Understanding how to identify and adjust them is crucial for ensuring your trades flow smoothly and your project runs efficiently. Make sure you plan for constraints, adjust as needed, and keep the “train” on the right track.
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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