What Are My Bottlenecks?

How to Identify and Handle Bottlenecks in Your Production Plan

When managing a construction project, bottlenecks can be a significant challenge. They don’t mean anyone is underperforming; they’re often a result of complexity, overlapping tasks, or extended durations. In this blog, I’ll share insights into how to identify bottlenecks in your production plan and actionable steps to address them effectively.

What Are Bottlenecks?

Bottlenecks arise when a specific activity or trade struggles to maintain the required pace of the project. This could be due to:

• Zone transitions requiring more coordination.
• Longer task durations conflicting with the established Takt time.
• Overlapping activities leading to resource constraints or overburdened crews.

It’s important to note: bottlenecks don’t indicate poor performance. Often, they reflect the inherent difficulty or complexity of certain tasks.

How to Spot Bottlenecks:

During a recent pull planning session with 20 trade partners, we identified bottlenecks using a step-by-step process:

1. Color-Coded Activities: Using stickies, we mapped out activities and Takt time sequences to visualize workflow.
2. Buffer Analysis: We checked if each trade had sufficient buffer time. If not, it became a potential bottleneck.
3. Specific Example:
   • A plumbing trade had a 10-day activity within a 5-day Takt time, creating overlap with another zone.
   • Possible solutions included splitting the crew into two, adding a larger crew, or leapfrogging zones.

This process revealed the bottlenecks early, allowing us to plan solutions collaboratively with the trades involved.

How to Address Bottlenecks:

Once you’ve identified a bottleneck, here’s what to do:

1. Prioritize the Trade: Ensure their needs are front and center for logistics and communication.
2. Preconstruction Preparation: Verify everything is ready before they begin. A “full kit” approach ensures materials and resources are in place.
3. Lean Into Collaboration:
   • Support from the general contractor and other trade partners can make a significant difference.
   • Address issues as a team to ensure progress without delays.

The goal is to empower the bottleneck trade to succeed, not to place blame or add pressure.

Key Takeaways:

• Bottlenecks are a natural part of complex projects and require a proactive approach.
• Identify them through pull planning and buffer analysis.
• Support the trades involved by providing resources, communication, and teamwork.
• Collaboration and preparation are crucial to overcoming these challenges effectively.

Bottlenecks don’t have to derail your project. By identifying and addressing them early, you can ensure smoother workflows and a successful outcome.