What Is Takt Steering & Control?

In this blog, we’ll dive into the essential concepts of Takt Steering and Control as they apply to Takt planning. If you’re working in lean construction or are interested in integrating lean practices, you’re in the right place. I’ll walk you through methods to ensure your train of trades flows smoothly through a project, how to handle constraints and roadblocks, and ways to absorb delays—all to maintain flow on-site. Let’s get started!

What is Takt in Construction?

First, let’s clarify what “Takt” means. Takt is a German word that roughly translates to rhythm or cadence. Imagine breaking down a construction project into zones, where each trade partner moves through those zones in a planned sequence. If this flow aligns with a consistent rhythm, we achieve true flow in construction.

In lean construction management, Takt planning is where you create the flow, while Takt Steering and Control involves guiding that “train” of trades through the project and managing the environment to support this flow.

Takt Planning vs. Takt Steering & Control

• Takt Planning: This is your blueprint for achieving flow by organizing the trades and zoning.
• Takt Steering: Think of it as steering the trades through your carefully planned project zones, configuring the layout of zones (tracks) and trade partners (wagons). This process includes adjusting parameters, like trade pacing and zone boundaries, to handle constraints that can impact flow.
• Takt Control: This is about environmental control. Here, we focus on removing potential roadblocks, ensuring the path ahead remains clear for the trades.

Let’s dig deeper into these elements.

What Are Constraints in Construction?

In lean construction, constraints refer to the bottlenecks and limiting factors that can disrupt flow. As described in the book ‘The Goal’ by Eliyahu Goldratt, every production system has constraints. In construction, these constraints could be zone boundaries, crew availability, or the pace at which trades can operate.

Constraints can’t be eliminated entirely but can be managed. For instance, adjusting zone boundaries, tweaking takt time, or balancing crew composition are all methods to increase flow within a project’s “train” of trades.

What Are Roadblocks in Construction?

Roadblocks are obstacles that arise along the way and threaten to disrupt the flow. Unlike constraints, which are inherent to the system, roadblocks are external issues like adverse weather, material shortages, or unforeseen obstacles in the work area. Think of roadblocks as the debris on the train tracks that must be cleared before they can derail your project. While constraints require strategic adjustments, roadblocks need tactical removal, often handled by foremen on-site.

Implementing a Meeting System to Keep Flow Consistent

The meeting system is the backbone of takt steering and control. Here’s how it works:

1. Strategic Planning and Procurement Meeting: Start by setting your master plan and procurement log.
2. Trade Partner Weekly Tactical: Develop a pull plan, look-ahead schedule, and weekly work plan to clear roadblocks before they impact the trades.
3. Daily Foreman Huddle: On-site, the foremen gather daily to address roadblocks and align on the upcoming tasks.
4. Worker Huddle: Finally, everyone reviews the day’s plan together before getting to work.

In these meetings, constraints can be adjusted as needed, and roadblocks are identified, discussed, and cleared. This proactive approach allows us to maintain flow without panic or rushing.

Zone Control: Boots on the Ground

Zone control is the on-site aspect of Takt control. It’s where you go zone by zone, ensuring trades are moving through as planned, identifying real-time issues, and making adjustments on the fly. With effective zone control, you’ll be able to see and respond to deviations immediately, keeping the project flowing smoothly.

Ways to Absorb Delays

Even with thorough planning, delays are sometimes inevitable. Here are some ways to handle them without derailing the project:

• Adjust Takt Time or Sequence: If needed, you can tweak takt time or rearrange sequences.
• Use Workable Backlog: Keep a backlog of tasks that can be worked on if there’s a delay in a critical area.
• Rezone: In extreme cases, redefine your zones and work around the delay.

With these tactics, you can absorb delays efficiently, keeping the trades engaged and the project on track.

Building a Flowable System

By knowing your constraints, preemptively managing roadblocks, and using a structured meeting system, you create a robust, flowable system. Incorporate zone control, track your KPIs, and improve constantly based on real-time data. This way, foremen stay accountable, and you prevent delays from cascading into broader issues.

If you hear the term “Takt Planning,” remember that it’s about organizing for flow in lean construction. “Takt Steering and Control,” on the other hand, is about navigating that train of trades through the project efficiently.