Balanced Production: A Tale of Time and Money
Takt Production and Lean Construction
It’s no secret that the methodology used to both manage and sustain labor and resources when it comes to production scheduling has been evolving for centuries. And why is that? The most obvious answer is time. The necessity to get things done faster and more efficiently is always a driving force when it comes to developing a production matrix that can withstand the test of, well, time itself. It is, after all, the one thing we never have enough of, so it makes sense to continue striving for improvement directly on its behalf.
What’s the other driving force that has been keeping our production managers up all night for centuries? Money, of course. And I see no need to go into the obvious reasoning behind that.
So, that leaves us with time and money. How do we make the most of what we have and ensure a balanced production flow that optimizes capacity in both of these arenas?
Where It All Began
Before Takt and Lean
The origin of the construction schedule dates back to nearly 4,000 years ago. You could say this is where it all began… an ancient papyrus production log detailing the logic and application theorems used to erect the awe-inspiring Pyramids of Giza. And, oh, how we learned from that undertaking. The Arsenal of Venice followed after with another significant evolution to the industry standard.
What did we learn from these projects and what do we still use today in Lean Construction?
The Beat of a New Drum
Takt Production Takes the Lead
Starting in the 1920s and extending well into the production methodology used throughout World War II, manufacturing was introduced to the takt construction schedule. The word “takt” comes from a German word associated with keeping a musical “beat” and was used by Junkers Aircraft as early as 1926 in describing their manufacturing methodologies. In Junkers concept, aircraft manufacturing was timed so that the airplane assemblies moved from one production station to the next station at fixed intervals or takt time.
How did the Takt Construction Schedule shape the industry standard?
Production Gets Critical
The Critical Path Method
Evolving once more in the essence of time, the standard construction schedule gets revolutionized yet again with the Critical Path Method (CPM) introduced in 1962. Replacing Line of Balance, Gantt charts and other methods of construction scheduling, CPM caught on at warp speed primarily due to its capacity to calculate the completion date. In a general sense, however, CPM does not address production of work, but rather indicates the logical path of construction required to complete the work.
How has CPM Influenced the Takt Production Matrix?
Production Gets Balanced
Takt Planning and Takt Control
Trades, whether brought onto the project as trade crews of the general contractor or as trade crews of subcontractors, desire to optimize their efforts on their portion of the project to reduce expenses and increase profit margins. Also, trades seek stable resource utilization with limited peaks and valleys. The construction manager, on the other hand, desires to turn over the completed works according to the need of the building developer – the ultimate customer in the project. What is needed in construction scheduling is a production management and control program that encourages all team members to work congruently to satisfy both of these project goals.
Check Out The Takt Production Timeline!
Production Gets Clear
The Takt Production Matrix
The Clear Flow Matrix concept combines the terminology of lean construction, the timing of takt production and the logic of CPM to provide a truly efficient snapshot of your production matrix. It takes the detail of the Gantt chart and condenses it into a one-page overview of the entire construction schedule that is navigated by pacemakers and areas in a manner that ensures a collaborative and coherent production flow. And, most importantly, it saves a tremendous amount of time and money – our two most coveted resources:
- Time: Build your takt construction schedule in just 2-3 hours versus the typical 2-3 days required for the traditional Gantt chart matrix.
- Money: Complete tasks on time and ensure a continuous flow with no costly bottlenecks.
For more information, visit us at the 2022 Lean Conference!
Recent Comments