Elevate Construction

Are you on the same page about lean beliefs? In this foundational episode before the Integrated Production Control System series, Jason delivers a comprehensive overview of the lean beliefs and concepts every construction team must understand. You'll learn why flow is the single most important condition we strive for, the difference between resource efficiency and flow efficiency (attach people to work, not work to people), the three types of buffers required for Takt planning (material, capacity, time), why overproduction and excess inventory are the mother and father of all wastes, the definition of lean in construction (respect for people/resources, stable environments with flow that see/fix problems, total participation with visual systems, continuous improvement and fanatical quality), and the 14 principles of the Toyota Way applied to construction. What you'll learn in this episode: Flow is everything: Single most important condition, path to increasing profits, employee satisfaction, customer delight, reduced durations; work on increasing and seeing flow every day Resource constraints are a gift: Lack of workers/materials forces us to respect people and resources like Japan (island, pay workers 54x China, rice culture); companies that don't start lean journey will fail with inflation and trained worker shortage The 3 buffers required for Takt: Material buffers (inventory just ahead of work, not excessive), capacity buffers (never plan 100% utilization, things break down), time buffers (1.5-5% contingency like financial); if you don't have visual schedule + crew/work flow + buffers + stabilized pace/one-piece flow/limited WIP, you don't have a Takt plan The 8 wastes: Overproduction and excess inventory are mother/father of all other wastes (transportation, motion, defects, overprocessing, waiting, not using team wisdom); when you overproduce you have inventory that needs transport creating motion, distraction creates defects, defects need fixing (overprocessing) creating waiting Definition of lean in construction: (1) Respect for people and resources, (2) Stable environments with flow in culture that sees and fixes problems, (3) Total participation with visual systems, (4) Continuous improvement and fanatical quality "About half the construction industry has these concepts wrong and are using them wrong—that's where most of our waste and lost productivity and financial losses are coming from. We have to believe the right things to act the right way. Usually if somebody isn't acting the right way, it's because they believe something that is causing them to do so." If you like the Elevate Construction podcast, please subscribe for free, and you'll never miss an episode. And if you really like the Elevate Construction podcast, I'd appreciate you telling a friend (Maybe even two 😊). Also, here are links to our YouTube Channels: · Jason Schroeder YouTube Channel: https://www.youtube.com/channel/UC4xpRYvrW5Op5Ckxs4vDGDg · LeanTakt YouTube Channel: https://www.youtube.com/c/leanTakt · LeanSuper YouTube Channel: https://www.youtube.com/channel/UCzQDevqQP19L4LePuqma3Fg/featured · LeanSurvey YouTube Channel: https://www.youtube.com/channel/UC-Ztn3okFhyB_3p5nmMKnsw

Are you focused too much on resource efficiency when you need to focus on flow efficiency? In this final episode of the flow series, Jason unpacks the critical difference between optimizing individual resources (keeping equipment and people busy) versus optimizing the entire system (getting work to customer in shortest time with highest quality). You'll learn the Japanese principle ("Do not attach work to people, attach people to work"), why US manufacturing overproduces to keep tools busy while Japan produces only what's ordered just-in-time, The Goal book example (equipment at full individual efficiency creating bottlenecks from overproduction), the submittal process problem (batching through siloed departments vs one-piece flow to worker), and why everything should flow to the worker, not be leveled within individual departments. What you'll learn in this episode: Resource vs flow efficiency: Resource efficiency = optimizing individual resources (keeping them busy); Flow efficiency = optimizing entire system (work to customer in shortest time with highest quality); Takt planning lets you see and optimize both, but always prioritize flow efficiency Japanese principle: "Do not attach work to people, attach people to work", don't attach work to resources to make them busy, attach resources to work you want to flow from start to finish Manufacturing examples: US overproduces to keep factory tools busy (creates inventory, defects, motion, transportation, overprocessing, waiting); Japan produces only what's ordered (375 cars → make 400-450 just-in-time, then switch tools for next order) Submittal flow example: Trade partners batch all submittals at once → GC batches review → architect reviews when convenient → supplier queues by their efficiency = individual siloed companies optimizing themselves, causing inordinate waiting; Instead: send one submittal package at a time (central plant, then floors), swarm submittals with PM help, invite architect to tabletop review = flow to worker Everything flows to worker: Focus on new work starting in 2-6 week window (why Last Planner's 6-week look-ahead and weekly work plans work); manage flow of layout/information/quality/safety/materials/workers/equipment to starting scopes, then nail the handoffs "Everything should flow to the worker. Stop worrying about 'Is that loader busy? Is that blade busy?' Look at: Is work flowing from one end to the other as quickly as possible? Stop worrying about optimal individual crew efficiency even if you bury other people. Ask: How can I work in sequence to optimize the whole flow of the entire project?" If you like the Elevate Construction podcast, please subscribe for free, and you'll never miss an episode. And if you really like the Elevate Construction podcast, I'd appreciate you telling a friend (Maybe even two 😊). Also, here are links to our YouTube Channels: · Jason Schroeder YouTube Channel: https://www.youtube.com/channel/UC4xpRYvrW5Op5Ckxs4vDGDg · LeanTakt YouTube Channel: https://www.youtube.com/c/leanTakt · LeanSuper YouTube Channel: https://www.youtube.com/channel/UCzQDevqQP19L4LePuqma3Fg/featured · LeanSurvey YouTube Channel: https://www.youtube.com/channel/UC-Ztn3okFhyB_3p5nmMKnsw

Are you more confident in working overtime than you should be? In this episode, Jason unpacks the truth about overtime based on a Construction Industry Cost Effectiveness Task Force report from November 1980. You'll learn why overtime disrupts the local economy and reduces productivity (60+ hours/week for 2+ months delays completion beyond what 40-hour weeks could achieve with same crew), the productivity decline timeline (starts immediately, recovers briefly, then steady decline, at week 6 working 60 hours you're at 75% capacity, week 12 at 62% capacity), why light work takes 3 hours to produce 2 additional hours of output and heavy work takes 2 hours to produce 1 hour, the auction atmosphere created when one project goes to overtime, and why the return on investment disappears after 6-9 weeks depending on hours worked. What you'll learn in this episode: Overtime extends projects: 60+ hours/week for 2+ months causes decreased productivity that delays completion beyond what could have been realized with same crew size on 40-hour week; disrupts economy, magnifies labor shortage, creates excessive inflation without benefit to schedule Productivity decline is brutal: Light work, takes 3 hours to produce 2 additional hours output; Heavy work—takes 2 hours to produce 1 hour additional output; 8-hour day = 120 pieces/hour, 9-hour day = 100 pieces/hour Timeline of decline: Productivity drops initially, recovers by end of week 1, holds 2-3 weeks, declines next 2-3 weeks, further drop at 5-6 weeks, hits low point at 9-12 weeks; Working 50 hours/week: Week 6 at 85% capacity, Week 12 at 72%; Working 60 hours/week: Week 6 at 75%, Week 12 at 62% Auction atmosphere: When one project goes to overtime, other projects go to overtime to hold labor creating bidding process; local labor supply constant but additional capacity of transient workers offset by reduced productivity of all workers on overtime Return on investment disappears: 60+ hours/week = no ROI after 6 weeks, 50-60 hours/week = 7.5 weeks, 40+ hours/week = 9 weeks; at 65 hours/week you pay twice as much per unit hour; all negative conditions still happen within those weeks "The current condition is we throw money and manpower at things to try and fix them. All of the negative adverse conditions still happen. After 9 weeks there is no return on investment even from a productivity or completion standpoint. When we increase manpower and overtime, it increases costs, safety issues, fatigue, and in most cases we're extending the overall project duration." If you like the Elevate Construction podcast, please subscribe for free, and you'll never miss an episode. And if you really like the Elevate Construction podcast, I'd appreciate you telling a friend (Maybe even two 😊). Also, here are links to our YouTube Channels: · Jason Schroeder YouTube Channel: https://www.youtube.com/channel/UC4xpRYvrW5Op5Ckxs4vDGDg · LeanTakt YouTube Channel: https://www.youtube.com/c/leanTakt · LeanSuper YouTube Channel: https://www.youtube.com/channel/UCzQDevqQP19L4LePuqma3Fg/featured · LeanSurvey YouTube Channel: https://www.youtube.com/channel/UC-Ztn3okFhyB_3p5nmMKnsw

What do construction professionals need to understand when it comes to their children? In this special episode recorded in the truck, Jason sits down with his 16-year-old daughter Effie Schroeder for an unscripted conversation about raising remarkable children in the construction industry. You'll learn Effie's advice to construction parents (listen, watch for problems, maximize moments, one meaningful moment worth an hour of meaningless time), the study showing children's connection to family culture depends on whether dad is approachable, why you shouldn't overthink parenting (kids love their parents deep down, want to hear about work), examples of involving kids in construction (slip sheeting drawings, posting RFIs, cleaning trailers, job walks, boot camps), and how making construction family-friendly preserves families and elevates the industry. What you'll learn in this episode: Listen and watch: Be attentive, know your kid, know when they need to talk (especially mental health), if you're not there listening, that could really hurt them; also kick their butt when they need it Maximize moments over hours: Never going to have as much time as you want, so focus on making moments meaningful, one meaningful moment worth an hour of meaningless time; reconnect intentionally after trips (connection goes away when you're gone) Don't overthink it: Deep down kids love their parents, they want to hear about funny things at work, cool new techniques; don't stress or everyone gets stressed Be approachable: Study shows children stay connected to family culture/traditions based on how approachable the father is; being loving but firm shapes kids to be better Involve kids in construction: Take them to job sites (Effie excited to wear PPE at age 8-9, felt "so swag" walking through store in hard hat), have them help (slip sheeting, posting RFIs, cleaning trailer, job walks, boot camps), make construction family-friendly and inclusive so you can invite your children to work "Don't overthink it. Kids love their parents. They want to hear about the funny thing that happened at work or this cool new technique you learned. Love your kid. Love yourself. If you bring them into your work, they'll start to take ownership of that, be proud of that, be proud of you, and it works for everyone." If you like the Elevate Construction podcast, please subscribe for free, and you'll never miss an episode. And if you really like the Elevate Construction podcast, I'd appreciate you telling a friend (Maybe even two 😊). Also, here are links to our YouTube Channels: · Jason Schroeder YouTube Channel: https://www.youtube.com/channel/UC4xpRYvrW5Op5Ckxs4vDGDg · LeanTakt YouTube Channel: https://www.youtube.com/c/leanTakt · LeanSuper YouTube Channel: https://www.youtube.com/channel/UCzQDevqQP19L4LePuqma3Fg/featured · LeanSurvey YouTube Channel: https://www.youtube.com/channel/UC-Ztn3okFhyB_3p5nmMKnsw

Are you finishing as you go? In this final episode of the flow series, Jason unpacks why finishing as you go creates flow and reduces waste. You'll learn the banner quote ("Cleanliness, organization, and right sizing of inventory buffers are a project's best indicator of health and stability. Plan it first, build it right, finish as you go"), the California hospital wall-framing example (frame walls, do overhead MEP, bring branch lines down into walls as they go, finish as you go even if walls are in the way), examples across all trades (concrete patching immediately after stripping, grading building pad AND perimeter at same time, completing as-builts when utilities are installed), the Japanese manufacturing principle (switch tools in 5 minutes to produce only what's ordered vs US overproduction), and how finishing as you go reduces your footprint and allows teams to focus on smaller critical areas. What you'll learn in this episode: The banner principle: "Cleanliness, organization, and right sizing of inventory buffers are a project's best indicator of health and stability. Plan it first, build it right, finish as you go", put this on every project opening/door Finish areas as you move: California hospital example, frame walls, install overhead, bring branch lines down into walls as they go (walls may be in the way but waste of coming back multiple times is greater) QC/punch/clean as you go: Don't leave work without inspecting it; pull gang boxes/materials/greenies out; clean and turn over areas 100% complete Specific examples: Concrete, patch tie holes and clean cream immediately after stripping; Civil, grade building pad AND perimeter to stabilize for rain (don't come back); Underground utilities, camera lines and complete as-builts immediately Japanese vs US manufacturing: Japan switches tools in 5 minutes to produce only what's ordered (375 Tacomas then switch to Camrys); US overproduces for economies of scale creating waste; Construction application—have two tool carts so crew can finish area without coming back for different scope "When you finish as you go, you reduce work in progress, reduce operating area, allow team to focus on smaller critical areas, keep trades balanced and healthy, minimize waste/uncleanliness/trade damage/motion. You reduce your footprint in the building. This is a true principle, it will always be true and will make us a ton of money if we adhere to it." If you like the Elevate Construction podcast, please subscribe for free, and you'll never miss an episode. And if you really like the Elevate Construction podcast, I'd appreciate you telling a friend (Maybe even two 😊). Also, here are links to our YouTube Channels: · Jason Schroeder YouTube Channel: https://www.youtube.com/channel/UC4xpRYvrW5Op5Ckxs4vDGDg · LeanTakt YouTube Channel: https://www.youtube.com/c/leanTakt · LeanSuper YouTube Channel: https://www.youtube.com/channel/UCzQDevqQP19L4LePuqma3Fg/featured · LeanSurvey YouTube Channel: https://www.youtube.com/channel/UC-Ztn3okFhyB_3p5nmMKnsw

Do you have too many things going on on your project at one time? Should you limit your work in progress? In this flow series episode, Jason unpacks why one-piece flow and limiting work in progress make you a ton of money, even though most superintendents resist these concepts. You'll learn the Tucson project recovery story (sent everyone home, got a plan, brought them back one by one in flow order), the envelope game demonstration (one-piece flow wins every time even though batching looks busier), examples of one-piece flow in construction and office work, the three types of buffers (inventory, capacity, time), why overproduction and excess inventory are the mother and father of all wastes, and when it's okay to get ahead vs when it's damaging. What you'll learn in this episode: One-piece flow beats batching: Envelope game proves it every time, fold/stuff/lick/stamp one envelope completely vs batching all folding/all stuffing looks busier but takes longer; same principle on projects Site work in phases not all at once: Don't grade 500 acres and maintain it, bring out less equipment, better trained operators, work out ahead in one-piece flow; compare costs before claiming "we have to do it all at once" Three buffers you need: Inventory buffers (bar joist early if scarce, drywall 1-2 days if reliable), capacity buffers (mental capacity to plan/prevent roadblocks), time buffers Overproduction creates all wastes: Overproduction and excess inventory are mother/father of all other wastes (transportation, motion, defects, over processing, waiting), we lose money in the in-betweens not when crews are working When overproducing is damaging: Can get rained on, have to maintain, weather sensitive, can get damaged, brings team out of balance and disallows proactive roadblock removal; early foundations okay (low risk, one contractor) vs interiors with 20 contractors (high risk) "When a superintendent dispatches a trade partner into an area too soon, they stretch supervision, lose production, have less materials, more chaos, more quality problems, more materials in the way, costs go up, profits go down, using more unqualified people, everyone sandbags, areas get damaged sitting empty, team isn't focused on planning or removing roadblocks. That superintendent just created so much variation it's hard to recover from." If you like the Elevate Construction podcast, please subscribe for free, and you'll never miss an episode. And if you really like the Elevate Construction podcast, I'd appreciate you telling a friend (Maybe even two 😊). Also, here are links to our YouTube Channels: · Jason Schroeder YouTube Channel: https://www.youtube.com/channel/UC4xpRYvrW5Op5Ckxs4vDGDg · LeanTakt YouTube Channel: https://www.youtube.com/c/leanTakt · LeanSuper YouTube Channel: https://www.youtube.com/channel/UCzQDevqQP19L4LePuqma3Fg/featured · LeanSurvey YouTube Channel: https://www.youtube.com/channel/UC-Ztn3okFhyB_3p5nmMKnsw

Do you want a better way to manage your exterior? In this episode, Jason unpacks how to plan and execute building exteriors like a pro. You'll learn the Blue Beam exterior tracking system from DPR's Banner Good Samaritan Tower (polygons with status and colors matching the Takt plan showing daily updates and roadblocks), why exteriors are like site work (spatial/interface/rhythm management), how to do an exterior flow analysis (break into Takt zones, schedule Takt trains, plug in constraints, identify flow, it's all about interfaces not production), the critical steps from design development through testing, and the one rule that will save your project: never fail an exterior water test with your owner. What you'll learn in this episode: Exterior flow analysis is everything: Break exterior into production areas/Takt zones by types/scopes/interfaces, schedule Takt train, plug in constraints, pick bottleneck trades, do flow analysis, then align procurement with that sequence or you're in trouble Start in design development: Bring trade partners on early, start procurement ASAP, plan 8-9 months for curtain wall, do mock-ups at Field Verified location early (performance/design mockups not just assembly, 10% of cost), start bi-weekly coordination meetings Points of release management: Schedule every point of release as Outlook meeting (dye release, glass release, shop fabrication start, field measurements), show up Monday and call to confirm it happened Get drawings from trade partners: Field measurements vs standard dimensions, unitized vs stick-built, lead times written on drawings (8 weeks, 6 weeks, 20 weeks), transitions/constraints, staging/logistics—all the data to plan/schedule/manage Never fail owner testing: Pre-test yourself first with Field Verified or similar, pay extra money to test before owner sees it (unlean but necessary)—buildings leak at intersection of contracts AND at fluctuation of crews, need flow and consistent crews "Do not ever fail an exterior water test with your owner. Ever. As soon as you fail a test, they're like 'The whole thing is wrong.' I once failed some tests and they made me test every stinking window on the building. Do not lose their trust. Pre-test yourself first, pay extra money if you have to. That waste is a million times more tolerable than losing the owner's trust." If you like the Elevate Construction podcast, please subscribe for free, and you'll never miss an episode. And if you really like the Elevate Construction podcast, I'd appreciate you telling a friend (Maybe even two 😊). Also, here are links to our YouTube Channels: · Jason Schroeder YouTube Channel: https://www.youtube.com/channel/UC4xpRYvrW5Op5Ckxs4vDGDg · LeanTakt YouTube Channel: https://www.youtube.com/c/leanTakt · LeanSuper YouTube Channel: https://www.youtube.com/channel/UCzQDevqQP19L4LePuqma3Fg/featured · LeanSurvey YouTube Channel: https://www.youtube.com/channel/UC-Ztn3okFhyB_3p5nmMKnsw

Are you absolutely crazy, weird, over-the-top, fanatical, and creepy about roadblock removal? In this flow series episode, Jason unpacks why roadblock removal is the #1 priority, not PPC, not production tracking, not CPM. You'll learn the General Patton donkey story (shoots donkeys blocking the bridge to clear the path), the cow catcher and boat wake analogies, why PPC is a lagging indicator and roadblock removal is a leading indicator, the Duck Hunt game principle (bring roadblocks to the surface so you can shoot them), why "whiny" trade partners are actually angels giving you the key to success, and the systems to implement fanatical roadblock removal. What you'll learn in this episode: Flow is everything: Everything in lean leads to flow, "Plan it first, build it right, finish as you go"—precon, coordination, cleanliness, organization all create flow Roadblock removal > PPC: Stop tracking percent plan complete (lagging indicator), track roadblocks removed, time to resolve, how far out you're seeing them (leading indicators) Commitment brings problems to surface: Like proposing marriage vs dating, once you commit people with Takt planning, they raise their hand with roadblocks (this is GOOD) Whiny trades are angels: That electrician constantly complaining? Thank God for them, they're giving you the key to success, telling you exactly what to remove Systems and behaviors: Afternoon foreman huddle → morning worker huddle → team huddle with PM for fanatical roadblock removal; make it your #1 priority (RR underwear, bumper stickers, name your son Roadblock) "Your whiny electrician foreman that constantly tells you what's wrong? That's your angel. He just gave you the key to the universe. Get rid of their problems. Once you commit them, they will tell you what their problems are, then it's just like Duck Hunt." If you like the Elevate Construction podcast, please subscribe for free, and you'll never miss an episode. And if you really like the Elevate Construction podcast, I'd appreciate you telling a friend (Maybe even two 😊). Also, here are links to our YouTube Channels: · Jason Schroeder YouTube Channel: https://www.youtube.com/channel/UC4xpRYvrW5Op5Ckxs4vDGDg · LeanTakt YouTube Channel: https://www.youtube.com/c/leanTakt · LeanSuper YouTube Channel: https://www.youtube.com/channel/UCzQDevqQP19L4LePuqma3Fg/featured · LeanSurvey YouTube Channel: https://www.youtube.com/channel/UC-Ztn3okFhyB_3p5nmMKnsw

Do you know the best way to make your numbers? In this episode, Jason unpacks the biggest secret in construction: we don't lose money when crews are working—we lose it in the transitions. You'll learn why the bottom 25% of workers are more productive than average bid units when actually working, why focusing on production units is the wrong game, the whiteboard circles-and-lines visual (circles = productive work, lines = transitions where we lose money), and the four solutions to create flow: plan with Takt (not CPM), limit work in progress, fanatically prevent roadblocks, and finish as you go. What you'll learn in this episode: The secret: We lose money in the transitions/in-betweens, not when crews are in flow, focus on interruptions, roadblocks, sequence changes, not production units The wrong focus: Telling crews "make production" focuses their minds on the circles (when working), but we win in the timeouts and transitions, not when playing Unskilled workers myth: Bottom 25% still beat production rates when environment is ready, you make money by removing roadblocks, not complaining about skills Four flow solutions: (1) Plan with Takt not CPM to stack sequences with consistent crew sizes, (2) limit work in progress (overproduction is mother of all wastes), (3) prevent roadblocks fanatically, (4) finish as you go The comparison: Flow project = 20 weeks, 248 people, $1.6M saved vs non-flow = 24-36 weeks, 380 people, inflated costs, you gain 11% fee and 40% schedule by focusing on transitions "You will not make money by focusing on when the crew is working. You will make it by focusing on transitions, did you change sequence? Were areas ready? Did roadblocks hold up work? That's where we lose money." If you like the Elevate Construction podcast, please subscribe for free, and you'll never miss an episode. And if you really like the Elevate Construction podcast, I'd appreciate you telling a friend (Maybe even two 😊). Also, here are links to our YouTube Channels: · Jason Schroeder YouTube Channel: https://www.youtube.com/channel/UC4xpRYvrW5Op5Ckxs4vDGDg · LeanTakt YouTube Channel: https://www.youtube.com/c/leanTakt · LeanSuper YouTube Channel: https://www.youtube.com/channel/UCzQDevqQP19L4LePuqma3Fg/featured · LeanSurvey YouTube Channel: https://www.youtube.com/channel/UC-Ztn3okFhyB_3p5nmMKnsw

Do you want a secret to scaling excellence? In this episode, Jason unpacks the concept of anchor projects, putting your best people on your best projects with the best circumstances to create a visible standard of excellence that scales throughout your company. You'll learn the difference between craft production and production control systems, the getting started syndrome (waste from starting projects too early), why continuous learning beats the "tenure" mentality, and how anchor projects allow people to actually see what excellence looks like instead of just hearing about it in concept. What you'll learn in this episode: Continuous learning: The last day on earth you should still be learning, no such thing as "tenure" superintendent, you earn your paycheck every day Craft production vs production control system: With fewer skilled craftsmen, we need systems, prefabrication, and consistent results like car manufacturers Getting started syndrome: Starting projects before materials arrive creates waste, erosion control, supervision, security costs $5K-$30K/month for nothing Anchor projects: Take your best people, best owner, best contract, best trade partners, best budget, put them together and take it to the next level Challenge: Create visible examples people can tour weekly/monthly so they see what lean/IPD/Takt looks like, not just hear concepts The current condition is we're attempting to scale in environments where people can't see what we're talking about. "Let me go see what you're talking about." "Well, we don't have it up and running yet." That's very difficult to scale. If you like the Elevate Construction podcast, please subscribe for free, and you'll never miss an episode. And if you really like the Elevate Construction podcast, I'd appreciate you telling a friend (Maybe even two 😊). Also, here are links to our YouTube Channels: · Jason Schroeder YouTube Channel: https://www.youtube.com/channel/UC4xpRYvrW5Op5Ckxs4vDGDg · LeanTakt YouTube Channel: https://www.youtube.com/c/leanTakt · LeanSuper YouTube Channel: https://www.youtube.com/channel/UCzQDevqQP19L4LePuqma3Fg/featured · LeanSurvey YouTube Channel: https://www.youtube.com/channel/UC-Ztn3okFhyB_3p5nmMKnsw