Ep.1603 - Eliminating Waste Is Not the Whole Story

In this episode, Jason explains why a pull plan alone is not enough to create reliable schedules. While pull planning is critical for collaboration, sequencing, and trade buy-in, it must always be balanced against historical project data, what Jason calls the "reference class." Jason also revisits the difference between CPM, single-train Takt planning, and multi-train Takt planning, explaining why the real goal is not forcing every trade into one uniform rhythm, but enabling multiple trains of work to flow properly together. The key lesson: never let optimism override reality. Great pull plans combine collaboration with historical evidence. What you'll learn in this episode: Why CPM and rigid single-train Takt planning are both flawed extremes. What multi-train Takt planning actually means. How trades can flow together without forcing unnatural rhythms. What a "reference class" is and why it matters. Why pull plans must be validated against historical project data. How optimism and "rose-colored glasses" can derail schedules. Why historical throughput data should guide milestone commitments. Are you building schedules based only on opinions or grounding them in real production history? 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  

In this episode, Jason challenges one of the most misunderstood concepts in lean construction: the idea that eliminating waste is always the primary goal. While waste reduction matters, Jason explains why focusing only on "cutting waste" can actually destroy flow, destabilize systems, and hurt project performance. Using examples from NASCAR pit crews, buffers in Takt planning, foremen supervision, and the Theory of Constraints, Jason explains that lean is not about maximizing utilization everywhere, it's about protecting throughput, flow, and system stability. Sometimes what looks like "waste" is actually critical support for the system to function properly. What you'll learn in this episode: Why eliminating waste is not the ultimate goal of lean. How the Theory of Constraints changes the way we think about efficiency. Why buffers and stabilization time are essential to production flow. How over-focusing on utilization can damage project performance. Why non-working foremen, empty zones, and standby resources are sometimes necessary. How system thinking prevents "lean" from becoming destructive. Are you optimizing individual activities or protecting the overall flow of the system? 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  

In this episode, Jason dives into a powerful logistics concept that can completely change how construction teams organize work in the field. He explains the "five-and-five" principle: can workers access everything they need within five steps and five seconds? along with the idea that all visual information and standard work should be understandable from ten feet away. Drawing from lean manufacturing, military logistics, and real-world construction examples, Jason explains why logistics is one of the most overlooked but critical systems in construction. From strike zones and kitted carts to de-trashing stations, Kanban replenishment, and visual controls, the goal is to eliminate wasted motion, reduce confusion, and allow crews to focus entirely on installation instead of scrambling for materials or information. What you'll learn in this episode: What the "five-and-five" principle means in construction logistics. Why all tools and materials should be accessible within five steps and five seconds. How visual systems should be readable from ten feet away. Why logistics not firefighting is the key to production flow. How strike zones, carts, shadow boards, and Kanban systems improve efficiency. Why the field is for installing work not figuring things out. Are your crews spending their time installing or searching, walking, and scrambling for what they need? 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  

In this episode, Jason tackles a major misconception in the construction industry: the idea of "pre-Takt," "out of Takt," or "non-Takt" areas. He explains why every part of a project can and should be Takt when you truly understand what the Takt Production System is designed to do. Jason breaks down the core principles behind Takt planning: creating flow, sequencing trades properly, stabilizing production with buffers, and organizing work by zones or work packages. He explains that Takt is not just about having one perfectly uniform rhythm everywhere, it's about enabling respectful production flow throughout the entire project. What you'll learn in this episode: Why "pre-Takt" and "out of Takt" are misconceptions. What the Takt Production System is actually designed to accomplish. Why every project area can be organized into zones and sequences. How buffers stabilize production flow. Why Takt planning is about flow and progression, not perfect uniformity. How different Takt times can still work together within one production system. 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  

In this episode, Jason introduces a powerful leadership and production concept: focusing on the critical factors that control project success. Instead of reacting to problems after they happen or simply observing normal work in progress, leaders should concentrate their attention on the areas most likely to impact flow, create bottlenecks, or fail the system. Drawing from conversations with a high-performing trade partner integrator, Jason explains how elite construction teams identify and monitor the most difficult transitions, trade bottlenecks, risky connections, and limiting factors before issues occur. The goal is not reaction,  the goal is prevention. What you'll learn in this episode: Why supervisors should stop reacting and start preventing. What "critical factors" are in construction operations. How bottlenecks, difficult transitions, and risky connections impact flow. Why mock-ups and first-run studies are essential for identifying failure points. How field engineers and superintendents should focus their attention ahead of work. Are you spending your leadership energy reacting to problems or preventing the critical factors that create them? 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

In this episode, Jason delves into the complexities of lean principles and how to decide which principle to follow in the face of conflicting priorities. He explores a key dilemma with Ryan, his CFO, regarding over-processing and respect for people in the context of lean, and uses Eliyahu Goldratt's Theory of Constraints to offer guidance on how to resolve such conflicts. Jason discusses how to evaluate which lean principle will have the most significant impact on the project or the business, and he breaks down how to make decisions when faced with seemingly contradictory principles. The message is clear: it's not about blindly following all lean principles, but about applying the most appropriate one in the context of your project's current limitations. What you'll learn in this episode: How to navigate conflicting lean principles on the job. The importance of the Theory of Constraints in lean decision-making. Why some lean principles can conflict and how to resolve that. The practical approach to identifying the most limiting factor in a situation. How striving for perfection can sometimes conflict with eliminating waste. When faced with a tough decision, are you identifying the most limiting factor and applying the lean principle that will provide the greatest impact? 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  

In this episode, Jason discusses how to manage a spread-out project effectively. Whether you're working on a massive hospital or a smaller, sprawling project, Jason breaks down the approach you need to take to maintain operational control, safety, and organization. He explains that while you may need to break large projects into functional teams, a spread-out project doesn't automatically require separate functional areas. The key is logistical control getting around efficiently, staying connected, and ensuring smooth communication. From using tools like Kawasaki mules and drones to coordinating with your team, Jason emphasizes the importance of keeping the project aligned, even if it covers a large area. What you'll learn in this episode: How to manage a spread-out project without losing control. The importance of logistical planning and communication in large projects. Why having separate functional teams isn't always necessary. Tools and methods to keep your project organized, even in expansive spaces. How to use technology and team coordination to ensure safety and efficiency. Are you managing a spread-out project? How are you maintaining control and keeping things moving smoothly?   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  

In this episode, Jason dives into a critical issue in construction: having the wrong trades on your team. He explains why the key to success in pre-construction starts with choosing the right trades and trade leaders. If you're struggling with trades who aren't performing, it may be a sign of a failure in the pre-construction process. Jason discusses how selecting the right trades and ensuring they're aligned with your culture is crucial to the success of a project. Drawing from his experience with the Bioscience Research Laboratory, Jason outlines how a strong pre-construction process can help avoid the frustration of dealing with non-performing trades and sets up the project for long-term success. What you'll learn in this episode: Why having the wrong trades signals failure in pre-construction. The importance of pre-qualifying and interviewing trades before selection. How to align trade partners with your project's goals and culture. Why a good pre-construction system sets the project up for success. How the Bioscience Research Laboratory project demonstrated the value of the right trade selection. Are your pre-construction processes strong enough to ensure you have the right trades on your projects?    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  

In this episode, Jason explores a key leadership concept called "The Dilemma of Command" deciding where a field leader should spend their time. Should superintendents stay in the field? Should they stay in the office? Jason explains that the answer is neither. Great leaders must be where they are needed most. Using examples from military leadership and real construction experience, Jason breaks down how field leaders should think through the lens of the Theory of Constraints. The goal is not to look busy in the field or hide in the office,  the goal is to identify the project's biggest constraint and place leadership attention where it creates the most value. What you'll learn in this episode: Why leadership is not about being "always in the field" or "always in the office". How the Theory of Constraints applies to field leadership. What "The Dilemma of Command" means for superintendents and PMs. Why leaders must focus on the project's biggest constraint. How confidence comes from knowing you are exactly where you need to be. Are you spending your time where you feel comfortable or where the project truly needs you most?   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  

In this episode, Jason clears up a major misunderstanding about work-life balance. Balance does not come from doing less, caring less, or becoming disengaged at work. It comes from becoming lean using personal organization systems, time blocking, full focus, one-piece flow, full kit, buffers, and disciplined work habits so you can perform at a high level without burning yourself out. What you'll learn in this episode: Why balance does not mean doing less. How personal organization creates freedom. Why focus and full kit matter in daily work. How lean thinking applies to your personal productivity. Why being balanced still requires commitment and performance. Are you chasing balance by doing less or creating balance by becoming more effective?   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