Ep.1449 - The Masugata (mah-soo-gah-tah) and the Genkan (GEN-kahn)

It’s not about materials arriving on cue, it’s about everything moving in rhythm. In this episode, Jason Schroeder and Kevin break down the second great pillar of the Toyota Production System: Just In Time. But as they reveal, this principle goes far beyond supply chains and delivery schedules, it’s the heartbeat of flow. Through firsthand reflections from Toyota plants and lean pioneers, Jason and Kevin show how Just In Time is really about designing a perfectly balanced system where people, machines, and materials move in harmony, free of strain, waste, and interruption. From riveting stations built in the perfect “strike zone,” to 50-ton die changes completed in under five minutes without power, to two operators working one machine in seamless rhythm, this episode captures what true flow looks like in motion. In this episode, you’ll learn: Why Just In Time isn’t about inventory, it’s about stability and flow. How Japanese manufacturers design balance between humans and machines. The real definition of pull: Takt-based pull, not reactive production. How flow state eliminates bottlenecks, strain, and waiting. Why nothing in Japan is built without Takt time and why construction shouldn’t be either. Jason and Kevin also reveal a simple truth learned on the trip: you can’t have Just In Time without Takt. It’s not speed, it’s synchronization. And when teams find that rhythm, work stops being stressful and starts being beautifully predictable. 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 if the smartest thing your team could do was stop? In this special episode of the Elevate Construction Podcast , Jason Schroeder and Kevin unpack one of the most misunderstood yet powerful principles of Lean: Jidoka “automation with a human touch.” Fresh from their reflections in Japan, they trace this concept all the way back to Sakichi Toyota’s original loom where a single broken thread would automatically stop the machine to prevent defects. That simple idea became one of the two foundational pillars of the Toyota Production System, right alongside Just in Time. But this episode isn’t just history, it’s transformation. Jason and Kevin reveal how Jidoka’s Stop. Call. Wait. mindset can revolutionize construction culture. Instead of “go, go, go,” imagine a jobsite where anyone at any level can stop work the moment they see variation or risk. No fear. No blame. Just precision, safety, and respect for people. In this episode, you’ll discover: How Toyota designed “intelligent stopping” into its systems over a century ago. Why Stop. Call. Wait. creates psychological safety and eliminates rework. The shocking truth: Toyota averages 2,000 Andon pulls per day and celebrates every one. How construction can apply the same principle without slowing down production. Why leadership’s reaction to an Andon call defines your culture more than any mission statement. Jason and Kevin break down real examples from Toyota’s factory floors, powerful analogies from the field, and practical steps to bring Jidoka to your own teams, so quality isn’t inspected in at the end, it’s protected from the start. 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 happens when two builders visit the birthplace of Lean and realize it’s not just a system, it’s a way of living? In this powerful and emotional episode, recorded live from Haneda Airport in Tokyo, Jason Schroeder and Kevin reflect on their life-changing journey through Japan with Paul Akers’ Two Second Lean Study Tour. What started as a professional training trip turned into something much deeper, a rediscovery of purpose, humanity, and what it truly means to lead. Jason shares how Japan didn’t just refine his understanding of Lean, it healed it. From Toyota’s leadership philosophies to the culture’s deep respect for people, he found a nation that values consideration, alignment, and connection. For Jason, the revelation was personal: “I feel whole. I finally found a place where kindness isn’t weakness, it’s the standard.” Kevin opens up about his own transformation, from learning new tools to completely rethinking leadership and fatherhood. Inspired by Japan’s shoulder-to-shoulder culture, he now sees that leadership isn’t about sending people off to figure it out, it’s about walking beside them. In this episode, you’ll learn: Why the true power of Lean begins with love and respect for people. How Japan’s “Gemba-first” mindset reshapes leadership and humility. The lessons from Toyota executives that every builder should hear. How a simple app and mindset shift rebuilt Kevin’s productivity and peace. Why real leadership at work or home means standing shoulder to shoulder. This isn’t just a recap of a trip. It’s a blueprint for becoming whole again as leaders, as parents, as people. 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 if your construction site had two gates, one for entry, and one for alignment? In this electrifying episode recorded live from Kyoto, Jason Schroeder takes lessons from ancient Japanese castle design and transforms them into a modern leadership framework every builder needs to hear. Drawing from the Masu Gata (a defensive courtyard designed to trap intruders) and the Genkan (the sacred entryway of every Japanese home), Jason reveals a radical truth: your morning worker huddle is your Genkan - the moment that separates chaos from flow, and disunity from one team. You’ll hear powerful lessons from Japan’s culture of respect, Toyota’s leadership philosophy, and a story of how one former Lexus CEO explained why Suzuki fell while Toyota rose. It all comes down to loving the Gemba people , the workers and creating a jobsite culture where no one walks in unaligned. In this episode, you’ll learn: Why Japan’s entry rituals can revolutionize your project culture. How to protect your team from “enemies of alignment”. The real reason every job must have a morning worker huddle. How two gates can prevent disrespect, chaos, and safety risks. Why loving and training your Gemba people is the ultimate leadership act. This isn’t just about construction, it’s about honor, respect, and discipline. Step into the Genkan. Leave your shoes and your ego at the door.   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  

Most projects bleed money and time long before the first worker lifts a tool. The problem isn’t the field, it’s the logistics. In this eye-opening episode, recorded live from Japan on Paul Akers’ Two-Second Lean trip, Jason reveals what Toyota, Lexus, and top-performing DPR projects all have in common: they don’t manage waste, they design it out before it ever reaches the jobsite. Discover how a single shift in thinking from “cut it and toss it” to “build it right upstream” can eliminate overproduction, motion, transport, and rework across your supply chain. Hear the true story of a lab project that cut waste by 30%, the kaizen lesson that stunned Toyota engineers, and why framing crews should never have to haul, cut, or fix bulk materials again. If you’re serious about lean logistics, reducing worker overburden, and building flow into your operations from procurement to placement, this episode is a masterclass. Listen in to learn: The hidden waste your logistics system creates every day. How Toyota thinks upstream to prevent chaos downstream. Why cutting waste on-site is already too late. Simple, proven ways to pre-cut, pre-kit, and pre-plan for flow. How to protect your crews from burnout, waste, and unevenness. Stop fixing symptoms. Start designing flow. 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  

Jason answers a listener from Brazil who is leading a delayed, complex facade restoration and does not know where to begin. He lays out a simple, field-tested starting plan that replaces panic with clarity and momentum. You will learn: The first three daily habits to regain control: read the drawings, visualize the plan with zones and logistics, and walk the field. How to use crew input to shape sequence even without a formal pull plan. How to launch short daily huddles around visuals to surface and solve roadblocks. What full kit really means and how to refuse starts without it. How to hold the line on the system instead of firefighting when pressure rises.   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

Seeing Through Trade Partners’ Eyes This short episode reframes “problems with the trades” as problems with systems, culture, and inputs. Jason explains why most crews arrive wary and defensive, how our consistency can pull them back into a window of tolerance, and why emotionally intelligent supervision beats control. You will leave with a humane, practical lens that improves trust, flow, and results. You will learn: Why blaming people fails and fixing systems works. The idea of ill-wired vs ill-prompted behavior and why inputs matter. How to earn trust in six to eight weeks with consistent huddles, pull planning, and clear norms. What emotionally intelligent superintendents do and why one toxic leader can sink a site. Who should listen: Supers, assistant supers, foremen, and field engineers ready to replace control with trust and get better work from better systems. 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

Help, Don’t Control: Make Zone Control Walks Work Stop chasing fifteen handoffs and start creating flow. Jason explains how to focus on the vital few, run quick joint walks, and enable trades to self-verify so you follow up instead of firefight. You will learn: How to shortlist the day’s critical handoffs in the afternoon foreman huddle. How to run brief, pull-based walks using full kit principles. How to use feature-of-work and zone control checklists for trade self-verification. How to assign remaining handoffs to trade-to-trade walks with written commitments. How to distribute checklists via WhatsApp to foremen and capture quick proof. How to log outcomes in Takt the same afternoon and review the next morning. How to keep supervision tied to field work without micromanaging. 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 is catching up on powerful lessons and field-tested practices that can make your projects safer, cleaner, and more effective. Here’s what you’ll learn: The Builder’s Code: How you treat workers and foremen is exactly how they’ll treat the building, and what the client ultimately experiences. Lessons from Japan (Gemba): Start with 2–3S (sort, straighten, shine), watch people’s movement, and stop where things don’t make sense to reveal hidden constraints. Problems vs. Dilemmas: A problem has a clear solution; a dilemma forces you to choose between imperfect options. Jason shares examples every builder will recognize. Trash Management Done Right: Pre-kit and pre-cut to reduce waste, use scrap-out units, and manage dumpsters with visual Kanban triggers at half or three-quarters full. Daily Logistics Discipline: Assign a logistics owner to check the perimeter, cleanliness, recycling, and traffic control every single day. Why Saturdays Don’t Work: Crews show up thin, productivity drops, and you lose momentum. Stop relying on weekend work as the answer. AEDs on Every Site: More lives are lost to cardiac arrest than auto accidents. Affordable AEDs (around $1,400) save lives. Every project needs one. This episode is practical, fast-moving, and packed with insights you can take straight to the field. 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 running on continuous improvement or just the appearance of it? In this fast, practical conversation, Jason sits down with Patrick Adams, author of Avoiding the Continuous Appearance Trap, to expose the difference and show leaders how to build systems that actually sustain. What you will hear: Patrick’s journey from the United States Marine Corps to leading Lean Solutions and coaching teams worldwide. The trap: companies that look “lean” on the surface but suffer toxic culture, high turnover, and flat KPIs. The telltales of a true CI culture: clear expectations that cascade to the front line, time and space to problem-solve, and relentless sustainment. Why short-term fixes fail and why real operational excellence takes structured daily behaviors, not silver bullets. How Patrick’s 12 questions help leaders assess where they are and design their own roadmap. One practical challenge: Adopt leader standard work today. Structure your day, review it at the end, and align your actions to the results you claim to want. 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