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?"
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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
