HOW A TAKT PLAN CAN FAIL: APPLYING FAILURE MODES AND EFFECTS ANALYSIS IN TAKT CONTROL

Abstract

Construction projects need adequate planning to set a structure and direction for production, but simultaneously call for effective control to maintain the direction when something unexpected happens. Effective control is of utmost importance for takt production, which is especially vulnerable when disruptions occur. While previous takt production research has primarily focused on how to form a good takt plan, little attention has been given to how to control and continuously improve takt production systems effectively. Addressing the gap, this study inspects takt control through the lenses of failure modes and effects analysis (FMEA). First, we argue that takt control can be perceived through three different failure categories: failures within wagons, failures in handoffs, and failures in takt trains. We discuss the peculiarities of takt control through these categories and provide examples of failures with their respective failure mode(s) and possible control action(s). Second, we construct an FMEA-based framework for effective takt control that shows how to recover from failures and avoid them altogether. Future research may consider validating the failure categories and the framework through case studies or simulations, and examining their applicability in supporting digital takt production.