Physical Project Constraints

The first in a five-part series on applying the Theory of Constraints in the project setting.

Projects of all types get bogged down. Something happens - unexpected - that puts the team members into a react mode. From there it is all downhill. While many people will offer good advice (they've got no skin in the game) few can offer a perspective that can keep a project on track. Enter the Theory of Constraints.

In the simplest terms think of a constraint as a restriction to flow. A bottleneck restricts the flow of liquid. Widen the neck and the bottle is emptied faster. Cranes are an obvious possible constraint on construction projects. Anything that must be lifted has to be carried by the crane. On any given day there may not be enough crane time to move all the material desired. Therefore the crane restricts the amount of work that can be performed in the day.

These are the physical constraints:

• People - not enough engineers for the work needed in a given time
• Space (access) - often there isn't room for two people to be working in the same location
• Equipment - availability of any one tool can limit progress on a given day

Think of physical constraints as anything that carries a load — people, tools, equipment, space (access), and talents (special competence). Projects are often long enough that we often have time to address physical constraints.

We manage our physical constraints through a five-step process of focusing.

1. Identify the constraint - look for places that work bunches up
2. Exploit it - get everything you can from it.
3. Subordinate all other actions to it - don't use the constraining resource if you can use another resource…even if it looks less efficient to do so
4. Elevate it - find ways to increase the capacity
5. Repeat the cycle - usually another pass through will improve the situation

Of course, this can be done prospectively. Look forward on your project. Ask, "What could keep us from proceeding at the intended pace?" Use the five focusing actions to stay out of trouble.

Now visit Frank Patrick and Joe Ely for their concurrent postings on TOC for projects.

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