The construction industry has long struggled with schedule drift, resource inefficiency, and fragmented project data. As projects grow in complexity, general contractors are turning to lean construction software to bring order to the chaos. One standout example comes from The Boldt Co., a $1 billion contractor that has integrated TouchPlan into its production system to improve project transparency, cut labor peaks, and keep schedules on track. This case study offers valuable lessons for any contractor looking to modernize their approach to project management.
Contractors aiming to stay profitable in this environment need the right project management tools to maintain control over timelines and budgets. Boldt’s experience demonstrates that the right digital platform can turn fragmented scheduling into a cohesive, transparent workflow.
Understanding Lean Construction and the Last Planner System
Lean construction is a production management approach that traces its roots to the Lean Construction Institute, where Boldt has been a member since the organization’s early days. Unlike traditional project management, which pushes work according to a fixed master schedule, lean construction pulls work through by ensuring that each task’s prerequisites are met before work begins. The philosophy centers on maximizing value while minimizing waste across all project activities.
At its core, lean construction challenges the conventional assumption that construction projects are inherently unpredictable. Instead, it argues that with the right planning systems, real-time visibility, and continuous improvement practices, teams can achieve reliable workflow and predictable outcomes. This shift in thinking has profound implications for how contractors approach scheduling, resource allocation, and team collaboration.
The Boldt Production System
Boldt’s commitment to continuous improvement led to the creation of the Boldt Production System, a methodology rooted in the Last Planner System. This system operates at multiple levels of planning:
- Master schedule: High-level project milestones and overall timeline
- Phase schedules: Production strategies for each major phase of work
- Make-work-ready plans: Detailed lookahead planning that identifies constraints
- Weekly work plans: Commitments for what will be done in the coming week
- Daily production tracking: Real-time monitoring of progress against commitments
This layered approach ensures that every level of the organization understands not just what needs to be built, but what needs to happen to make that work possible.
The Role of Technology in Lean Implementation
While the Last Planner System is a manual process at its core, technology amplifies its effectiveness. TouchPlan became a standard part of the Boldt Production System at the end of 2021, after the company recognized that digital tools could solve problems their paper-based and spreadsheet-driven processes could not.
“Our focus has been on executing projects more successfully,” said Nick Loughrin, group manager of project delivery services at Boldt. “By making our plans visible to more project stakeholders, problems come to the surface faster and help our teams focus on what will make the project better.”
This visibility is the cornerstone of lean construction. When everyone on the team can see the plan, they can identify bottlenecks before they become delays.
How TouchPlan Addresses Common Scheduling Challenges
Traditional scheduling approaches rely on tools like Oracle P6 or Microsoft Project for the master schedule, supplemented by Excel spreadsheets for detail and separate constraint-tracking boards. The result is a cumbersome, disconnected process that adds non-productive time to already busy days.
Eliminating Data Silos
Before TouchPlan, Boldt’s project teams managed schedules across multiple platforms. Each project became its own silo of stand-alone data, making it difficult to share best practices or identify patterns across the organization. TouchPlan unified these systems into a single platform.
“What we’ve traditionally done is taken our master schedule, captured in P6 or Microsoft Project, and added layers of detail per phase that is hard for the team to follow,” Loughrin explained. “Now, using TouchPlan, we are able to tie our master schedule and the production strategy together in a clear and visual way that the team understands.”
Real-Time Constraint Management
Constraints are the invisible killers of construction schedules. Missing materials, unavailable labor, incomplete prerequisite work, and unresolved design issues can halt progress unexpectedly. TouchPlan allows teams to capture and tie constraints directly to the plan.
| Constraint Type | Traditional Approach | TouchPlan Approach |
|---|---|---|
| Material availability | Separate tracking spreadsheet | Linked to schedule task with status updates |
| Labor resources | Weekly check-in meetings | Real-time visibility into resource allocation |
| Prerequisite work | Manual verification | Visual workflow showing dependencies |
| Design/approval | Email chains and file shares | Integrated constraint log tied to schedule |
Resource Leveling and Manpower Optimization
One of the most compelling results from Boldt’s implementation came from a Wisconsin project where the team was experiencing schedule drift. Using TouchPlan to develop a production strategy based on flow, the team analyzed and leveled out resources to make the plan more efficient.
“The team would have probably found a way to finish on time, but it would have cost exponentially more by working overtime and adding resources,” Loughrin said. “We finished the project on time and with a lot less hours.”
This real-world result demonstrates that lean construction software does not just track schedules; it actively helps teams optimize them.
Integrating Production Systems with Digital Tools
Successful lean construction requires more than purchasing software. It demands a cultural commitment to continuous improvement and a production system that the technology can support.
Building Standards from Best Practices
Boldt’s strategic initiative focuses on developing better standards based on internal best practices. The company recognizes that rigorous and disciplined implementation of the Boldt Production System drives successful outcomes, and TouchPlan serves as the technology enabler for that discipline.
“One of our main strategic initiatives within our growing company is to develop better standards based on our best practices,” Loughrin said. “We know we will have successful outcomes if we are rigorous and disciplined in our approach.”
Cross-Project Performance Data
A powerful feature of digital lean construction tools is the ability to aggregate performance data across all projects. Instead of each project operating as a silo, the organization can see patterns, identify which production strategies work best, and transfer lessons from one project to another.
As the construction industry moves toward greater software integration and interoperability, the ability to connect production planning with actual performance data becomes increasingly valuable. Teams can compare planned vs. actual performance, track percent plan complete (PPC), and continuously refine their processes.
Scalability Across Project Types
Boldt had about 30 projects using TouchPlan shortly after its adoption. The software works across different project types and sizes, from small renovations to large-scale new construction. This scalability matters for contractors who need a single system that can adapt to varying project demands.
Key factors that make a lean construction platform scalable include:
- Phased rollout: Start with pilot projects, then expand
- Standardized templates: Reusable phase plans and production strategies
- Training programs: Consistent onboarding for new project teams
- Integration APIs: Connections to existing ERP and accounting systems
Key Takeaways for Contractors Evaluating Lean Construction Software
Boldt’s experience offers a blueprint for contractors considering similar investments in lean construction technology.
Start with the Production System, Not the Software
Boldt had already developed the Boldt Production System based on Lean principles before adopting TouchPlan. The software was chosen to support an existing methodology, not to create one. Contractors should define their production processes first and then find technology that reinforces those workflows.
Understanding the phases of technology adoption helps organizations avoid the common trap of buying software without changing processes. The three-phase model of understand, adjust, and integrate provides a framework for successful implementation.
Prioritize Visibility and Transparency
Transparency in lean construction goes beyond simple schedule sharing. It means making the reasoning behind decisions visible, ensuring that every team member understands not just what they need to do but why it matters to the overall project flow. Boldt found that when field crews could see how their work connected to downstream activities, they became more proactive about resolving constraints before they became blockers.
This cultural shift toward openness requires deliberate effort. Project leaders must model transparency by sharing both successes and challenges openly. When a team misses a commitment, the focus should be on understanding what went wrong and fixing the process, not assigning blame. This learning orientation is what separates organizations that get lasting value from lean construction software from those that treat it as just another reporting tool.
The single biggest benefit Boldt experienced was improved visibility. When plans are visible to all stakeholders, problems surface faster. This transparency drives accountability and enables proactive problem-solving rather than reactive firefighting.
Measure What Matters
TouchPlan provided Boldt with production and performance data beyond simple ahead-or-behind metrics. This deeper data enables teams to understand why they are where they are on the schedule and what adjustments will have the greatest impact.
Evaluate with a Long-Term Lens
When assessing software options, contractors should ask key questions about construction software to ensure the platform aligns with their long-term strategy. Important considerations include:
- Does the platform support the Last Planner System or other lean methodologies?
- Can it integrate with existing tools like P6, Microsoft Project, or Procore?
- Does it provide cross-project analytics for continuous improvement?
- Is the interface intuitive enough for field teams to adopt quickly?
- Does the vendor offer implementation support and training?
Conclusion
Boldt’s successful implementation of TouchPlan demonstrates that lean construction software can deliver measurable improvements in schedule performance, resource efficiency, and team collaboration. By grounding technology adoption in a proven production system and prioritizing transparency across all project stakeholders, contractors can achieve the kind of results that Boldt realized: projects delivered on time with fewer hours and lower costs.
The construction industry is increasingly recognizing that the tools used to manage work are just as important as the tools used to perform it. For contractors ready to take the next step, Boldt’s journey provides both inspiration and a practical roadmap.