And converting our prefab wall‑panel pilot cell into a two‑shift line to hold a 14‑week delivery, we’re targeting a 22‑minute takt and I own both the schedule and the safety metrics — so I need to pull days without inviting forklift/pedestrian conflicts or rushed hot work. For teams that scaled this fast, where did you find safe cycle‑time gains — line balancing, visual controls, or material staging — without slowing inspections or weakening LOTO?
But forklifts weaving through the cell drives me nuts, so at a similar 22‑minute takt we yanked truck access from the line, set a “no‑fly” lane with barriers, and switched to milk‑run drops every 2 takts via a water spider — near‑misses vanished and we gained about 2–3 minutes without touching hot work. We also pushed all cutting/torch to a feeder cell under a strict “no hot work under takt pressure” rule; small caveat is rush parts get slower, but the predictability is worth it — OSHA’s pedestrian guidance was handy: https://www.osha.gov/etools/powered-industrial-trucks/operating.