How One City Reduced Rework by 22% in a Single Paving Season
A mid-size municipality implemented structured readiness gates and daily coordination huddles, resulting in significant cost savings and improved schedule predictability.
The Challenge
Problems Faced
- • 15% of lots required rework or replacement
- • Average 3-day delays per project
- • Poor communication between crews and inspectors
- • Inconsistent quality documentation
Impact
The Solution
Readiness Gates
Implemented 5-step checklist before any paving work could begin
Daily Huddles
10-minute morning coordination meetings between crews and inspectors
Real-time QC
Digital checklists and immediate escalation for out-of-spec conditions
Results After One Season
Reduction in rework
Cost savings
On-time completion
First-pass QC rate
Key Learnings
Front-end investment pays off
The 15 minutes spent on readiness checks saved hours of rework and coordination
Communication is critical
Daily huddles eliminated most misunderstandings between crews and inspectors
Simple tools work best
Digital checklists were more effective than complex project management software
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