For PMOs Managing Megaprojects Under Constraint

Flow measures how work moves through space, time, and shared services.

Unlike schedule % complete, flow KPIs expose the friction killing productivity.

These are the 12 critical flow indicators:

1️⃣ Gate Throughput Rate

How fast people/materials enter site

Formula:

Entries per hour ÷ Max safe capacity

Target: ≥ 85% efficiency

Why it matters: Anything below creates lost productive hours before the shift begins.

2️⃣ Time-to-Workspace

Travel + wait + clearance time to reach the job

Target: < 20 min from gate to tools-on

Why it matters: Every extra 10 min = 3–5% daily productivity loss.

3️⃣ Crew Productive Hour Ratio (CRU Signature KPI)

Formula:

Direct tools-on time ÷ Total shift time

Target: 65–70% (most sites sit < 45%)

Reveals: Congestion, poor coordination, waste.

4️⃣ Shared Service Wait Time

Lunchroom, elevators/hoists, washrooms, safety stations

Target: < 5% of total shift

Reveals: “Invisible congestion” bottlenecks.

5️⃣ Delivery Flow Adherence

How many deliveries arrive on time + correct + safe route

Target: 95%+

Impact: Smooth material availability = continuous workfronts.

6️⃣ Workfront Readiness Index

Are crews arriving to workfronts that are actually ready?

Target: ≥ 90% of planned shifts

Impact: Avoids “wandering craft” & idle crews.

7️⃣ Progress Confirmation Latency

Time from work completion → confirmation in system

Target: < 24 hours

Why: Delays break the Resource Intelligence Loop™.

8️⃣ Shift Flow Synchronization

Alignment between site access, shared services, and crew surge times

Target: Zero peak conflicts

Impact: Smooth day vs. disaster day.

9️⃣ Space Density Index

Trade workers per m² per hour

Target: Balanced density across zones

Why: Too high = safety risk & chaos. Too low = underutilization.

🔟 Material Touch Count

How many times a material is moved before installation

Target: 1–2 touches max

Impact: More touches = more wasted labour.

1️⃣1️⃣ Unplanned Relocation Events

Crew forced to move mid-shift due to access/priority changes

Target: Zero

Impact: Flow interrupter + morale killer.

1️⃣2️⃣ Logistics Interference Events

Incidents where movement stops movement

(e.g., forklift blocking forklift, trades blocking trades)

Target: Zero

Impact: The true congestion metric everyone ignores.

💡 The CRU Truth Behind These KPIs

Flow KPIs measure the friction schedule metrics hide.

If flow breaks, productivity breaks—no matter what P6 says.