I should have put a couple of smiley faces in mine so it wouldn't come across as being so harsh. My apologies. I wasn't trying to be difficult. I just kind of jumped on it because I didn't want other people to use your yield numbers until we figured out how you did it.
In your original post you mentioned doing a group of 125ppl and having leftovers. With 116lbs of cooked meat, I would hope you did have leftovers!
Most BBQ restaurants figure on about 8oz of meat on a generous sized plate. That's also the figure I use unless I KNOW I'll be feeding a teen age hockey team or mens athletic team after the game. Then I might figure 10oz, but I'll usually regret it. 8oz of meat(on average) is a lot of meat if you have other sides to eat as well. You had almost a full pound, and I've never seen an average group of normal people average more than 7-8oz of meat. So you had plenty to say the least.
The line setup thing is completely up to you and how you want to do it. But most caterers will go with the less expensive, more filling items at the beginning of the line to keep people from getting carried away. Same reason many caterers will use servers even for buffets. The staff costs less than the food cost/waste if the crowd is large enough. Usually folks in the line can see the other end so they know what awaits them down where the good stuff is, or they can even get a second plate. Caterers count on peer pressure to reduce the number of people that engage in this activity. Kind of like counting cards in Vegas. It may not be illegal, but it is frowned upon.
If you really want to see this example in action, the next time you're doing ribs for a crowd, put the ribs in front of the line. Watch as people walk off with half slabs and maybe even whole slabs as your planned 1/3 slab portion estimate goes right out the window.
If you have big eaters, like football players, this can get real ugly.
As for your yield, I just don't know what to say. That kind of yield would not only keep a lot of BBQ restaurants in business, but it would make their owners rich. I would only question the yield for the following reasons: 1) My family's BBQ restaurants cooked about 1 ton of pork shoulders and butts daily, 5-6 days a week, for about 70 years. We monitored our yield on every batch, and for skin on shoulders it was consistently about 47-52%. For butts it was about 53-58%. The variations there were more due to inconsistencies in cooking practices than in the meat itself., and 2) I make buckboard bacon pretty much monthly, you know, bacon made from butts instead of belly. Well, after butterflying a butt and removing the bone in preparation for curing, the meat is at about 80% of original weight even before cooking. Raw., and lastly, 3) If you search you'll find info on the board about boneless butts/shoulders. I've cooked a few and some of the other caterers here have cooked thousands as it is their preferred item to cook. Their yield numbers are usually around 65-70% for an item that started out boneless.
I'm not knocking your numbers at all. In the food business, it's about 20% cooking and about 80% number crunching, so if you can help me get my yield up to your level, or even bump it 5%, I'll be grateful and think of you next year as I sun myself on some nice beach while on the vacation I paid for with the extra 5%. I'd take you with me but you don't want to see me in a Speedo.