Offsite Manufacturing: We Need to Train the Workforce We Can’t Hire
In two recent advisory engagements with offsite manufacturing operations, I encountered a familiar problem, one I dealt with throughout much of my manufacturing career.
Both operations had opportunities to increase production but were struggling to achieve the productivity necessary to meet demand. In discussions with production managers and supervisors, I asked what was preventing them from increasing output. Their answers were remarkably similar: they couldn’t find enough skilled production workers, and they lacked the training programs and personnel necessary to develop the inexperienced people they hired.
That raises a question I believe deserves more attention: If we can’t hire the skilled workers we need, why aren’t we developing them ourselves?
MANAGEMENT NEEDS TO RECOGNIZE THE PROBLEM AND THE ROOT CAUSE
Finding skilled manufacturing workers has always been a challenge, and offsite construction is certainly no exception. But I wonder whether we’ve become too comfortable blaming the availability of skilled labor without examining our own responsibility for developing it.
In one of these operations, upper management seemed largely unaware of the training deficiency. In the other, the owner recognized the problem only after becoming directly involved in production.
When production falls short, we naturally examine equipment, materials, scheduling, and labor costs. But how often do we ask whether employees have actually been taught to perform their jobs properly?
AN OFTEN-OVERLOOKED ADVANTAGE OF OFFSITE MANUFACTURING
One of the fundamental advantages of offsite manufacturing is the ability to break construction into specific, repeatable tasks through assembly-line production.
We don’t necessarily need to train someone to frame an entire house or wire a complete building. Many production jobs involve a particular task, a part of the whole, that an inexperienced employee can be taught to perform competently. As employees gain experience, their skills and responsibilities can expand.
Certainly, some positions require experienced tradespeople and specialized qualifications. But expecting to hire a workforce of fully trained construction workers overlooks an important advantage of the manufacturing process itself. We can develop the specific skills we need rather than depend entirely on finding them.
TRAINING REQUIRES STRUCTURE AND ACCOUNTABILITY
Throughout my manufacturing career, we recognized that hiring experienced production workers would always be a challenge. Our response was to develop a structured training program built around individual specific job responsibilities.
With HR guidance, supervisors and production management developed job-specific training manuals, generally six to eight pages each. We had them professionally printed and bound because presentation mattered. We wanted employees to recognize that we took their training seriously.
New employees were assigned mentors and entered a two-week training period. Their supervisors were responsible for verifying competency, which qualified employees for full-time status and a wage increase. Those demonstrating competency sooner received that recognition sooner.
The manuals weren’t the real accomplishment. The important point was that training had structure, accountability, and a measurable outcome.
TRAINING IS AN INVESTMENT, NOT AN EXPENSE
An important part of our approach involved something less obvious: how we accounted for training costs.
Training wages were charged separately rather than against the direct production labor budgets used to evaluate supervisors and determine their monthly bonuses. We didn’t want supervisors penalized for taking the time necessary to develop capable employees.
Expecting supervisors to train inexperienced people while holding them accountable for the resulting short-term labor inefficiency creates conflicting incentives. Training is an investment in future productivity, and our management practices should reflect that.
HR AND LEADERSHIP MATTER
I’ve always considered a capable HR professional essential to a manufacturing management team, well beyond hiring, benefits, and compliance. HR should work closely with production management to develop employees, understand their concerns, and help create an environment where people want to succeed.
Our supervisors participated in interviewing prospective employees and recommending hiring decisions. After all, they would be responsible for training and managing those individuals. Interestingly, in one recent advisory engagement, supervisors weren’t involved in hiring interviews at all.
We also measured turnover and conducted exit interviews to understand why employees left. Occasionally, our training made employees more attractive to other employers offering higher wages. That’s a risk, but hardly a reason not to train them.
There’s an old expression I’ve always appreciated: People don’t care how much you know until they know how much you care.
THE RESPONSIBILITY RESTS WITH MANAGEMENT
Offsite manufacturing continues to invest in equipment, automation, technology, and expanded production capacity. Those investments may be necessary, but their value is limited without a workforce capable of using them effectively.
The availability of skilled labor may be beyond a manufacturer’s control. The decision to develop the people we hire is not.
Before blaming the labor market for disappointing production results, perhaps factory leadership should ask: Have we made the same commitment to developing our workforce that we’ve made to developing our manufacturing capacity?

Bill Murray, [email protected]
Offsite Innovators brings decades of hands-on manufacturing leadership and operational experience to the challenges facing today’s offsite construction industry. If you’re evaluating an operation, planning expansion, or facing production challenges, let’s talk.
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