Highlighting the thinkers and their ideas driving the evolution of Offsite Construction. 
Be inspired, be informed, be innovative!

Before You Consider Building Offsite, Make Sure Your Project Fits

A developer once came to me with what seemed like a straightforward assignment. He wanted to build a project using modular construction and needed help finding the right manufacturer.

I had spent most of my career in offsite manufacturing, so finding and evaluating manufacturers was familiar territory. I began the engagement assuming the developer understood more about offsite construction than he actually did. It turned out to be a classic case of putting the cart before the horse—and I had made the same mistake.

He knew he didn’t know everything about modular construction. What neither of us recognized at the outset was just how much he didn’t know—and how much of that needed to be understood before we ever started looking for a manufacturer.

As we got further into the project, questions began surfacing that should have been addressed much earlier. The local building requirements were particularly demanding, including materials and construction practices the manufacturers we approached didn’t commonly use. The regulatory process itself created another layer of complexity, and most manufacturers simply weren’t interested in taking it on.

After spending considerable time trying to make the pieces fit, I eventually gave the developer advice he didn’t particularly want to hear: I didn’t believe modular construction was the right solution for this project. He decided to continue pursuing it anyway. Many months later, ground still hasn’t been broken.

The experience reinforced something I’ve seen repeatedly during more than four decades in this industry. Developers sometimes begin their offsite journey by asking questions that should come much later. “Who can build this for me?” is one of them.

One of the most persistent misconceptions about offsite construction is that moving work into a factory should automatically make a project less expensive. It may, but the mistake often happens when the factory’s price is viewed as the cost of the building.

It doesn’t. It represents the manufacturer’s scope of work, and what that scope includes can vary substantially from one manufacturer or system to another. Everything the factory doesn’t provide still has to happen somewhere—and somebody has to pay for it.

Transportation, setting, foundations, utility connections, site work, finish work and numerous other responsibilities may fall elsewhere. The dividing line between factory scope and field scope becomes enormously important, yet I’ve seen projects move surprisingly far down the road without everyone having the same understanding of where that line actually is.

A factory invoice that looks attractive can become considerably less attractive once you add the rest of the project.

Another common mistake happens even earlier. A developer hires an architect, develops the project, and then decides to investigate whether the building can be manufactured offsite. They send the drawings to manufacturers, expecting someone to figure out how to build it.

Sometimes they can, but often changes are needed to accommodate the manufacturing process. By then, the architect and developer may already be invested in a design they don’t particularly want to change. Much of that friction is avoidable if you introduce manufacturing considerations earlier.

Manufacturing isn’t simply conventional construction performed underneath a roof. Every offsite system has parameters. Production equipment, material flow, engineering, transportation, module dimensions, panel sizes and plant capabilities all influence what can be efficiently manufactured.

Forcing a building designed without those considerations into a manufacturing process can quickly erode the efficiencies that attracted the developer to offsite construction in the first place.

That doesn’t mean the factory should design the building. It means manufacturing needs to become part of the conversation early enough to matter.

Another problem is how the industry talks about offsite construction. We frequently use offsite as though it describes a particular product. It doesn’t.

Volumetric modular, panelized construction, light-gauge steel systems, components and HUD-code construction can all involve manufacturing portions of a building away from the jobsite. Beyond that common characteristic, they can be very different animals.

Those differences affect design, engineering, transportation, erection, code compliance, financing, scheduling and the work that remains to be completed in the field. Understanding those differences matters before a developer commits to a particular approach.

The question therefore shouldn’t begin with, “Should we use offsite?” It should begin with the project itself.

What are we trying to build? Where are we building it? What does the jurisdiction require? What constraints does the design create? What portions of the work can realistically benefit from manufacturing, and what will still have to happen on site?

Only after understanding those issues does it make much sense to decide which offsite approach—if any—belongs in the conversation.

Sometimes the Right Answer Is No

Bill Murray, Advisor[email protected]

People who make their living in an industry naturally tend to advocate for it. I’ve spent most of my working life in offsite construction, and I believe strongly in what manufacturing can bring to building. But that doesn’t mean every building should be manufactured.

A project can be too small, too geographically difficult, poorly suited to available manufacturing capacity or burdened by regulatory requirements that eliminate much of the expected advantage. A particular design may simply be a bad fit for the manufacturing systems available to the developer.

Recognizing that before committing substantial time and money isn’t a failure of offsite construction. It’s good development.

The best offsite projects I’ve encountered weren’t successful simply because somebody found a good factory. They worked because the design, manufacturing process, scope of work, site construction and project requirements were understood as parts of the same delivery system.

Before asking who should manufacture your building, ask the more important question: Does offsite really fit this project?

Your Business May Be Ready to Sell. Are You?

Sometimes the idea of selling a business doesn’t begin with the owner at all. An M&A firm makes an unexpected call. A potential buyer expresses interest. A competitor sells. Suddenly, something that had always been somewhere off in the distance becomes a real possibility.

Often, though, that outside event simply brings to the surface thoughts that were already there. After years of running the same business, the owner is tired. Financial results may have slipped, problems that once would have been attacked aggressively aren’t getting the same attention, and the enthusiasm required to make another round of changes isn’t quite what it used to be.

That’s when the owner begins asking, “Maybe it’s time?” But considering a sale and being ready to sell are two very different things.

Before talking about valuation, potential buyers, multiples, or marketing the company, I think we need to have a more basic conversation. Why is the owner considering a transition in the first place?

There isn’t a wrong answer. Age, burnout, declining financial performance, family circumstances, the absence of a successor, or simply wanting to do something different can all be perfectly legitimate reasons. Sometimes an unsolicited inquiry is enough to cause an owner to seriously consider a possibility that had previously been little more than a passing thought.

What matters is understanding whether the owner genuinely wants to make a transition or is simply attracted to the idea of one. Until that distinction becomes reasonably clear, discussions about valuation and potential buyers may be getting well ahead of the most important decision.

For someone who has spent 20, 30, or 40 years building and running a company, selling isn’t simply a financial transaction. The business may determine where you go every morning, who you talk to every day, the problems you’re responsible for solving, and a significant part of how you define yourself.

Then there is the practical question: What comes next? Family financial responsibilities may remain, continuing income may be important, or the owner may simply have no interest in retiring. Even when the financial terms make sense, the owner still has to picture what life looks like after the transition is complete.

Those aren’t reasons not to sell. They are reasons to understand what you’re really deciding before beginning a process that becomes increasingly difficult to stop once advisors and prospective buyers become involved.

Throughout this series, we’ve looked at many of the things that can make an offsite manufacturing business more—or less—attractive to a prospective buyer. We’ve considered first impressions, owner dependency, management depth, financial information, customers, systems, costs, and the enterprise’s overall health.

A company can be well positioned in many of those areas and still have an owner who isn’t ready to sell. The opposite can also be true. An owner may be completely ready to move on, while the business itself needs considerable work before it can go to market.

Recognizing that difference early matters. If the owner isn’t emotionally prepared to make a transition, months of preparing information, talking with buyers, and negotiating terms may simply lead everyone back to the question that should have been answered at the beginning: Do I really want to sell?

Owners sometimes feel that once they’ve started exploring a sale, they’re somehow committed to following through. They’re not. A conversation about transition can result in the perfectly reasonable conclusion that now isn’t the time.

Discovering that early may be one of the most valuable outcomes of the process. It gives the owner an opportunity to address weaknesses in the business, strengthen management, improve financial performance, and think seriously about what the next chapter should look like. Six months or two years later, both the owner and the business may be better prepared.

Once an owner decides they genuinely want to pursue a transition, another basic question follows: What exactly do I have to sell?

A factory, equipment, backlog, and financial statements are part of the answer, but they don’t define the entire enterprise. Management depth, customer relationships, systems, culture, operational discipline, and the business’s ability to perform without constant owner involvement all influence what a prospective buyer is really considering.

Understanding those strengths and weaknesses before entering the market gives an owner something equally important: choices. Problems can be addressed before a buyer discovers them, expectations can become more realistic, and the owner can decide whether selling now—or improving the business first—is the better course.

Bill Murray, Advisor, [email protected]

Preparing a business for ownership transition takes work. Preparing the owner may be just as important.

Before asking what your company is worth, who might buy it, or how quickly a transaction could be completed, start with the questions that don’t require a spreadsheet: Why am I considering selling? Do I really want to do it? And what do I want life to look like afterward?

Then comes one final question: If the right buyer showed up tomorrow, are you actually prepared to say yes?

Thinking About the Future of Your Offsite Business?

You don’t have to decide today that you want to sell in order to begin thinking seriously about transition. Understanding where both you and your business stand before making that decision can create considerably more options later.

At Offsite Innovators, we work confidentially with owners who are considering what’s next—whether that means preparing for a sale, positioning the business for a future transition, or simply determining whether the time is right to begin the conversation. If you’re asking yourself some of these same questions, we’d welcome a confidential conversation.

Can You Prove the Health of Your Business?

Owners generally have a pretty good idea of whether they believe their business is healthy. They know the sales numbers, they know what’s in the pipeline, and they certainly know whether they’re making money. After years of running the company, they develop an instinctive sense of how things are going.

A prospective buyer has a different problem. Instinct isn’t enough. A vital key is the presence of adequate management information systems (MIS).  If an owner says the company has a strong backlog, good margins, loyal customers, and significant growth potential, an experienced buyer eventually has to ask a simple question: Can you prove it?

That’s where evaluating an offsite manufacturing business begins to get interesting. The numbers certainly matter, but so does understanding what’s behind them.  Observable MIS is essential.

A substantial backlog sounds impressive, and it may be. But one of my first questions is how that backlog was determined. Are these firm orders? Have deposits been received, and can they be verified in the company’s financial records? Are the projects realistically scheduled, or are some of them still dependent on financing, approvals, or decisions outside the manufacturer’s control?

Then I want to understand whether the operation can actually deliver what has been promised. Conversations with procurement, sales, and production often tell you things a backlog report cannot. What are current purchasing lead times? Are material shortages affecting production? Is inventory available for the work being scheduled? What does the yard inventory look like?

None of this means the backlog is suspect. It simply means that a buyer needs to understand the quality of the backlog, not just its dollar value.

Financial statements provide another part of the picture, but they can also raise questions. High labor costs, excessive overtime, aging payables, missed purchasing discounts, and irregular physical inventories can all be indicators that deserve a closer look.

Cost information is particularly important in manufacturing. Material and labor costs move, sometimes quickly, yet I’ve seen companies that don’t update their cost decks on any consistent schedule. When that happens, management may be quoting today’s projects using yesterday’s costs and not discover the problem until the financial results arrive months later.

A profitable company doesn’t have to be perfectly efficient. Very few are. But management should understand where the money is being made, where it’s being lost, and why.

Over the years, one of the more revealing answers I’ve received to a management question has been some variation of, “We don’t really have that information.” Almost as concerning is, “I can get it for you,” followed by information that is weeks or months out of date.

A healthy business should generate meaningful information that management actually uses. That doesn’t require elaborate software or reports stacked three inches thick. It does require current information that allows management to understand what’s happening in production, purchasing, sales, labor, inventory, and profitability while there is still time to do something about it.

Systems and procedures matter for the same reason. I don’t simply want to hear that a company has them. I want to see evidence that they’re being used in the normal course of running the business.

A buyer also needs to understand where the company’s sales are coming from. A business with a broad distribution network and a healthy mix of builders and developers presents a different risk profile from one where a substantial percentage of annual sales depends on one or two customers.

That doesn’t automatically make customer concentration bad. A large, long-standing customer can be enormously valuable. But the buyer needs to understand the relationship, the volume discounts being provided, how secure that business really is, and what would happen if one major customer went elsewhere.

Again, the question isn’t simply how much the company sells. It’s the quality and sustainability of those sales.

Ultimately, I’m trying to understand the actual health of the business, and that means looking at more than a snapshot of the current year. How does today’s operation compare with the past three years? Are margins improving? Is productivity improving? Is the customer base becoming stronger or more concentrated? Is the company becoming more disciplined as it grows, or simply becoming busier?

This is also where culture enters the picture. A management team aligned around maximizing the company’s people, equipment, materials, systems, and profitability will generally behave differently from one that spends most of its time reacting to the crisis of the day. Financial statements tell you what happened. The way the organization operates often helps explain why.

Growth potential deserves the same scrutiny. Nearly every business can tell an attractive growth story. The important question is whether that story is supported by available capacity, market demand, capable management, realistic capital requirements, and facts.

Owners considering a transition sometimes assume that a buyer will evaluate the company primarily through its financial statements, equipment, real estate, and perhaps a multiple of earnings. Those things are certainly important, but a serious evaluation goes much deeper.

A healthy business should be able to support the story its owner tells about it. Backlog should be verifiable. Costs should be understood. Management information should be current. Customer relationships should be identifiable and measurable. Growth expectations should be grounded in reality.

The real question isn’t whether you believe you have a healthy business.

It’s whether a prospective buyer can reach the same conclusion.

Thinking About the Future of Your Offsite Business?

Whether you’re planning an ownership transition in the near future or simply want to build a stronger, more valuable company, understanding the actual health of your business is an important place to start.

At Offsite Innovators, we help owners evaluate, prepare, and position their businesses for ownership transition. If you’d like a confidential conversation about where your business stands today and what a prospective buyer is likely to see, we’d welcome the opportunity to talk.

CLICK HERE for a FREE video Consultation.

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Is Your Business Too Dependent on You?

Part 3 of the Offsite Innovators Business Transition Series

In the first two articles of this series, we looked at what creates value in an offsite manufacturing business and how buyers begin forming opinions long before they review financial statements or step onto the production floor.

Now it’s time to ask a more difficult question.

Some owners answer that question quickly. “No, my team handles most of the day-to-day operations.” The better question, however, is this:

Is the business running you, or are you running the business?

There is an important difference.

I’ve walked through manufacturing facilities where it becomes obvious within the first hour that every meaningful decision eventually finds its way back to the owner’s office. The phone rings constantly. Employees stop by with seemingly simple questions, with obvious answers. Department managers ask for approval on routine matters. Even while touring the production floor, line employees interrupt to ask where my prints, or where are these materials located?   None of those interruptions seems significant by itself, but collectively they tell a very different story about how decisions are really being made throughout the organization.

Many owners wear those interruptions as a badge of honor. They believe being involved in every decision demonstrates commitment and leadership. It often demonstrates something else entirely.

If every purchasing decision requires the owner’s approval, does the purchasing manager really manage purchasing? If production supervisors can’t solve routine issues without finding the owner, are they truly leading production? If every customer concern, transportation issue, scheduling question, or personnel decision eventually reaches the owner’s desk, then the organization hasn’t delegated responsibility—it has simply distributed tasks.

Responsibility without authority isn’t leadership. It’s dependency, and dependency creates a business that revolves around one individual instead of a management team.

Well-managed businesses have interruptions too. Manufacturing is dynamic, and unexpected issues arise every day. The difference is that most of those issues are resolved by the people responsible for that department. Good owners don’t disappear from the business; they build an organization that knows how to function without requiring their constant involvement.

One of the first things I often ask to see is the organizational chart. Then I ask to meet the department heads. It’s a simple request, but it tells me a great deal about how the company is managed. On one recent visit, there were only two department heads to meet. That immediately raised questions about how decisions were being made throughout the rest of the organization.

Strong systems, meaningful management information, and capable department leaders don’t cause an owner to lose control of the business—they provide better control while requiring less direct involvement. Owners maintain a clear pulse on every department without becoming the heartbeat of the organization.

Sophisticated buyers understand that the future value of a company depends on more than its financial performance. They’re evaluating whether the business can continue operating successfully after ownership changes. Importantly, will the current owner remain in place to allow a proper and comfortable transition.

Less experienced buyers often focus almost entirely on buildings, equipment, and financial statements. Those things certainly matter, but they don’t reveal whether the organization has the leadership depth to continue performing when the owner is no longer making every decision.

One question often reveals more than a stack of financial reports:

“If the owner disappeared for ninety days, what would happen?”

The answer tells buyers far more than most owners realize.

Every owner eventually reaches a point where working harder no longer solves the problem. Growth requires something far more difficult: trusting capable people, investing in experienced managers, and giving them both responsibility and the authority to make decisions.

That investment certainly increases overhead, but it also increases the long-term value of the business. Owners who understand that distinction aren’t simply building a company that performs well today—they’re building one that others will have confidence owning tomorrow.

Every phone call that only the owner can answer, every routine decision that waits outside the owner’s office, and every department that cannot function without approval quietly tells a buyer that the business depends on one person.

Owners often believe they’re making themselves indispensable. In reality, they may be making their business less valuable. The most valuable companies aren’t built around one individual. They’re built around capable people, sound systems, and leaders who have both the responsibility and the authority to make decisions.


Whether you’re planning an ownership transition in the near future or simply want to build a stronger, more valuable company, the decisions you make today will shape your options tomorrow.

At Offsite Innovators, we help owners evaluate, prepare, and position their businesses for ownership transition. We’d welcome the opportunity for a confidential conversation about your business and the steps that can strengthen its long-term value.

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Your Business Starts Talking Before You Do


In the first article in this series, I suggested that the value of an offsite manufacturing business is
determined by far more than its building, equipment, or production capacity. That observation
generated some thoughtful conversations because many owners naturally focus on the tangible
assets they can see and measure.

After more than forty years leading, evaluating, and advising offsite manufacturing companies,
I’ve learned that experienced buyers begin evaluating a business long before they review
financial statements or walk onto the production floor. Their impressions often begin forming
within the first few minutes of arriving on the property.

That’s because your business starts talking before you do.

Some businesses project organization, confidence, and discipline from the moment you arrive.
Others communicate something entirely different. Most owners don’t even realize it’s happening
because they see the same surroundings every day, while a prospective buyer sees everything
with a fresh set of eyes. Those first impressions won’t determine whether a business ultimately
sells, but they often influence how buyers perceive the company before the real due diligence
even begins.

When people prepare to sell a home, they understand the importance of first impressions. They
mow the lawn, touch up the paint, and straighten the furniture because they know buyers begin
forming opinions the moment they pull into the driveway. Businesses are no different.

As I arrive at a manufacturing facility, I’m already making observations. Is the property
maintained? Does the office project professionalism? Is someone there to greet visitors, or does
everyone seem surprised that someone has walked through the front door? I notice whether the
receptionist (if there is one) is engaged and welcoming, whether the office is organized, and
whether the owner’s office reflects order or constant firefighting. I also notice whether the owner
is prepared for our meeting or is repeatedly interrupted by phone calls and employees needing
decisions that only he or she can make.

None of those observations determines the value of the business by itself. Collectively, however,
they begin telling a story long before anyone discusses production, profitability, or financial
performance.

Eventually we walk into the factory.

I don’t expect a modular manufacturing plant to look like an operating room. Lumber creates
sawdust, production creates noise, and manufacturing is active by its very nature. But there is a
tremendous difference between a busy operation and a disorganized one.

Within a few minutes, I begin watching the production flow. Are crews working steadily, or are
they waiting for material? Does work move smoothly from station to station, or are bottlenecks
obvious? Is the production line balanced, or do certain departments seem overwhelmed while
others wait? I pay attention to whether supervisors are leading production or simply spending the
day putting out fires. I also notice whether materials are staged where they’re needed, whether
damaged materials are accumulating, and whether rework appears to be routine rather than the
exception.

None of these observations is intended as criticism. Together, however, they provide a
remarkably accurate picture of how the operation is managed, and they tell me far more about
the business than any inventory of equipment ever could.

One of the most interesting parts of any plant tour is listening to what owners naturally want to
show me. They proudly point out a unique project on the production line, a recently purchased
machine, or a new process they’ve developed. Those accomplishments deserve recognition
because they often represent years of hard work, investment, and pride in what they’ve built.

Experienced buyers, however, tend to ask very different questions. They want to know how
many people are on the production line, which departments are difficult to staff, whether
overtime has become routine, and how dependent the business is on the owner. Their questions are less about today’s project and more about whether the business can consistently perform long after the current owner has moved on.

That’s the difference between admiring what has been built and evaluating what can be sustained.

Successful businesses leave clues everywhere, although owners often stop noticing them because they see the same operation every day. Visitors don’t have that luxury. They notice how employees interact, whether supervisors appear to be leading or simply reacting, how
information moves through the organization, and whether materials are organized or constantly
being moved from one place to another.
No single observation determines the value of a company. Collectively, however, they paint a
remarkably accurate picture of how the business is managed and how likely it is to continue
performing after a change in ownership. That is precisely what serious buyers are trying to
determine before they ever begin negotiating terms.

Financial statements matter. Equipment matters. Real estate matters. Every experienced buyer
expects those assets to be evaluated carefully. But long before spreadsheets are opened or
appraisals are discussed, another evaluation has already begun.


Buyers are quietly asking themselves whether this feels like a business they would be
comfortable owning. They’re observing how people work together, how decisions are made, and
whether the organization appears disciplined, organized, and capable of succeeding without
constant intervention from the owner. Those impressions don’t replace due diligence, but they
shape it. They influence the questions buyers ask, the risks they perceive, and ultimately the
confidence they have in the business they’re considering.


By the time everyone gathers around the conference table, your business has already been
speaking for quite some time. The only question is whether buyers like what they’ve heard.

Thinking About the Future of Your Offsite Business?


Whether you’re considering selling in the near future or simply want to build a more valuable
company, the decisions you make today will determine the opportunities you have tomorrow.


Request a FREE consultation

At Offsite Innovators, we help owners evaluate, prepare, and position their businesses for
business and ownership transition. If you’d like a confidential conversation about where your
business stands today—and what steps might strengthen its future—we’d welcome the
opportunity to talk with you.

Next in the Offsite Innovators Business Transition Series
What Buyers Really Buy

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Questions We Hear From Owners

What’s My Offsite Business Worth?

An article by Bill Murray

Over the past few years, Gary Fleisher and I have had the opportunity to help owners think through one of the biggest decisions they’ll ever make—what comes next for their offsite business.

Some are actively considering a sale. Others simply want to understand what their business might be worth someday. A few aren’t interested in selling today but recognize that preparing early often leads to better options later. What’s been interesting is that, regardless of where they are in the process, they tend to ask many of the same questions.

Rather than answering those questions one owner at a time, I thought I’d begin addressing some of them here, drawing on more than forty years of leading offsite manufacturing operations and the advisory work Gary and I have been doing over the past several years.

It’s an understandable question. If you’ve spent years—perhaps decades—building an offsite business, naturally you want to know what it’s worth.

My answer, however, usually isn’t what owners expect.

Before we talk about value, we need to talk about what creates value.

Those aren’t necessarily the same thing.

During my career, I’ve learned that two companies can build roughly the same number of homes, generate similar revenues, and even report comparable profits, yet one may be significantly more attractive to a buyer than the other.

The reason is simple.

Buyers don’t evaluate a business the same way owners do.

Owners naturally focus on what they’ve built. Buyers focus on the risk they’re assuming.

When I walk through a business, I’m not immediately thinking about equipment values or the financial statements. I’m watching the operation. Does production move with purpose? Do supervisors appear confident in their responsibilities? Does the organization rely on well-defined processes and systems, or does every important decision still depend on the owner? Does the business reflect discipline and accountability, or does it seem like people are simply reacting to the latest problem?

None of those observations determine value by themselves. Together, however, they begin telling an important story. Every serious buyer is trying to answer one fundamental question:

Can this business continue to succeed after the current owner steps away?

I’ve often said that buyers aren’t simply purchasing equipment, inventory, or even a building.

They’re buying confidence.

Confidence that the business is well managed. Confidence that capable people are making good decisions throughout the organization. Confidence that effective processes and systems are supporting consistent performance. Confidence that the business isn’t dependent upon one individual.

Even something as difficult to measure as organizational culture contributes to that confidence. I’ll spend more time on that subject in a future article because I believe it’s one of the most overlooked drivers of long-term business value.

One point often surprises owners. Value isn’t created during negotiations. It’s created long before a buyer ever walks through the front door. The businesses that attract the strongest interest have usually spent years building capable leadership, establishing effective processes and systems, and creating an organization that buyers believe can continue to succeed after the ownership changes.

Those things reduce uncertainty.

And when uncertainty goes down, value generally goes up.

Whether you’re thinking about transitioning your business next year or simply beginning to consider your long-term options, it’s worth stepping back and asking yourself one important question:

If I were the buyer, would I be confident buying my own business?

CLICK HERE for a free confidential video consultation

Next in this series: Why businesses that depend too heavily on the owner often become the hardest businesses to sell—and one of the biggest obstacles to maximizing value.

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Sustainability, through the use of readily available Ponderosa Pine, redefined by Timber Age Systems

Several weeks ago I had an opportunity to learn about a panelized start-up in Durango, CO. I was immediately struck by their innovative approach to maximizing sustainability through the use of readily available underharvested Ponderosa Pine. Timber Age and their use of cross-laminated timber (CLT) which is composed of sustainable Ponderosa Pine, epitomize true sustainability.

I talked with Kyle Hanson, co-founder of Timber Age Systems about his team’s approach and work at this innovative panel manufacturer in the heart of sustainable timber country. Thank you Kyle for leading the charge on providing innovation through sustainability in Offsite manufacturing.

Kyle and Charlie. Kyle is the one on the left!

Bill Murray, Offsite Innovators: Would you summarize your current business model?

Kyle Hanson, Cofounder of Timber Age : First and foremost, Timber Age™ makes durable, attainable, high-performance homes in an off-site modular factory. The homes are produced from locally and sustainably harvested Ponderosa Pine.

Our business model leverages a local value chain and community partnerships supplying design, engineering and installation support. This focus on circular economics allows Timber Age™ the chance to address forest health, housing constraints and job creation while significantly improving the built environment in terms of embodied and operational carbon content.

Secondly, Timber Age™ is continually refining a replicable production model in preparation for widespread expansion over the coming decade. This production model prioritizes shared ownership, a short amortization of investment capital and a flexible and adaptive learning environment supplied through the Timber Age Operating System (TAOS).

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Bill: What inspired you to found Timber Age Systems?

Kyle: After spending four years as the Business Unit Leader for a local wood products manufacturer working closely with the US Forest Service, I developed a curiosity to better understand how to create a use for the overabundance of Ponderosa Pine in our region.

In addition to unhealthy forests, many teachers of my two daughters struggled to establish stable local housing. An inability to establish an “anchored” existence in our community frequently ended in job openings. This damaging pattern of churn repeats across public servant roles resulting in instability for schools and local government.

Last, but not least, many in our community maintain seasonal and overlapping jobs in an attempt to achieve sustainable adjusted median income (AMI) levels. My background studying and implementing Lean Operating Systems to achieve world-class manufacturing operations illustrates how the creation of predictable, safe and rewarding skilled labor jobs could help create more anchored community members.

A 2018 USFS Wood Innovation Grant award catalyzed an amazing group of individuals collaborating around the key market definition and challenges. This group problem solving process eventually allowed our co-founder Andy Hawk to enter the fray as team member number two.

Most of the idea development has followed the ideas inherent in the world of Lean (Operational Excellence, TPS, etc). These themes surrounding rapid experimentation and improvement have been codified in the excellent book “The Lean Startup” by Eric Ries. Our team is continually working to clearly identify a problem and its causes and then establish an experiment where we can test a hypothesis to address the problem. When we do this in a disciplined and continuous manner, Timber Age™ gets better and we all get smarter and more connected as a team.

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Bill: How would you describe some of the most innovative solutions Timber Age Systems has developed for offsite construction?

Kyle: Our approach to vertical integration and small scale manufacturing of Cross-Laminated Timber (CLT) seems to be a differentiating factor in the worlds of mass timber and off-site manufacturing. We don’t have a huge factory with giant cranes, and yet we create beautiful enclosures which are easily installed.

In the long-term, we believe our integrated approach to helping create housing, fulfilling jobs and healthy forests will provide a powerful model for sustainable community development around the world.

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Bill: In what way does Timber Age prioritize sustainability in its innovative approaches to construction?

Kyle: Timber Age™ is intensely focused on both the embodied carbon and operational carbon of buildings. A key mission metric for our team is miles traveled/ pound. In this way, we can look at the many components in one of our assemblies and create a weighted average of the total waste associated with transportation. In addition, our assemblies are almost completely foam-free.

Our CLT is constructed from trees which would have otherwise released carbon dioxide into the air due to overcrowding, fire and disease.

This approach to using a carbon-sequestering structural material (CLT) combined with recycled cellulose insulation (also carbon-sequestering) means an enclosure with net-zero embodied carbon and a home with super low operational carbon emissions due to the passive house building science behind our system design.

The Timber Age™ Modular Building System (TAMBS) incorporates low-carbon materials and is designed to meet the Passive House building standard.

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Bill: What are some of the biggest challenges you have faced in gaining an acceptance of your innovative approach both locally and regionally?

Kyle: Since the Timber Age Modular Building System (TAMBS) contains many unique innovations, our biggest challenge was proving out the ability to manufacture the system at a hyper-local scale. After proving out the system, our biggest challenge has been builder uptake of our approach. Introducing an innovative building system into a marketplace where demand for the status quo is still outstripping the capacity of local builders doesn’t incentivize builders to seek out or make time for learning a new system even if many of the builders understand and appreciate the inherent value proposition.

Matt Betts, Value Stream Manager

The world of building, much like the world of healthcare, encompasses multiple customers with varying definitions of value. We are working hard to collaborate with as many stakeholders as possible to ensure the highest level of value is created for each step off the value chain. We believe our system is easy for designers to implement, very quick and effective to install for the builders and beautiful, durable and very energy efficient to help enforce the inherent value for the end users.

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Bill: How important are collaborations and partnerships as you seek to grow your business?

Kyle: Timber Age™ would not exist without the help of our local forest collaboratives, fellow building scientists, collaborating designers and contractors and especially the funding and support of the US Forest Service and our incredible mission-driven shareholders.

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Bill: What are you short- and long-term goals for Timber Age Systems and what philosophy did you use in developing these?

Kyle: Short-term: Get our new interim factory running to produce our current backlog of projects and hire another ten great team members.

Long-term: Construct our new prototype factory and housing models in Mancos and then replicate this model across all viable markets to help create 1000+ fulfilling jobs and hundreds of thousands of durable, beautiful high-performance housing units around the world.

Our philosophy around planning, Hoshin Kanri, follows the teaching and examples of Toyota and other world-class companies.

Tens of thousands of acres of sustainable pine being put to use by this innovative panelizer in Durango, CO. Sustainability is more than a buzzword at Timber Age Systems, its a way of doing business and a way of life.

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Bill: I want to thank you , Kyle, for a very insightful, behind the scenes look at what you and Timber Age Systems are currently doing and what you have planned for the future.

Bill Murray, co-founder of Offsite Innovators, is a 40-year veteran in the Offsite industry. His goal is to assist in the growth of the industry by presenting and sharing innovation.

CLICK HERE if you would like to be interviewed about something innovative you have designed or are currently using.

The Tools Have Changed. The Fundamentals Have Not

Recently, I read yet another article discussing AI, specifically Agentic AI. By the time I
finished reading it, I found myself feeling something I hadn’t experienced in quite a while:
Overwhelmed.

After more than 40 years of managing modular manufacturing operations, I started wondering
if I was getting left behind. Was my experience still relevant in a world of ERP systems, MES
platforms, AI forecasting, digital dashboards, and technologies that seem to evolve faster
than I can understand them?

I spent several days trying to learn more about Agentic AI. The harder I tried, the more
confused I became. Eventually, I stopped trying to understand every technical detail and
started asking a different question.

What if I was focusing on the wrong thing? Did I really need to understand all the nuances
or simply just be aware of technology as a tool?

That question led me back several decades to a time when another innovation was making
waves throughout manufacturing. It was called Total Quality Management, and at the time, it
felt every bit as revolutionary as AI feels today.

Many developers and entrepreneurs looking at offsite construction today are being
bombarded with technology. AI. Automation. Digital twins. Predictive analytics. Smart
factories, robotics, and the like, the latest and greatest.

The promise is always compelling. Better decisions. Better productivity. Better results.
The danger is assuming the tool is the solution.

I have watched several waves of innovation move through manufacturing over the years.
Some delivered enormous value. Others delivered far less than promised. The common
denominator was never the technology itself. The common denominator was how
effectively management used the technology as a tool with the end result being a better
managed team.

When I joined a larger multi-plant organization years ago, I was introduced to TQM. At first,

I didn’t understand much of it. The terminology was new. The processes were unfamiliar.
Frankly, it felt overwhelming.

Unlike AI, however, I didn’t have the option of ignoring it. TQM was expected it was literally
mandated. It became part of how we operated.

Over time, I discovered something important. TQM wasn’t magic. It wasn’t a silver bullet. It was a framework that forced us to focus on the basics.

Communication between departments improved. Data became more meaningful.

Accountability became clearer. Problems were measured rather than debated. Decisions
became less emotional and more fact-based. The tool mattered, but the discipline mattered
more. The culture it helped me create was one that developed a management team that
was truly engaged, not to mention a team of over 300 production employees that
became involved, not simply bystanders collecting a paycheck.

The longer I worked with TQM, the more I realized that most improvements came from
executing fundamentals better. The fundamentals like inventory accuracy, vendor
relationships, supervisor accountability/ training, communications, plant cleanliness, and
customer satisfaction remained at the forefront of a profitable enterprise.

None of those issues were new. TQM as a tool simply gave us a better way to address them.
The results were undeniable. Productivity improved. Warranty performance improved.
Employee turnover improved. Profitability improved. Our operation was eventually
recognized as one of the most improved in a large corporate organization.

The lesson wasn’t that TQM solved our problems. The lesson was that it helped us solve our
problems.

Today, I suspect AI will create opportunities we can barely imagine.

It will likely help engineering teams work faster. It may improve scheduling, forecasting,
purchasing decisions, and project management. Companies that learn to use these tools
effectively will almost certainly gain advantages.

AI cannot create accountability or build trust between departments. Importantly, it alone
cannot create a culture. It cannot develop leaders or make people care about quality—
These responsibilities remain with management.

For developers evaluating offsite opportunities, that distinction matters. A factory can have
every modern technology available and still struggle if leadership, culture, and operational
discipline are missing. This significant aspect of the feasibility aspect of determining if
offsite construction is for you is very often overlooked. Equally important, “Is this
manufacturer what I need to meet my needs”?

One of the advantages of experience is that you begin to recognize patterns.
Every generation believes it has found the breakthrough that will finally solve the industry’s
problems. Sometimes those breakthroughs are genuinely transformative, but the
organizations that benefit most are the ones that already have strong fundamentals in place.
Technology tends to amplify good management. It rarely replaces it.

Neither you nor I may ever fully understand every aspect of Agentic AI. That’s okay.

What I have come to understand is that my discomfort with the topic led me to a valuable
reminder. The tools have changed dramatically. The fundamentals have not.

For those evaluating factories, investing in offsite construction, or considering vertical
integration, that may be the most important lesson of all.

Before you ask what technology a factory is using, ask yourself a simpler question:
Are the fundamentals in place?

Because no innovation, no matter how impressive, can compensate for the absence of sound
management, accountability, communication, and execution.

What do you think? Are we sometimes too focused on the newest tools and not focused
enough on the fundamentals that determine whether those tools actually create value?

Bill Murray is a modular manufacturing veteran with more than 40 years of leadership
experience in offsite construction. Through Offsite Innovators, he advises developers,

entrepreneurs, and investors evaluating manufacturing opportunities, factory acquisitions,
and offsite business strategies.

If you’re evaluating an offsite manufacturing opportunity and would like an experienced
operator’s perspective, contact Offsite Innovators

YOU DON’T HAVE A TECHNOLOGY PROBLEM — YOU HAVE A CULTURE PROBLEM

One of the more interesting things about the offsite construction industry is how often
companies convince themselves that the next piece of technology is finally going to solve the
problems they’ve been struggling with for years.

A new production system gets installed. A factory invests in automation. Management
software is introduced to improve scheduling, purchasing, communication, and
accountability. Sometimes an entire shift in building philosophy takes place — panelization,
volumetric modular, light-gauge steel framing, or some new manufacturing process that
promises greater efficiency and predictability.

At first, the enthusiasm is understandable. Ownership sees cleaner reporting. Managers
envision better coordination. Production personnel are told the new system will reduce
confusion and eliminate bottlenecks. Everyone talks about efficiency, scalability, and getting
ahead of the industry.

After enough years around factories and manufacturing operations, you start noticing
something else. In many companies, six months later the same frustrations quietly begin
resurfacing. Production delays continue showing up. Departments still struggle
to communicate with one another. Purchasing problems continue affecting production.


Scheduling becomes reactive again. Supervisors work around systems instead of through
them. Eventually, the conversation shifts from excitement to frustration, and the technology
itself often becomes the thing blamed for the disappointing results.

What makes this interesting is that the technology frequently wasn’t the problem to begin
with. The real issue was whether the organization itself was prepared to operate within the
level of discipline, communication, consistency, and accountability the system required. In
other words, the success or failure of innovation often has less to do with software or
automation and far more to do with the culture surrounding it.

THE TECHNOLOGY DIDN’T FAIL
One software developer we know built an impressive management platform specifically
designed for modular manufacturers. It addressed real operational challenges that factories
constantly fight — material tracking, scheduling, interdepartmental communication,
visibility into production flow, accountability, and coordination between engineering,
purchasing, production, and service.

In one operation, the software dramatically improved performance. Material shortages
dropped. Labor efficiency improved. Departments communicated better because
information became more visible and harder to ignore. Managers gained a much clearer
understanding of what was happening throughout the operation on a real-time basis.

In another facility using essentially the same platform, adoption struggled almost
immediately. Information wasn’t entered consistently. Departments resisted the
transparency the system created. Managers bypassed procedures because they felt the
process slowed them down. Employees continued operating independently rather than
collaboratively, and before long, frustration started building around the software itself.
The difference wasn’t the technology. The difference was the environment the technology
entered. One organization was prepared to embrace structure, accountability, and
operational discipline. The other really wasn’t, even if leadership believed otherwise.

CULTURE SHOWS UP UNDER PRESSURE
Most people hear the word “culture” and immediately think of mission statements, morale,
employee events, or slogans hanging on a wall. In manufacturing, culture is much more
practical than that. It reveals itself in how people behave under pressure. It shows up in
whether departments communicate or protect themselves. It becomes visible in whether
leadership consistently enforces standards or quietly allows exceptions whenever
schedules tighten.

People within organizations quickly learn what leadership truly values. Not from
speeches or posters, but from what management tolerates every day when production
pressure starts building.

OFFSITE EXPOSES WEAKNESS QUICKLY
That becomes especially important in offsite construction because factory environments are
far less forgiving than traditional jobsites. Conventional construction often allows room for
improvisation. Experienced field personnel can adjust on the fly, work around mistakes, and
solve problems in real time without bringing the entire project to a halt.

Manufacturing systems don’t operate that way. Factories depend on sequencing,
consistency, timing, communication, and coordination between multiple interconnected
departments. Engineering affects purchasing. Purchasing affects production. Production
affects shipping. Shipping affects field-set crews and downstream builders. When one part
of the operation breaks rhythm, everyone behind it feels the consequences.

Strong cultures usually recognize this early. Weak cultures tend to fight it.

THE REAL PROBLEM IS OFTEN OPERATIONAL ALIGNMENT
That’s why many builders and developers entering offsite construction struggle more with
operational alignment than with the technology itself. They often approach factories with a
traditional construction mindset, relying heavily on experience, instinct, and reactive
problem-solving in environments that actually require process discipline and consistency to
function properly over time.

The factory eventually exposes those weaknesses. What leadership initially viewed as
“technology problems” often turn out to be communication problems, accountability
problems, leadership problems, or cultural resistance to structure itself. The technology
simply made those weaknesses more difficult to hide.

THE BEST FACTORIES ARE USUALLY THE MOST DISCIPLINED
Visit enough factories, and you begin seeing the difference almost immediately. Some
operations feel stable, organized, and consistent even when they’re extremely busy. Others
feel chaotic despite having similar equipment and similar production capabilities. In many
cases, the real separator is leadership consistency and the culture that developed around it
over time.

The strongest factories are usually not the ones with the flashiest technology. They’re the
ones where leadership established operational discipline early, departments communicate
consistently, accountability exists without constant drama, and employees understand that
systems are there to support the operation rather than work around it.

That type of culture doesn’t happen accidentally. It gets built deliberately, often long before
the technology arrives.

The offsite industry will continue evolving. New systems will continue entering the market,
and many of them will improve the way homes are designed and built. But at some point
every organization considering innovation has to answer a more difficult question than
which software to buy or which production system to implement.

Is the organization actually prepared to support the discipline, accountability, and
What operational alignment does innovation require?

Because in the end, most companies don’t really have a technology problem.

They have a culture problem.

Offsite Innovators continues to work with developers, manufacturers, and entrepreneurs
evaluating offsite opportunities, operational structures, factory performance, and the real-
world challenges that determine whether innovation succeeds or quietly becomes another
expensive disappointment.

Bill Murray

Contact Bill

Bill Murray has over 40 years of operational management experience in the Modular industry.  Bill began his Offsite career as a contractor/builder.  He then entered the manufacturing side, quickly advancing through the sales ranks to become a General Manager/COO of multi-plant operations.  Bill provides professional advisory services to owners, prospective owners, and builder developers considering Offsite construction.  He has consulted throughout the U.S. and Mexico, as well as on overseas assignments.

If you’re evaluating offsite construction—whether LGS, wood, or hybrid—and want a clear, experience-based perspective before committing, reach out. A brief conversation up front can prevent costly assumptions later.

The Most Dangerous Words in a Modular Factory: “Ask the Boss”

Over the past several months, I’ve spoken with several modular factory owners, managers, and developers considering vertical integration into manufacturing.

In almost every conversation, I hear some version of the same statement:

“I’m buried.”

“There just aren’t enough hours in the day.”

“Things are completely crazy right now.”

Anyone who has spent time in manufacturing understands that pressure comes with the territory. Modular factories are complicated operations. Production schedules shift. Vendors miss deliveries. Service issues arise. Engineering changes happen. Customers want answers immediately.

Busy is normal.

But after more than 40 years around manufacturing operations, I’ve learned there’s an important difference between productive pressure and organizational dysfunction.

Oftentimes, the problem is not the workload.

Sometimes the problem is the organizational chart.

Most people look at an organizational chart as little more than boxes, titles, and reporting lines.

Experienced operators tend to see something very different.

A good organizational chart reveals:
• delegation,
• accountability,
• communication flow,
• leadership depth,
• and operational maturity.

More importantly, it reveals whether the organization is built to function through managers — or whether everything still depends on ownership.

That distinction matters.

Especially in modular manufacturing, where operational complexity compounds quickly.

Factories rarely struggle because of one major issue. More often, they struggle because too many decisions, too many problems, and too much responsibility are handled by too few people.

Eventually, the organization becomes dependent on the owner or GM for nearly everything.

That is where exhaustion begins.  “Too busy” is a reality.

One of the most common situations I encounter is an owner or GM simultaneously acting as:
• sales manager,
• production manager,
• problem solver,
• customer relations department,
• and operational traffic controller.

In startup operations, some overlap is unavoidable. Financial realities often require people to wear multiple hats early on.

But many companies never evolve beyond startup structure.

That is where trouble begins.

At a minimum, even smaller operations need clear accountability around:
• production,
• purchasing,
• sales,
• and financial management.

As companies grow, engineering management, service management, and quality assurance quickly become essential leadership roles.

Without those layers, nearly every operational issue eventually flows upward to ownership.

And over time, employees unintentionally become conditioned to stop solving problems independently.

The response becomes:

“Ask the boss.”  (And the boss really is “too busy”.)

I’ve walked through factories where ownership could barely move through the facility without being interrupted every few minutes.

Questions about production scheduling.

Questions about purchasing approvals.

Questions about service issues.

Questions that should have already been solved lower in the organization.

At first glance, some people interpret that constant interruption as leadership or dedication.

I often see it differently.

I see an organization lacking sufficient delegation and management depth.

Healthy manufacturing organizations are not built around one exhausted person making every important decision. They are built around trusted managers who understand and have agreed to their responsibilities and have the authority to act on them.

That is what a healthy organizational chart actually reflects.

Not titles.

Trust.

This is another issue that quietly creates problems inside many modular operations.

Sales and production naturally operate with different priorities.

Sales focuses on:
• customers,
• commitments,
• customization,
• and backlog growth.

Production focuses on:
• scheduling discipline,
• labor efficiency,
• consistency,
• throughput,
• and execution.

That tension is healthy when responsibilities are clearly separated.

But when one individual controls both sales and production, accountability lines quickly blur.

Production delays become harder to evaluate objectively. Scheduling problems become easier to rationalize. Operational discipline begins to erode quietly within the organization.

And eventually, the factory starts reacting instead of operating.

That disconnect may not show up immediately on financial statements.

But it almost always shows up eventually on the production floor.

I’ve always believed the real test of a company’s organizational health is simple:

What happens when the boss leaves the building or takes time off?

Can the company continue operating effectively when ownership is traveling?

Can managers solve problems without constant approval or looking over their shoulder?

Can production continue moving without daily intervention from the owner or GM?

Or does decision-making slow down until the boss returns?

Developers considering modular manufacturing often focus heavily on equipment, production capacity, automation, and backlog.

Experienced operators often study the organizational structure first.

Because machinery alone rarely determines whether a factory succeeds.

People, delegation, accountability, and leadership depth do.

And when those things are missing, owners eventually find themselves saying the same thing over and over again:

“There just aren’t enough hours in the day.”

But sometimes the problem is not time.

Sometimes the problem is structure.

So here’s the real question:

If you stepped away from your operation for a week, would the company continue to function effectively — or would everything begin to bottleneck around your absence?

At Offsite Innovators, we continue exploring the operational realities, risks, and opportunities shaping the offsite construction industry. We welcome conversations with factory owners, developers, and industry leaders navigating growth, operational challenges, and the evolving realities of offsite manufacturing.

Bill Murray

Contact Bill

Bill Murray has over 40 years of operational management experience in the Modular industry.  Bill began his Offsite career as a contractor/builder.  He then entered the manufacturing side, quickly advancing through the sales ranks to become a General Manager/COO of multi-plant operations.  Bill provides professional advisory service to owners, prospective owners and builder developers considering Offsite construction.  He has consulted throughout the U.S., and Mexico, as well as overseas assignments.

If you’re evaluating offsite construction—whether LGS, wood, or hybrid—and want a clear, experience-based perspective before making a commitment, reach out. A short conversation upfront can prevent costly assumptions later.