Cause and Effect: The Factory That Tried to Open WithoutKnowing Its Costs
October 22, 2025
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Cause and Effect Series
Cause and Effect Series
A new “Cause and Effect Series” by Bill Murray I’ve been asked many times, “Why do some modular factories make it while others don’t?” There isn’t one single answer—there are patterns. Over the next few articles, I’m taking a closer look at some of the most common causes I’ve seen
Everyone loves numbers. They’re clear, comforting, and easy to display in a meeting. Backlog, labor costs, and inventory utilization—these are the figures that fill spreadsheets and define progress reports. In my experience, they don’t tell the full story. Some of the most successful factories I’ve seen and managed weren’t the
It’s not a someday problem—it’s a now problem. Ford CEO Jim Farley has been warning that the shortage of skilled tradespeople is already choking the nation’s “essential economy.” He’s talking about construction workers, electricians, machinists, and auto techs—the people who physically make and maintain everything that keeps our society running.
In Albuquerque,New Mexico, a provocative new proposal is stirring up discussions about how cities can reclaim idle land and address housing shortages. Under the plan, modular housing units would be installed on vacant lots across the city—fast, affordable, and with less red tape. What if those modular units were made
For decades, the story was the same: graduate high school, go to college, get a degree, land a career. But for many of today’s young people—especially Gen Z—that story doesn’t feel like the right fit anymore. Instead, they’re taking a serious look at trade schools, particularly in the MEP (mechanical,
A Simple Habit That Can Change Your Entire Factory Originally, I thought of writing this just for offsite factory owners and general managers, but as the words started to form, I realized something important: this message is for everyone. Everyone in an offsite construction factory. Everyone in any workplace, really.
Walk into any offsite construction event, from IBS to a regional builders’ association meeting, and you’ll hear it. Factory owners swapping stories over coffee, leaning on bar counters, or waiting in line for a shuttle bus. And like clockwork, advice flows freely—everything from how to solve labor shortages to why
For generations, $80,000 a year was the picture of middle-class comfort. Families earning it could buy a house in a decent neighborhood, drive a reliable car, pay the bills, and even set a little aside for vacations and college funds. It was the number that seemed to promise stability. But
If you’ve been around the building industry for more than five minutes, you’ve heard the word modular. It’s the golden child of construction right now—hailed as the solution to housing shortages, rising labor costs, and the need for speed. But here’s the problem: too many companies are calling themselves modular
In offsite construction, margins are measured with a microscope. Materials rise and fall in cost like the tides, labor shortages never seem to ease, and project delays chew through profits faster than a dull saw blade through plywood. And yet—despite all the hand-wringing over the economics of building—an astonishing 36%
Walk into a house built in the 1960s, 1970s, or even the 1990s, and you’ll feel the difference before you spot it. There’s a subtle draft around the windows, a little cold pocket by the front door, and if you hold your hand up to an electrical outlet on an
In a quiet corner of Durham, North Carolina, a small team of engineers is quietly working on something that could reshape the future of homebuilding. The company is called BotBuilt, and their mission is simple—but far from easy: use AI-powered robotics to solve one of the biggest problems in construction
In the words of Peter Drucker, “The greatest danger in times of turbulence is not the turbulence—it is to act with yesterday’s logic.” Never has that statement rung more true than in the current crisis gripping housing markets across North America. We are living in a time of turbulence: high
The construction industry often resists change, but one startup is proving that with vision, engineering, and perseverance, the system can be reimagined—quite literally. San Leandro-based Reframe Systems just won the prestigious 2025 House Building Prize from the Centre for Natural Material Innovation at the University of Cambridge, recognizing their groundbreaking
CertainTeed stands out as a pioneer, especially with its innovative ONE PRECISION ASSEMBLIES™ (OPA™) system. This cutting-edge approach to building is redefining efficiency, quality, and sustainability in residential construction. photos – OPA™ system Understanding ONE PRECISION ASSEMBLIES™ Introduced in March 2023, the OPA™ system offers fully constructed wall, floor, ceiling,
Offsite construction as a segment of the homebuilding industry, often times suffers from a common bafflement, lack of an understanding coupled with an appreciation for Building Science. In a recent conversation with Mark Eckard,President of Restoration North he attempts to cut to the chase. Mark is a veteran builder as
Gary’s viewpoint is for informational purposes only…and a few chuckles! Starting a modular home factory is easy! All you need is a building, some equipment, a few workers, a design, a sales team, a delivery system, a set crew, a finishing crew… oh, and a small fortune. Simple, right? Today,
For centuries, builders have relied on natural ventilation to keep buildings cool and dry. Before the era of modern air conditioning, homes featured elevated roofs, ventilated attics, and airflow gaps behind exterior materials to regulate temperature and moisture. These passive cooling techniques not only enhanced comfort but also preserved the
When it comes to modern modular homes that balance functionality with style, the Foxboro Model by Quality Homes stands out. Designed with both aesthetic appeal and practical living in mind, this home offers a thoughtfully crafted floor plan that caters to a variety of lifestyles. Whether you’re a growing family
Bureaucratic delays, logistical challenges, and high costs have long marked the journey of disaster relief housing. But now, a pioneering solution is rolling down the highways, offering wildfire survivors not just a roof over their heads but a renewed sense of stability. Nano Nest, a modular housing innovator, is changing
What were you doing in high school? Struggling through trigonometry? Fumbling through extracurriculars? Meet Ajith Varikuti, a Charlotte, NC high school student with a passion for design and an eye on the future. While most teenagers are figuring out prom dates, Ajith is designing homes to tackle rising sea levels—and
Dive into the future of sustainable solutions with Joel Wurschmidt, Director of Business Development at Envirobon. Known for their groundbreaking innovations, Envirobon is reshaping the way industries approach eco-friendly products. In this exclusive interview, Joel reveals the vision and technology behind their innovative offerings, providing a glimpse into how Envirobon
Behind every groundbreaking innovation lies a journey of overcoming obstacles, and for Brian Iverson, the path to creating Thermal Studs was no exception. In Part One of his Interview, we talked about how solving problems in sustainability and energy efficiency was the idea for his innovative product the T-Stud. Today,
Cause and Effect Series
A new “Cause and Effect Series” by Bill Murray I’ve been asked many times, “Why do some modular factories make it while others don’t?” There
Everyone loves numbers. They’re clear, comforting, and easy to display in a meeting. Backlog, labor costs, and inventory utilization—these are the figures that fill spreadsheets
It’s not a someday problem—it’s a now problem. Ford CEO Jim Farley has been warning that the shortage of skilled tradespeople is already choking the
In Albuquerque,New Mexico, a provocative new proposal is stirring up discussions about how cities can reclaim idle land and address housing shortages. Under the plan,
For decades, the story was the same: graduate high school, go to college, get a degree, land a career. But for many of today’s young
A Simple Habit That Can Change Your Entire Factory Originally, I thought of writing this just for offsite factory owners and general managers, but as
Walk into any offsite construction event, from IBS to a regional builders’ association meeting, and you’ll hear it. Factory owners swapping stories over coffee, leaning
For generations, $80,000 a year was the picture of middle-class comfort. Families earning it could buy a house in a decent neighborhood, drive a reliable
If you’ve been around the building industry for more than five minutes, you’ve heard the word modular. It’s the golden child of construction right now—hailed
In offsite construction, margins are measured with a microscope. Materials rise and fall in cost like the tides, labor shortages never seem to ease, and
Walk into a house built in the 1960s, 1970s, or even the 1990s, and you’ll feel the difference before you spot it. There’s a subtle
In a quiet corner of Durham, North Carolina, a small team of engineers is quietly working on something that could reshape the future of homebuilding.
In the words of Peter Drucker, “The greatest danger in times of turbulence is not the turbulence—it is to act with yesterday’s logic.” Never has
The construction industry often resists change, but one startup is proving that with vision, engineering, and perseverance, the system can be reimagined—quite literally. San Leandro-based
CertainTeed stands out as a pioneer, especially with its innovative ONE PRECISION ASSEMBLIES™ (OPA™) system. This cutting-edge approach to building is redefining efficiency, quality, and
Offsite construction as a segment of the homebuilding industry, often times suffers from a common bafflement, lack of an understanding coupled with an appreciation for
Gary’s viewpoint is for informational purposes only…and a few chuckles! Starting a modular home factory is easy! All you need is a building, some equipment,
For centuries, builders have relied on natural ventilation to keep buildings cool and dry. Before the era of modern air conditioning, homes featured elevated roofs,
When it comes to modern modular homes that balance functionality with style, the Foxboro Model by Quality Homes stands out. Designed with both aesthetic appeal
Bureaucratic delays, logistical challenges, and high costs have long marked the journey of disaster relief housing. But now, a pioneering solution is rolling down the
What were you doing in high school? Struggling through trigonometry? Fumbling through extracurriculars? Meet Ajith Varikuti, a Charlotte, NC high school student with a passion
Dive into the future of sustainable solutions with Joel Wurschmidt, Director of Business Development at Envirobon. Known for their groundbreaking innovations, Envirobon is reshaping the
Behind every groundbreaking innovation lies a journey of overcoming obstacles, and for Brian Iverson, the path to creating Thermal Studs was no exception. In Part