Solving Modular Factory Problems: An Innovative Lesson from a Conference Speaker

A few years ago, I attended a conference on modular construction and its challenges. Among the lineup of experts and thought leaders, one speaker stood out not because of the number of solutions he presented but because of his approach to making the audience reflect on their own problems.

The room was filled with modular factory owners and general managers, many of whom were grappling with issues ranging from production bottlenecks to labor shortages. The speaker began by listing some of the most common problems he had encountered in modular factories. These included department miscommunication, inconsistent quality control, and difficulty retaining skilled workers. He then offered a few practical solutions—streamlining processes, investing in training programs, and leveraging technology to monitor production more effectively. While the suggestions were insightful, they were not groundbreaking.

But then, he pivoted.

He told the audience he could eliminate their single biggest problem before his presentation ended. The room, initially skeptical, grew quiet with intrigue. He asked each person to write down their biggest factory-related problem on a piece of paper, fold it, and hold it in their hand. Once everyone indicated they had completed the task, he asked them to bring their piece of paper to the front of the room and place it on the floor and their problem would disappear.

The room hesitated. People exchanged glances, unsure whether to participate. Finally, one person began to rise, seemingly willing to take the plunge. But before anyone could follow through, the speaker stopped them.

“I forgot to mention,” he said, “when you come up and leave your problem, you have to take someone else’s problem and solve it.”

Laughter rippled through the audience as everyone sat back down. His point was clear: every factory has its unique set of challenges. While it’s tempting to think that someone else’s problem might be easier to solve, the reality is that understanding and addressing your own issues is usually more manageable.

The lesson didn’t stop at acknowledging the universality of problems. The speaker went on to highlight a crucial point: many modular factory owners and general managers tend to keep their problems to themselves, turning to outside consultants for solutions rather than collaborating with peers.

He urged the audience to foster open dialogue within the industry. “You’re not competitors when it comes to solving foundational problems,” he explained. “Sharing experiences and solutions can lift the entire industry.”

This call for collaboration resonated deeply. Modular manufacturing, while innovative, is still navigating growing pains as it becomes more widely adopted. Challenges like supply chain disruptions, regulatory compliance, and maintaining quality at scale are not isolated to a single factory. By creating networks of communication among factory leaders, the industry can develop shared best practices and reduce the reliance on costly outside intervention.

The story underscores a timeless truth about problem-solving: it’s easy to assume that others have it better or that their challenges are more straightforward. In reality, every business faces complexities that are invisible from the outside. Instead of envying or trying to emulate others, focusing on one’s own unique challenges and strengths can be more productive.

Furthermore, the story highlights the importance of humility and mutual support. Modular construction’s future depends on its leaders being willing to share their insights and learn from one another. Peer-to-peer problem-solving groups, industry conferences, and forums can provide the space for such exchanges, fostering a culture of continuous improvement.

Embrace Your Problems: Acknowledge that every factory has challenges. Avoid the trap of thinking someone else’s problems are easier to handle.

Foster Collaboration: Create opportunities to discuss challenges with peers. Consider forming or joining industry-specific groups where factory leaders can share solutions.

Balance Consultants with In-House Expertise: While consultants bring valuable outside perspectives, your team often holds the key to solving your factory’s problems. Engage your employees in brainstorming and decision-making.

Prioritize Open Communication: Within your factory, ensure that all departments communicate effectively. Problems often arise from silos and misunderstandings.

Invest in Leadership Development: Equip your managers with problem-solving skills. Leadership training can empower them to tackle challenges proactively rather than reactively.

    The speaker’s exercise at that conference was a masterclass in reframing perspective. By making the audience confront the reality of problem ownership, he delivered a message that was both humbling and empowering. Solving your own problems isn’t just about finding fixes—it’s about understanding your unique context, leveraging your team’s strengths, and collaborating with others to build a stronger industry. In modular manufacturing, as in life, the first step to solving a problem is owning it.

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