Lean is a systematic approach to improving efficiency by eliminating waste and optimizing processes. It focuses on reducing delays, rework, material waste, and unnecessary movement to maximize output with existing resources.

For offsite manufacturing businesses, Lean helps: - Increase productivity—more output per labor hour (typically 30-50% improvement). - Reduce costs—less rework, shorter cycle times, and improved material efficiency. - Simplify workflows—organized, standardized processes that run smoothly. - Improve quality—fewer defects and inconsistencies in production.

By implementing LeanOffsite™, we help offsite manufacturers streamline operations without the need to hire and train additional workers.

We specialize in working with offsite manufacturing leaders managing factory-built components for construction, including:

- Modular Factories – Producing full building modules. - Panelizers – Wall panel and structural component manufacturers. - MEP Contractors – Offsite fabrication for mechanical, electrical, and plumbing systems. - Tiny House Builders – Factory-based small home manufacturers. - Truss Manufacturers – Roof and floor truss production facilities. - Precast Concrete Contractors – Manufacturing structural concrete elements.

If your business operates a shop or factory to produce prefabricated building components, we can help optimize your process for greater efficiency and profitability.

We offer a hybrid consulting model that combines the flexibility of remote support with the hands-on value of strategic on-site visits.

We start with a virtual walkthrough and video-based process analysis, allowing us to identify waste, delays, and inefficiencies without disrupting your operations. Then, depending on the engagement tier, we include targeted on-site visits for live observation, facilitation of Kaizen events, and team coaching.

This approach reduces travel costs, speeds up implementation, and ensures you get high-touch service without the overhead of full-time onsite consulting.

The LeanOffsite™ Discovery Session is a 30-minute discovery call designed to:

- Assess Your Current Challenges – Identify top inefficiencies holding back production. - Review Your Current Process and Goals – Understand workflow, bottlenecks, and waste areas. - Determine Your Fit - Enable you to ascertain whether LeanOffsite™ is a fit for your factory.

If you’re a production leader in modular, prefab, panelized, truss, or component manufacturing, and you’re dealing with inefficiencies, delays, or labor constraints, you're exactly who we help.

We work best with factories that:

• Have at least 10 direct labor team members

• Are experiencing growing demand or backlog

• Want to scale without simply adding more headcount

• Are open to change and ready to lead from the front

No prior Lean experience is required. We’ll meet you where you are and tailor the process to fit your people and your pace.

In most cases, no new equipment or expensive software is needed. We focus on optimizing your existing tools, layout, and workflow to eliminate waste and boost productivity.

Rather than relying on automation or costly upgrades, we help you unlock hidden potential within your current setup—through Lean process design, smarter scheduling, and better crew coordination.

If technology can significantly enhance your process, we’ll recommend practical, proven tools—but only if they deliver a clear ROI and integrate well with your team’s day-to-day operations.

We don’t just hand you a report and walk away. Every LeanOffsite™ engagement includes training, coaching, and on-the-floor guidance to ensure that your team understands and owns the improvements we implement.

We start by teaching core Lean concepts using your actual production environment—making learning relevant and practical. Then, as we redesign processes, we create standard operating procedures (SOPs), train your team in new workflows, and provide follow-up support to reinforce the change.

Our goal is to build internal capability so your team can sustain and scale results long after we're gone.

Most clients start seeing improvements within the first 4 weeks, especially with Quick Impact engagements. Full process transformations typically take 12 weeks, while long-term cultural shifts require 6 months for sustainable change. Key results include:

- Increased labor productivity (typically 10-50%) - Reduced cycle times and production bottlenecks - Improved workplace organization and standardization

Our guarantee ensures measurable results, so you’ll see progress quickly, with lasting impact. Schedule a call to see how soon we can optimize your factory!

Most clients see a 15–25% reduction in labor cost per unit and 30–50% improvement in output per labor hour within the first 2–3 months.

For example, a factory with 20 shop-floor employees could save $30,000–$50,000 per month, just by producing more with the same team and reducing costly rework, downtime, and chaos.

Our programs are structured to deliver at least 2–3x ROI, and many clients experience even more. Plus, we guarantee results—if we don’t help you increase productivity, we keep working at no extra cost.