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Is Your Factory Operating at Peak Efficiency?
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Labor shortages causing delays?
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Throughput limitations hindering growth?
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Disorganized workspaces leading to waste?
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Lack of standardized processes affecting quality?
59%
productivity increase
88%
reduction in defects
297%
faster station throughput
With Amazing Results:*
63%
decrease in cycle time
*Results Not Typical
Our Guarantee:
If we don’t help you achieve at least a 10% increase in labor productivity within 90 days, we’ll keep working until we do—at no additional cost.
No risk. Just results.
Our Clients
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Meet Your LeanOffsite™ Expert, Daniel Small
For over 25 years, I’ve worked in and around construction—first as an engineer, then as an executive, and now as a Lean consultant dedicated to one mission: helping offsite factories operate like world-class production systems.
I got into Lean because I saw firsthand how chaotic, wasteful, and inefficient most construction workflows are—especially in offsite. Unlike every other physical product industry, construction hasn’t industrialized. And that’s a problem.
The world needs more housing. More schools. More infrastructure. And the only way to meet that demand is by making the process faster, leaner, and smarter.
Offsite made immediate sense to me as an engineer. It offers the predictability, scalability, and quality control traditional construction lacks. But most offsite factories are still underperforming—not because the model is broken, but because the process hasn’t been optimized.
That’s where LeanOffsite™ comes in.
I’ve helped modular manufacturers, panelizers, and prefab contractors reduce cycle times by 40–80%, double throughput, and build a culture of continuous improvement without adding more labor. If you’re ready to unlock that kind of performance in your factory, book a discovery call with me now, and let's get started.
⏳ Limited Availability Notice:
We only onboard a few new clients per month to ensure hands-on support.
BOOK NOW to reserve your spot in the next implementation window.
Ready to See Results?
What to Expect in Your Discovery Call:
In this free 30-minute conversation, we’ll:
✅ Discuss your current challenges and production goals
✅ Ask a few key questions about your process, crew, and backlog
✅ Determine whether LeanOffsite™ is a strong fit for your factory
No pressure. Just a focused discussion to explore alignment and next steps.
Book Your LeanOffsite™ Discovery Call NOW
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What is Lean, and how can it help my business?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.
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What types of offsite manufacturing companies do you work with?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.
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How do you work with clients—remotely, onsite, or both?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.
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What is included in the free discovery call?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.
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How do I know if my factory is ready for LeanOffsite™?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.
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Will your recommendations require new equipment or software?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.
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Do you train our team or just make recommendations?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.
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How soon will I see results from LeanOffsite™ consulting?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!
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What kind of ROI can I expect from this investment?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.
Free Guide: 5 Steps to a More Efficient Offsite Factory
5 Steps to a More Efficient Offsite Factory” is your practical guide to eliminating waste, boosting productivity, and streamlining operations—without adding headcount.
Designed for modular, panel, and prefab leaders, this free ebook delivers quick wins and proven Lean strategies you can start using immediately to transform your factory’s performance.