Production

Ep.56: The Ins and Outs of Off-Site Construction with David Cooper

Remodelers and custom-home builders are used to being on a job site, building from the outside in, whatever the weather. Modular or prefab homes are built in a controlled factory environment, from the inside out, and have made strides in quality, architectural complexity, and production processes.

In this episode, David Cooper talks to Tim and Steve about modular homes, their history, what the future holds, and some of the misconceptions about prefab homes.

David is the managing director of Connecticut Valley Homes of East Lyme, CT, with design studios in Fairfield and Westerly, CT. David is an award-winning modular home expert. CVH has been in business for 40 years, building more than 1,600 custom homes, and specializes in teardowns, rebuilds, and coastal construction.

Modular home building is a growing industry, spurred by technology — especially AutoCAD — which allows modular builders to create custom homes. Modular builders can construct essentially the same homes as on-site and stick-built homes. They build to the same codes using the same materials, but the process is different. David says his company can have a homeowner move in 120 days (or less) from the time they put the house on the foundation, and he talks about other facets of off-site construction, including:

  • How they compete on quality
  • The five types of modular homes
  • Building in a controlled environment
  • Energy benefits of modular construction
  • Sustainable building processes
  • Having lower liability on site
  • What the building process looks like
  • Using robots to frame walls
  • Getting all the clients’ decisions up front
  • The differences in inspections
  • The ballet of coordination in the factory and on site
  • How the money works out
  • The beauty of no change orders
  • And more …

It’s an insightful look at another part of the home building business and the different production processes they use.
 

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After two outstanding years, we are excited to host the 3rd Annual Production Conference, held alongside the 2019 Remodelers Summit at the Hyatt Regency in Orlando, Florida. In addition to hosting the event in the same hotel as the Summit, we’ve made even easier to register for BOTH events at the same time!

 
 

Ep.53: Make Your Project Manager a Marketing Machine with Doug Panozzo

Of all the things you have in your marketing toolbox — your website, email and direct mail, or social media — there’s one you may have overlooked.

Positioning your Production team to be aware of sales and marketing can be an overlooked marketing strategy, and also help align the office and field teams.

In this episode, Tim and Steve talk to Doug Panozzo, who is a human marketing machine. We discuss how to make that switch in mindset for your Production team, and how it can boost your sales and profits.

Doug Panozzo is a Project Manager for Hogan Design & Construction in Geneva, IL. He’s been with Hogan since October 2017. He came from outside of the industry, from a tech company, and moved into a Project Manager role with Hogan almost a year and a half ago. Since then, he has grown familiar with the industry, became efficient with Hogan’s systems, hasn’t gone over budget on a single one of his projects, and has brought in over $100,000 in sales in the last year.

Sharing the big picture with your team is the start. Doug says working on marketing or sales is job security for him — the more work he can help bring in, the longer he has a job. He talks about how he does it, and how you can get your team involved, including:

  • Selling the company throughout the project
  • Sparking new leads
  • Following up with customers to touch base
  • Finding the incentive — referrals and bonuses
  • Asking for social media posts with tags and reviews
  • Wearing and being the brand everywhere
  • How to start those conversations
  • Picking the right customers to keep in touch with
  • Making the questions subtle and helpful
  • Keeping good notes and setting reminders
  • Building relationships and working the neighborhood
  • Finding the way for different personalities to market and sell
  • How to set the expectations in hiring
  • Giving Production the tools, training, and materials to do it
  • Getting the timing right
  • And much more …

 

Including why your Project Manager or Lead Carpenter should talk to the neighbors’ cleaning people, and how many leads can come from it.

Let’s Keep It Up

This episode was another spurred by a suggestion from our listeners. If you’ve got an idea for a guest or topic, send Tim an email at tim@remodelersadvantage.com.

 

Ep.52: Growing Through Team Engagement with Michael Sauri

We’ve talked about getting your Production team engaged in refining your systems and processes by encouraging them to make decisions and look for problems.

But have you considered involving Production in the Design process?   

In this episode, Michael Sauri talks about how and why he did just that with Tim and Steve. Through this change, Michael sped the growth of his company.

Michael and his wife Deborah started TriVistaUSA in 2005 and the company’s grown to four times the size in as many years — with decreased overhead and increased take-home for their family and employees. Michael received the 2018 Fred Case Remodeling Entrepreneur of the Year.

Engaging Production in Design started with Michael working with an architect on a project, and being frustrated — he wanted to offer more options for his client. Michael asked his Production Manager to offer his ideas. Now, everyone involved in a job is involved in the Design process. He tells you how you can do it, and why:

  • What a charette is
  • Employing a charette concept in other areas
  • Work with your team’s strengths
  • Looking back to other projects for inspiration
  • Using creativity in problem-solving
  • Why input spurs engagement
  • Reducing on-site problems before they can start
  • Changing processes as you grow
  • Why it saves time overall
  • Who to involve and when
  • How to get started
  • And more …

Tapping into your team’s experiences and insights is the first step to getting to the best outcomes and solutions. It’s a continuous process, but can pay dividends in your bottom line, and in employee loyalty.

Ep.49: The Numbers that Matter Most with Judith Miller

For many people, the actual building of the project is what Production is all about. Looking at the bigger picture, Production has a great deal of responsibility to keep profit up. Production is a huge contributor to the financial health of the company.

It’s about the numbers — but what numbers are critical for the Production team to know and track?

In this episode, Judith Miller talks about the critical numbers for Production with Tim and Steve.

Judith is the resident financial expert at Remodelers Advantage, and says the numbers tell the story of your company. In college she studied architecture — but failed physics — and switched majors, graduating with a degree in economics. She has combined her love of architecture and building with economics to become a high-level strategist in the remodeling industry. Judith has been a facilitator for Remodelers Advantage Roundtables for more than 15 years, is a featured speaker at industry events, and frequently published in Remodeling Magazine.

If you can lay out a roof, which can be complicated, you can understand the numbers if you put your mind to it, she says. Looking at what numbers are trending, Judith says she’s seeing over-billing numbers decreasing, indicating a drop in sales from last year to this year. The economy may be slowing, Judith says, which makes understanding the numbers from the production side even more important. She talks about:

  • How field labor efficiency affects the bottom line
  • Indirect costs
  • Controlling slippage to protect from slowing sales
  • Job costs to look at in Production
  • Acceptable gross margin levels
  • Profit, loss, and overhead
  • Why the little stuff matters in job costing
  • The 80/20 rule
  • Why to estimate hours over dollars for labor
  • The most important things to hit in your budgets
  • Solving problems together

The most important factor in your bottom line isn’t a number, Judith says, customer satisfaction is. And that’s driven by employee satisfaction. So as you dive into the numbers together, avoid finger-pointing, and work as a team to figure out how to make your company more profitable.

Here are the links to Judith’s webinar about the Labor Burden Calculator:

 

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Ep.48: A View From the Client’s Seat

Client satisfaction is a huge component of making any business successful. Remodeling has an extra personal factor — your team and your subs are in a client’s home every day. Most of the time, the homeowners are living in and around your job site.

Understanding their experiences, asking questions about what they really need, and figuring out how to solve their problems makes for a better customer experience.

In this episode, Andy and Rachel Blackledge talk to Tim and Steve about living through their kitchen remodel, and what made things better.

Andy and Rachel Blackledge own a home in Scottsdale, AZ, which was built in the 1950s. Their kitchen was outdated, and was in desperate need of remodeling. They called Rosie on the House to bring their plans to fruition.

They talk about how important the weekly meeting was to their project, how expectations were set throughout the job, and the power of listening and acting, including:

  • How they prepared
  • Working from home during the job
  • Why it’s important to tell people when utilities will be cut off
  • Introducing subs to the clients
  • Helping clients live through construction
  • The simple things your team can do that can make clients’ lives easier
  • The Sales to Production handoff from their point of view
  • And more …

A key takeaway is using your experiences with past clients to better prepare new ones for the inconveniences and challenges of living through a remodeling project.

Keep the Suggestions Coming!

This episode topic was suggested by our listeners — and we want more! Send your ideas about topics or guests to Tim at tim@remodelersadvantage.com.

Ep.47: An Introduction to LEAN with Doug Howard

Today we’re talking about LEAN in Production. Doug Howard has been helping remodeling companies see how they can make their processes better, cut wasted effort, and streamline their systems for better profits.

In this episode, Doug talks to Tim and Steve about what it can do for your company — especially in Production.

Doug Howard, RA’s director of consulting services, is an entrepreneur, government official and small business consultant with more than 25 years of experience in leading organizations and assisting his client companies.

LEAN is the idea of having principles and practices to fuel continuous improvement.

One of the best things about LEAN is how clear and simple the concepts are to understand — it works as well for small- to medium-sized companies as it does for huge global enterprises. Doug talks about getting from your current state to your future state with fewer steps in your processes, and where to start, including:

  • The Eight Wastes, and how to eliminate them
  • How to apply the Five Whys to Production to find the root cause
  • Addressing the workplace with the Five Ss
  • How LEAN works with the Zero Punch List concept
  • How it improves the customer experience
  • Why LEAN is like a GPS
  • Involving your subs in the process
  • Conditioning your thought process for the long haul
  • And more …

Including Tim’s interpretation of what LEAN stands for. You’ll learn how to build a system that fits your business.

 

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What’s on Your Mind?

If you have an idea for a guest or topic for the show, let Tim know at tim@remodelersadvantage.com.
 
 

Ep.46: Working with Architects with Jason Stearns

There are many different ways to work with architects in the remodeling industry, whether you’re working in the design/build model or as a builder using plans developed outside your company. Regardless of the work model, most remodelers agree the architectural plans they get at the beginning of the production process are only half done. So communication is paramount during the build phase.

In this episode, Jason Stearns discusses the ins and outs of working with different architectural firms from the Production standpoint with Tim and Steve.

Jason has been working in high-end residential market in San Francisco for almost 30 years. He joined Jeff King & Co. as Director of Production in 2017. Since then, he’s helped implement the use of Procore for their production teams, standardized the project scheduling formats, and started a weighted numeric skills assessment system for the evaluating the carpentry and labor staff to identify needed training for advancement.

In each of their projects, there are two clients — the homeowner and the architect, Jason says. He and his team want to deliver the project that realizes the original vision for both parties. To make everyone happy takes clear communication and rigorous documentation of every email, phone call, and design change. Jason tells you how to make that happen, including:

  • Getting information when you need it
  • Establishing good working relationships
  • Creating schedules that work off the budget
  • Looking at the schedule as a living document
  • Identifying milestones for the architect
  • Making objective arguments
  • Staying ahead on change orders
  • And more …

Keeping track of all communications is a major challenge, but it’s the best way to ensure that the completed project is a success for all parties.

Keep the Suggestions Coming!

This topic was suggested by one of our listeners. If you have an idea for a subject or guest, send it to Tim at tim@remodelersadvantage.com.

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Ep.44: Special Guest Kevin O’Connor of “This Old House”

Television is full of construction and remodeling shows, but we all know many of them leave false impressions of how fast and easy the process can be. But the pioneering program This Old House still shows viewers how complicated it can be.

This year marks the 40th anniversary of the program, and they’re tackling a net-zero retrofit, a mid-century modern remodel, and spearheading outreach programs to get more workers into the trades.

In this episode, Kevin O’Connor, host of the Emmy Award-winning This Old House and Ask This Old House, talks with Tim and Steve about what you see on TV, and how it helps the construction industry as a whole.

Kevin has appeared on the two shows since 2003, and serves on the editorial board of This Old House magazine. He also hosts This New House airing on the DIY Network and Hidden History in Your House airing on the History Channel’s H2 network. Along with his four brothers and two sisters, Kevin grew up on various job sites led by his father, a civil engineer. When Kevin and his wife, Kathleen, were renovating their 1892 Queen Anne Victorian they sent an e-mail seeking advice from the Ask This Old House experts. The house call served as Kevin’s first screen test to serve as the new host (the third host in the history of the home-improvement series).

Kevin talks about the evolution of the show and about the Generation NEXT campaign, cosponsored by the mikeroweWORKS Foundation. It’s a high-profile effort to close the skills gap in the trades, encouraging young people to master those skills and look at construction careers. He also talks about the challenges of working on a job site that’s also a TV shoot, including:

  • Scheduling
  • Scrambling and adapting
  • More about the show’s two projects this season
  • How the show’s contractors juggle TV and their businesses
  • Using their big megaphone
  • And more…

Tim also talks a bit about how business owners can look at Generation NEXT and adapt it in their own communities to help bring more young people into construction and remodeling.

Tell Us About It

Do you have a topic you’d love to see covered or a guest you think we should interview? Drop Tim a line at tim@remodelersadvantage.com and let us know!

Ep.43: The Importance of Job Autopsies with Chris Beck

A good job autopsy can lay the foundation for better processes and more profits for your company. But you have to do it right. Some companies use them like a club, which leads to finger-pointing and the blame game. Some owners just brood over the numbers and do nothing. But the numbers tell the story, and doing the forensics can tell you how to improve.

In this episode, Tim and Steve talk to Chris Beck of Normandy Remodeling in Hinsdale, IL. Normandy Remodeling has just started involving Production in the job autopsy process at the close of a project.

Chris has been with Normandy for 11 years. He started as Superintendent, and was promoted to Production Manager in April 2015, then Director of Production in January 2018. In 2018, it marked the fourth year in a row of record produced volume. Last year, they completed 220 jobs.

Chris began involving Production in Normandy’s job autopsies last year. Previously, the autopsy had been more focused on sales and design. He saw slippage increasing, and needed to figure out why that was happening. He discusses how what data to look at, and how having Production in a job review can make significant changes for the better, including:

  • How to make changes so you’re not repeating mistakes
  • Getting involved in the financials
  • Changing processes
  • Why it can help you refine your cost book for the higher-end projects
  • Avoiding finger-pointing and blame
  • Why an interactive culture makes it all easier
  • What to document and why
  • Bringing it all together
  • Handling issues before the job ends — or even starts
  • How much time it takes
  • And much more…

Including how to pitch it to your owner if your company isn’t doing a post-mortem. Taking the steps toward doing a complete job autopsy can take you from good to great, and find extra profits for you company.

It’s Your Turn

We’re getting great suggestions for topics and guests — what do you want to hear us talk about? Shoot Tim and email at tim@remodelersadvantage.com with your ideas about subjects to cover and guests to talk to!

Ep.42: Becoming a Production Manager Without a Construction Background with Brad Yetman

With growth comes a need to hire a Production Manager — someone responsible for the entire department. It can be a difficult transition to move a Production Manager or Lead Carpenter up into that role. It’s about managing a department and the people, and it’s much more complex than running a job. Your company may benefit by looking outside the industry for your Production Manager. 

In this episode, Brad Yetman talks to Tim and Steve about his experience coming into a Production Manager role from outside the remodeling and residential construction industries.

Brad is the vice president of construction, as well as part owner of Anthony Wilder Design/Build in Cabin John, MD. Brad is responsible for overseeing the production department, which produced about $14,000,000 last year. Brad has developed a financially focused approach to production management with an emphasis on “knowing the numbers,” both in the field and in the office, an approach which fits well with the company’s open book policy. But it wasn’t always a smooth transition.

Before joining Anthony Wilder, Brad had a limited background in carpentry and construction. He had worked in in commercial development and real estate. When he took the Production Manager job, he was overwhelmed for the first six months. In his second six months, he began to figure out it was about managing a department and people — and keeping a keen eye on profits. He tells business owners why and how to look outside the industry, as well as what to do when your hire someone, including:

  • Hiring for cultural fit
  • Setting Gross Profit and Net Profit goals at the outset
  • Bypassing hostility from within the department
  • Translating the numbers for those in the field
  • Networking to find an outside candidate
  • The importance of staying open to learning
  • And much more…

Including why having dogs in your office is a cool idea. But the most important thing, says Brad, is hiring a good manager — because the industry specifics can be learned.

What’s the Big Idea?

Do you have a great idea for a future topic or guests? Shoot Tim and email at tim@remodelersadvantage.com.

 

Project Manager Training with the Experts at Remodelers Advantage

Remodelers Advantage presents a Masterclass course designed specifically for Project Management personnel in the remodeling and custom-building industries.

This program, led by Tim Faller, Victoria Downing and Doug Howard, consists of two days of intensive training and instruction focused on two of the most important aspects of managing a project; (1) hitting the agreed-upon budget and (2) working with and managing the team effectively. Click here for more information.

 
 

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