In 1908, Henry Ford instituted the first assembly line in order to build his Model T car. At the time, the process was unheard of, but Ford knew what he was doing. He knew that by following a logical, step by step building process for each and every vehicle and using all the parts in a sequential manner that he could increase both speed and efficiency. By instituting this strange, new method, he was able to increase wages while also lowering the cost to customers. In fact, Henry Ford paid his workers a never before seen $5 for an eight hour day, when the rest of America was making much less for a longer day. Needless to say, Ford knew what he was doing and the idea of an assembly line is used throughout the world in the production of cars and many other fine products. One of the products that benefits from the efficiency of an assembly line is the manufactured home.
Manufactured homes, which can also be called pre-fabs, are built in a factory with the same materials used by their stick-built counterparts. In fact, everything from the 2 x 4’s and the fiberglass insulation to the shingles and the front door are the same. Sometimes they even use the exact same suppliers for those products. The only difference is the physical location of the construction process. So, what are the benefits to building a home in a factory?
- Pre-fabrication of a home indoors saves time for excited new homeowners. In fact, homes built using this method can be constructed in weeks instead of many long months.
- Building a house in a factory can save up to 40% per square foot over the more conventional site-built house, which can decrease the average monthly mortgage payment considerably. In this economy, many people are reconsidering their housing options and opting for smaller payments.
- Mother Nature is the biggest player in the stick-built construction process. She can wreak havoc on everyone’s schedule by throwing curve balls like rain, wind, snow, extreme heat and frigidly cold weather at the tradesmen. The roofers can’t get those shingles installed in the rain and their delay may end up preventing another crew from starting their step in the process. On the other hand, when a house is built in a factory, the line keeps moving, rain or shine. The skilled teams can work in comfort all twelve months of the year, without delays of any kind.
- In addition to delaying the actual construction process, weather can also damage materials left on site. Quite often, materials like wood, siding or even landscape shrubs are left on site to ensure work continues at a consistent pace. Unfortunately, in an attempt to be organized, contractors may inadvertently be exposing themselves to loss and delays due to rain or other weather factors. Factory-built homes do not have such problems like this. Materials are stored indoors, in a protected environment, and are readily available for the team as needed.
- Like it or not, vandalism is always a problem on a construction site. Neighborhood teens are drawn to empty houses at night and may have a little too much fun at your expense. Sure, insurance covers any loss, but the time delays while waiting for new product can be frustrating. When a house is built in a factory, it is safe from any would-be thieves or vandals, eliminating what can be a devastating event during what should be an exciting time in your life.
- Time can also be wasted waiting for materials to be physically delivered to a stick-built site, whereas factories are well-stocked. Houses are built day in and day out; there is no down time to wait for supplies. No icy roads. No windy conditions causing traffic jams. In fact, the concept of the assembly line and factory construction of a house has greatly reduced almost every aspect that frustrated homebuilders for years.
- Manufactured homes also buy supplies in bulk, not for one or two houses at a time. So, in addition to no longer waiting for supplies, you can rest assured that you are getting the best price for them, a quantity discount. Just like Henry Ford, those cost savings are passed directly on to the consumer.
- Manufactured homes are planned meticulously. Modern home builders want to eek every last bit of efficiency out of the raw materials. The process in a factory is controlled and every last step is planned out. Things are dramatically different in the stick-built world. A general contractor cannot watchevery cut made on every sheet of plywood to ensure that it is being used the most effectively. Measure twice, cut once is a big reality that, unfortunately, comes out of the homeowner’s pocket. In fact, waste is always a big problem for any site-built home. Many general contractors try every way imaginable to fight it, sometimes to no avail.
- Every tradesman considers himself (or herself) a craftsman. Whether they work on site or in a factory, they take pride in the work that they do. A factory-built home, however, gives a much greater opportunity to hone one’s craft. In fact, the art of the assembly line allows for one precise action or series of actions to be repeated and, in turn, to be perfected. Many manufactured home companies have specialized teams trained to perform one specific task and to perform that task exceptionally well. That’s an experience that can’t be duplicated during traditional building practice.
- In using the assembly line method, the house can move quickly and efficiently through each phase of the construction process, saving that all-important time. That’s right. The house actually moves. There is little need to climb on roofs or carry around ladders. Work is performed at a comfortable height for the crew, which not only increases safety but also decreases the time that it takes to complete the task.
Maybe Henry Ford would be surprised at how far his ideas had led America and, really, the entire world. Maybe he already envisioned what was possible with the implementation of an assembly line. We’ll never know. What we do know is that time is money. Delays due to weather, vandals and unavailable product are not only unacceptable, but also expensive. In fact, many new homeowners may be temporarily making two mortgage payments, their existing one and payments on the construction loan. When it is tough to make that happen every month, hearing that a few raindrops is draining one’s bank account is unnerving. Sometimes homeowners sell their existing home and suddenly find themselves in the opposite situation – nowhere to live. Or, worse yet, some very unlucky homeowners have run in to so many delays and cost overruns that they are no longer able to afford their long-awaited dream home.
The use of a climate-controlled factory for the construction process virtually eliminates all of the above frustration. Being able to move into a new and much-anticipated home in weeks instead of months is great news for any new homeowner. Better still knowing exactly when it will be ready and how much it will cost. Henry Ford would be so proud.
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