"We never build the same thing twice"

This is the most common phrase we hear from prefab shops. And they're right: materials change or are no longer manufactured, every specifications seem to be all over the place, and requirements shift between projects. But while your final product might look different each time, your core processes don't have to be.

The Challenge

Looking at your shop floor, you might see a dozen different projects in various stages. Each one has its own unique requirements, materials, and specifications. The natural response is to treat each as its own prefab build. But this approach leads to:

- Inconsistent quality

- Unpredictable timelines

- Difficulty in training new team members

- Challenges in scaling production


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5 Steps to Standardizing Variable Work

The key to creating standard processes isn't forcing every project into the same box - it's understanding the patterns in how work flows through your shop. These five steps will help you identify those patterns and build processes that can flex with your needs while maintaining consistency where it matters most.

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1. Map Your Flow, Not Your Product

Most shops start by looking at what they're building. Instead, step back and watch how work moves through your facility. A mechanical contractor we work with found that regardless of whether they were building VAV boxes or complex mechanical skids, their material flow followed similar patterns. They standardized:

- Receiving and staging zones for different material types

- Quality check stations at key points

- Standard documentation stations

- Clear handoff points between teams

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2. Identify Common Processes

Even when builds look completely different, core processes often overlap. An electrical prefab shop noticed that while their power distribution centers varied widely in size and complexity, they shared common assembly sequences. They standardized:

- Basic material handling procedures

- Core quality control steps

- Team communication protocols

- Documentation requirements

3. Create Flexible Checkpoints

Quality requirements change between projects, but the verification process can stay consistent. A glazing contractor developed standard checkpoints that work across different window types:

- Critical dimension verification points

- Standard testing sequences

- Clear pass/fail criteria

- Documentation procedures

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4. Document What Matters

Don't try to document everything - focus on what drives quality and efficiency. A plumbing prefab shop simplified their documentation to capture:

- Key assembly sequences

- Critical quality checks

- Common failure points

- Lessons learned from each project

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5. Build in Adaption Points

Create standard ways to handle variations. A metal panel fabricator identified key points where their process needed flexibility:

- Material substitution procedures

- Design change protocols

- Schedule adjustment processes
- Quality requirement variations

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The Power of Standard Process

Remember: The goal isn't to make every build identical - it's to make your process predictable, even when the product isn't. By focusing on how work flows rather than what you're building, you can create consistency without sacrificing flexibility.


Want to learn more about standardizing your shop processes? Reach out to see how Building Swell can help.