In the building industry generally and industrialized construction specifically, the utilization of data has become increasingly pivotal. This trend parallels the data-driven advancements seen in Formula 1, where precision, speed, and strategic insights derived from data have revolutionized the sport. (I’ll have more to say about Formula 1 in the next few paragraphs.) Increasingly, we find operations that are languishing because they are not taking advantage of the one thing we have a lot of: data. I am reminded of the Matthew McConaughey commercial depicting the road in the middle of a town that turns to gold, and his words: ... “if AI is the wild west, does that make data the new gold?”
The Role of Data in the Structural Building Industry
Data is a cornerstone of Industry 4.0 for structural building component and volumetric modular plants, influencing every aspect from design to production. Many parts of our industry heavily rely on advanced software and digital tools for planning, modeling, estimating, and ordering structural elements. This digital transformation ensures precision and efficiency, reducing errors and waste, much like the meticulous data analysis in Formula 1 that optimizes car performance and race strategies. One of the motivating factors for me in buying the software company Moducore and other data-related companies was recognizing the importance of data and how we use it in our operations.
So why talk about Formula 1? What does it have to do with modular and panelized structural components? One of my associates, Mike Ruede, Jr., who leads our automation and robotics solutions team, knew that I enjoyed racing, but he did not understand where it really was driven from. Back in the 1980s when I went to my first Indy and Nascar races, what impressed me the most was how much manufacturers were spending testing new ideas, products, etc. in the racing vehicle. The result? Much about the vehicles we drive today came from testing that was done on the racetrack. When Mike told me about a show on Netflix, Formula 1: Drive to Survive, I was completely impressed with how racing teams were using data — not just data collected at the race and then reviewed after, but data captured and used in real time. If this technology produces winning results on a lightning-fast racetrack, imagine what it could do for your factory.
1. Design and Engineering Precision: The integration of data in the design phase allows for the creation of highly accurate structural elements. We now have the ability to render a structural design in 3D to ensure not only that it meets design engineering principles, but also that it is designed for optimal efficiency — both in the factory and in the field.
2. Quality Control and Assurance: Data plays a vital role in quality control and assurance processes. Industry manufacturing plants use data to monitor and maintain the quality of materials and finished products. Digital quality control resources and regular testing protocols ensure that the components consistently meet the required standards, much like F1 teams continuously monitor car performance metrics to maintain competitive standards. As a reminder, if you are not already using the SBCA Digital QC program in your structural component operations, I encourage you to reach out to the team at SBCA or myself to tell you more. SBCA’s Digital QC streamlines your in-plant quality control by substituting traditional pencil and costly vellum paper with a tablet and app, enhancing speed and enabling easy access to valuable data for refining manufacturing processes and component quality.
3. Operational Efficiency: Automation and data-driven decision-making enhance operational efficiency in manufacturing plants. For example, Builders FirstSource’s investment in automation has significantly improved their production capabilities and operational excellence. Their Villa Rica, Georgia plant, equipped with precision robots, exemplifies how data and automation can drive productivity and efficiency.
Data-Driven Innovations and Expansion
Industry manufacturers are experiencing rapid expansion and innovation, driven by data and digital advancements. Both legacy companies and new entrants to our industry are opening new manufacturing plants to meet growing market demands. These new plants utilize data to streamline operations, from inventory management to production scheduling, ensuring timely and cost-effective delivery of components.
Formula 1: A Model for Data Utilization
Formula 1’s reliance on data offers valuable insights into how our industry can further harness data for competitive advantage. In F1, teams collect and analyze vast amounts of data from sensors on the cars to make real-time decisions during races and optimize performance during practice sessions. This data-driven approach has led to remarkable advancements in car design, race strategy, and overall team performance.
Similarly, in industry manufacturing plants, data can be leveraged to optimize design processes, improve production workflows, and enhance supply chain management. By adopting a data-centric approach, companies can anticipate and mitigate potential issues, streamline operations, and deliver higher-quality products.
Challenges and Opportunities
While the integration of data offers numerous benefits, it also presents challenges that the industry must address. Ensuring data accuracy and reliability is paramount, as decisions based on faulty data can lead to costly errors. I am reminded of the adage I heard early from my Dad, Don Hershey, when he was using an inventory computer in the 1970s about GIGO: garbage in, garbage out. Additionally, there is a need for skilled professionals who can analyze and interpret data effectively, translating it into actionable insights. Too many times we see our teams increasingly shellshocked by the volume of data that is coming at them. There are some who are trying to sell, for example, a singular labor-tracking model that has been used since the late 1960s and early 1970s, using the same data from plant to plant. But data is far more than a singular element; there is so much more than just labor. As an example, it is also necessary to capture several other data points around the same work cell in the plant to accurately determine where the labor is deployed not only in that singular work cell but the entire line. Another example would be that data analytics can be utilized to track inventory levels, monitor supplier performance, and forecast demand, enabling manufacturers to optimize their supply chain processes.
Moreover, the industry must invest in the necessary infrastructure and technology to collect, store, and process large volumes of data. This includes adopting advanced software solutions and automated systems that can handle the complexity and scale of modern construction projects. (I’m not writing this to make a sales pitch, but I do need to mention that Moducore provides customized solutions based on how we collect, interpret, and effectively use real data.)
Future Prospects
The future of the building manufacturing industry lies in the continued advancement and integration of data-driven technologies. As the industry embraces digital transformation, we can expect to see even greater improvements in efficiency, quality, and innovation. The parallels with Formula 1 are clear: Both industries thrive on precision, speed, and strategic use of data to maintain a competitive edge.
Indeed, data is an invaluable asset in our industry, driving advancements in design, quality control, and operational efficiency. By learning from the data-centric approach of Formula 1, our industry can continue to innovate and excel, meeting the evolving demands of the construction market, while ensuring the highest standards of quality and performance.
Ben Hershey is the CEO of 4Ward Solutions Group and former President of SBCA. Ben has owned and operated several component and building industry companies. 4Ward Solutions Group is the parent company of 4Ward Consulting Group, 4Ward Design & Labor Group, Moducore, and Innovative Offsite.
Cover photo courtesy of Structural Truss Systems/Forma Steel, Fort Macleod, AB