John Kenney, CPRC, CEO, Cotney Consulting Group
According to a study published in the Journal of Construction, Engineering and Management, a lack of productivity among U.S. and Canadian construction contractors costs them about $5.4 billion annually. Construction has lost productivity over the past four decades. By increasing efficiency just 36 seconds per hour, contractors could gain billions of dollars, according to a Denmark Aarhus University report cited in the study.
This study’s data is based on all construction in North America, in which the roofing industry accounts for over ten percent of total construction revenue. That
translates to almost three-quarters of a billion dollars in losses for roofing contractors.
How to repair this? Invest in methods that will increase efficiency and effectiveness, such as a lean work system with integrated project delivery and location- based scheduling. Despite the popularity of lean construction principles in recent years, productivity gains have not materialized but our industry is ripe for change.
Lean processes alone will not fix this lack of productivity. There must be a shift toward increased productivity and efficiency using new technologies and a company’s desire and willingness to change. Small improvements can have a significant impact. The bottom line is this – everyone from top to bottom must produce more for each dollar spent on roofing installation. That includes contracting methods,
labor organization, management and project operations at the job site.
Numerous complex factors influence productivity on a roofing job site. There are also, arguably, morale and job satisfaction issues that come into play.
Productivity is defined traditionally as the ratio of input to output involving production rate, performance factors and unit person-hours. It is the physical progress achieved per person-hours and for each portion of a project completed, such as laying so many squares of roofing or installing “x” linear feet of flashing.
Here are two critical measures:
Contractors must visualize the roof installation process, including materials and personnel, equipment, management and money. Collect and process the information on production rates. Measure input and output using person-hours per unit and cost per unit. Then, measure productivity compared to the estimate or budget.
If a job’s productivity does not compare favorably with the estimated values, it is time to examine management practices. Management practices include scheduling, data collection, planning, controls and job analysis
Consider your procurement methods for timely materials delivery. Address motivation, environmental factors, job safety and physical limitations.
To accurately measure productivity in roofing, look at the number of squares produced per person-hour used. Observe the activity level on the job site but avoid the perception that you are spying on your workers. Conduct information and education sessions to create a team approach to productivity. Ask your employees for any valuable information they might have on efficiency needs.
Use what is known as a field rating. For example, a crew leader can make 100 observations of workers and note whether they were working or not when observed. If only 40 are classified as working, the field rating would be 40 percent or 40/100, which is unsatisfactory. This method does not tell you the sources of the inefficiencies but does tell you that you have a problem.
Work sampling is a slightly more sophisticated process. Use a small group of employees to collect a sample and analyze it. Observe the job site for a limited time to determine the level of productivity. Break down responses as productive, semi-productive and not productive and make random observations. Record your observations, then add up the checkmarks under each category to calculate the percentage of activity. If four of nine observations are productive, that would be 45 percent.
Here are ten ways to speed up your roofing projects
without losing quality.
Better communication: Communication is essential when it comes to boosting productivity. Workers need to know all pertinent information and understand it to improve their performance. Stay in touch through emails or text messages with any changes that might
affect your crew. Never leave employees in the dark about what is happening on a project.
Set realistic goals for your team: Roofing is time-consuming, so you need to set daily, weekly and monthly goals. You can even set an annual goal. This will help your crew strive to meet those goals. Setting small-bite goals helps workers see larger projects as more easily managed.
Offer employees incentives: Your workers put in long hours of physical labor in varied weather conditions. Offer incentives in the form of rewards to help increase productivity. Treat them to lunch delivered to the job site when the crew meets a goal.
Train employees well: You cannot expect good productivity without adequate training. You will have fewer injuries and increased productivity. Train your crew correctly to help get a job site moving. Even if this training costs extra money, it will be worth it.
Be a good listener: Listen well to your crew members. It will make you a better leader. Good communication requires you to not only convey information but also to obtain it from your employees. They have their own views about what works best on a job site and can tell you if your goals are realistic.
Plan with a purpose: Lay out a detailed plan before starting a roofing project. Write down a schedule for materials needed, workers and other job logistics. Keep the plan up to date to have a better idea of how the project is moving along. The more thoroughly you plan
ahead, the better your project will turn out.
Hire a good management team: This is a key to increasing productivity. Your team will respond positively to a respectful yet firm manager. Such managers keep your team focused and working toward your goals.
Be sure you have the materials you need: The last thing you want is to run out of materials before a job is completed. Check your inventory regularly.
Consider a long weekend off: Your crew works hard and if you have worked them particularly hard, consider giving them some time off, maybe a long weekend. This will show you care and improve crew morale.
Keep your crew on task: Always help your employees stay on task by reminding them of your end goal.
By training your team properly, communicating well, rewarding and listening to them, you can improve productivity on your job sites. Implement a lean scheduling process to help move your projects along more efficiently.
John Kenney has over 45 years of experience in the roofing industry. He started his career by working as a roofing apprentice at a family business in the Northeast and worked his way up to operating multiple Top 100 Roofing Contractors. As CEO, John is intimately familiar with all aspects of roofing production, estimating and operations. During his tenure in the industry, John ran business units associated
with delivering excellent workmanship and unparalleled customer service while ensuring his company’s strong net profits before joining Cotney Consulting Group. If you would like any further information on this or another subject, you can contact John at jkenney@cotneyconsulting.com.
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