“Making Construction More Accessible to People” – How Manufacturing Production Staff Fit into Offsite Timber Frame Building

In the move towards MMC, the pros for the business and the employee often go hand in hand. The builder, when operating at the right scale of production, can increase delivery while improving quality, plan operations more effectively, and reduce the numbers of staff required in an already-restricted workforce. For people working in offsite manufacturing, this model gives them access to what many in traditional construction never had – a regular working location and a 9-5 indoors. 

That’s why many Irish companies are pivoting operations around MMC. Even timber frame, one of the most traditional forms of building, can be done offsite and panels or other components simply assembled onsite. This model is key to one company’s growth at a modern production site. 

The team first uses a coordinated 3D design process to resolve details in the structural information of wall panels, floor systems, and roof structures, before manufacturing begins. These design files are then converted for the automated machinery, reducing the chance of manual errors. 

The system divides the timber structure into unique elements, with staff at each workstation interpreting the model and manufacturing these elements to required specifications. Components are then cut and processed before panels are framed, openings cut, and patterns fixed in a repeatable production sequence. 

Completed panels are labelled, weather-proofed and assembled into packs in the correct erection sequence, ready for onsite assembly. Construction kits are then loaded in a planned order so the installation crew can assemble the timber fame structure in the correct order.  

DTE Manufacturing starts by training new production staff in timber frame terminology, material identification, equipment operation, and quality requirements. Employees are then trained at individual production stations with experienced floor operators to pick up practical skills in machine operation, understanding production data, recognising faults, and process recovery. 

Training is built through a structured upskilling matrix in the company's academy. This defines competencies for each role and provides a clear career pathway in offsite manufacturing for staff to, according to Daragh, “progress into more skilled operational, technical or supervisory roles”. 

While Enda started his career in construction as a setting-out engineer and site foreman, after the 2008 Recession he moved into manufacturing as a machine operator for a food packaging company.  After switching to medical device production, Enda began to advance his career with training in Lean principles as he advanced from Line Lead to Team Leader to Production Manager. Undertaking Six Sigma training, he advanced from White Belt to Yellow to Green Belt, helping his company to streamline production and improve the manufacturing process.

Through all this, Enda wanted to return to the construction sector – with the right opportunity. 

Enda's daily tasks include production meetings with each shift, managing floor operations, and assessing the team's competencies to maximise efficiencies. Enda is responsible for two Shift Managers, who in turn manage six Shift Supervisors and a team of 100+ General Operatives. 

Among the skills Klaudia has developed in her time at DTE Manufacturing, she has learned the basics of timber frame cutting, machine operation and design interpretation, which she sees as a “major skill, in manufacturing or onsite”. Indeed, Klaudia has already had opportunities to advance these skills within her working hours, being invited to join company management training as a high-performing operative with an eye to advance to a supervisory role in the near future. 

This promotion of offsite construction skills has been key to DTE Manufacturing's success. It also shows how the Irish building sector has embraced upskilling as key to the workforce of the future.