From Disparate Data to Integrated Prefabricated Production

In the prefab industry, digitization is not an end in itself. The real benefit comes when data is entered only once and then remains available for engineering, planning, production, quality control, and logistics. According to Rony Verlee, managing director of i-Theses Group, many manufacturers still rely on standalone software, Excel files, and in-house databases. This is time-consuming, increases the risk of errors, and makes processes vulnerable—especially when knowledge of such a system rests with a single employee.

Automation Requires Focus

Prefabrication is ideally suited for automation. Components are manufactured in a controlled environment, making it easier to manage quality, speed, and material usage. Verlee observes that the top-performing manufacturers are constantly investing in refining their processes. This involves not only drafting and calculations, but also the integration of planning, machinery, and employees on the production floor. “The most profitable prefab companies are the ones that invest heavily in automation,” he says. Production data can be sent directly to plotters, sawing machines, and robots, among other equipment. Increasingly, information is also fed back from the factory. If something goes wrong during production, it is immediately recorded. The manufacturer can reschedule the component and prevent the agreed-upon delivery from being jeopardized. According to him, the greatest damage often stems from disruptions to scheduling and transportation.

From Delivery Date to Production Planning

An integrated system links the overall delivery date to all the steps leading up to it. Starting from the desired delivery date, the system can work backward to determine when drawings must be ready, when approval is needed, and when production must begin. As a project progresses, the data is continuously updated and refined. Freight planning, inventory management, and invoicing can also be aligned with this information.

Larger companies often continue to use an administrative ERP system. The production environment exchanges data with it via interfaces. As a result, an order does not need to be re-entered and is enriched with technical, logistical, and planning information within the production environment.

Start small and then expand

Implementing a fully digital environment all at once sounds appealing, but according to Verlee, it’s rarely a wise move. When employees are confronted with too many new features at once, the likelihood that applications won’t be used properly increases. That’s why an implementation often starts with drawing, production planning, and load planning. Quality control, order picking, and outdoor yard registration follow in the next phase. “Start small and expand gradually,” he advises. Web-based applications make that expansion easier. Employees can work via a browser on a computer, tablet, or phone. Updates are rolled out centrally, eliminating the need for multiple software versions to coexist. Furthermore, quality information—including photos of damage or discrepancies—can be recorded directly on-site.

Opportunities and Limitations

According to Verlee, artificial intelligence offers opportunities in software development, production optimization, and the analysis of business data. For example, a user can query a database to gain insight into sales trends or production figures. Tests have also been conducted on optimizing work schedules. Nevertheless, he warns against overly high expectations. A convincing demonstration does not necessarily mean that an application will recognize all exceptions and production conditions in everyday practice. Experienced analysts will still be needed to assess the results and define the correct parameters.

Data remains the limiting factor

According to Verlee, the biggest challenge lies in the quality of the source data. Especially when it comes to custom-made walls, beams, and columns, exchanged models still regularly lack data that is necessary for production. A model may be suitable for design and coordination, but that does not mean it is complete enough to control machines. Prefab manufacturers must therefore establish agreements with engineering and drafting firms regarding how information is provided. “You need to have the data and ensure it’s well-structured,” says Verlee. Without that foundation, further automation primarily results in a digital version of an incomplete process. Technology is advancing rapidly, but reliable data, phased implementation, and engaged employees determine whether digitization actually delivers a return on investment.