Frame of mind: a production framer's techniques and attitude help break the speed limit on custom homes

Tools of the Trade, May-June, 2003 by Don Dunkley

To some custom builders, "production framing" conjures up images of slapped-together walls, shoddy work, and general chaos. The truth is the term has no more relationship to poorly constructed buildings than the phrase "custom framing" has to suggesting well-built ones. In reality, production framers rely on an organized process, an attitude, and a mindset that, when applied to custom framing, can save you time and money.

I spent 10 years framing tract houses before I started framing custom homes. When I switched to customs, I naturally carried over the techniques and skills I learned framing the tracts. Surprisingly, few of my competitors knew the methods. As a result, I worked faster, my frames were better, and the next thing I knew, my reputation got me as much work as I could manage, at a fee considerably above the going rate.

Analysis

The first step to picking up the pace is to examine each aspect of your rough framing process. The major segments I focus on are crew size, layout, pre-planning, Day One, wall framing, plumb and line (straightening walls), ceiling joists, shear panels (sheathing), and roof framing. These are good places to start looking for--and eliminating--duplicate efforts, extra work, and any other inefficiencies. Even the simplest things need a second look: Do you leave all your fasteners in a central location? Are your tools accessible, or could the truck or gang box be better positioned? The goal is to find every way you and your crew can do each task faster, while still maintaining high quality work.

It's important to note that while I've found ways to streamline my process, I couldn't list them all here. Instead, I've provided good places to start. What works for me may not work for your crew and your jobs. That's why a production-framing attitude is important. To give relentless attention to streamlining, you must also practice what you've learned, using it to make better sense of your jobs. This means developing a mindset that searches out wasted motion and seizes it so you can eliminate it. This won't happen overnight, but with constant practice, it works.

I think the best place to start thinking like a production framer is with first-phase organization, which has three parts: determining crew size, pre-planning, and what I call "Day-One Framing."

First-Phase Organization

Crew Size. Before you string the first extension cords, you need to prep the job and assign the right sized crew. Start work with a crew organization that allows simultaneous actions on different tasks--layout, lumber organization, tool setup, cutting, and pre-assembly. Too many or too few people on site both cost money. Study your projects and determine the most effective crew size per house.

Next, know your crew and what they can handle then train them to work as independently as possible. After years of piecework, I've learned with total certainty that two men are not--and never will be--twice as fast as one for lots of tasks. Divide work among small crews. Pickup tasks are a good way to spread the team out over the field. Only amass the troops for things like tilting walls up, lifting beams, raising the ridge, or tasks that require manpower for ease and safety. My most efficient crew members could often work individually or with one other person. A quick way to calculate if your crew is too large: Divide your framing bid by the daily cost of your labor and overhead; if the quotient is larger than the number of framing days you've estimated, the crew is too big.

Pre-Planning. This is the basis for improving your speed. You've read every word of the blueprints and assigned a crew, now you need to control the job from the start. If you skimp on this, you'll be running uphill the rest of the way.

* Create cut lists for all framing parts, like headers, cripples, or special stud lengths.

* Dissect the plans and mark all unusual layout requirements like load-bearing posts, load-bearing headers, beam pockets, hold-down locations, and required metal connectors.

* Know the entire window and door package rough-opening measurements; mark them at each location on the plans.

* Create your own wall layout pull-dimensions. I convert the plan dimensions into a continuous measurement from one end of the building to the other, measuring it on site with a 100-foot tape. This conversion makes for a smooth flow of marking wall measurements and reduces time at the plans figuring out where to snap the next wall.

* Assemble a daily achievement list for your crew. They know they get paid the same whether they frame four walls or eight walls; it's your job to motivate them. Tell them each morning where you want to be by day's end, then take assessments and make adjustments.

Day One. Day One sets the stage for the rest of the job. Spread your team out over the field, attacking the lumber pile and layout.

* Break the lumber pile down into various sections and spread it out. For example, long framing plates go in one area, non-standard stud lumber, mudsill, and shear ply (sheathing) go to others.