The terrible two’s as parents call it when their children reach the age of two and start questioning everything they see. Why this, why that, why, why, why, until their parents either answer these questions or pass out. There were no questions too small or big. Their status quo is not developed yet and their minds are completely open to new ideas.  

In lean manufacturing and lean six sigma, this used to be annoying behavior, has become standard practice even earning the title “5W Analysis”. What industrial engineers are learning is to become that two-year-old child once more but with a bit more diplomacy and respect for all employees while conducting this analysis. Shigeo Shingo once said, “A relentless barrage of “why” is the best way to prepare your mind to pierce the clouded veil of thinking caused by the status quo. Use it often”.

One of the biggest barriers to building modularly is preconceived notions of trailer park homes or structures with lower quality. However, this could not be more further from the truth. Our sales manager, Tom O’Hara often says, “Would you want your car built outside in the elements or in an environmentally controlled manufacturing factory?” Would it not be nice to be able to have quality checks and measures being controlled during every aspect of the construction process?

At Capsys, every aspect of the construction process is broken down and analyzed. Then put back together so the plumbers, electricians, welders, and carpenters can work together as seamlessly as possible; thus, increasing output and quality.    

As the two year old would say, “why build it the conventional site built way when quality, efficiency, production rate, and supply chain’s all are better with a manufacturing line?” As an industrial engineer, every time I walk the production line I hear that two-year-old boy inside me saying, “Why” and it brings a smile to my face as the factory workers give me silly looks as I ask them.

Capsys is embracing the closed-cell Styrofoam Spray foam system by DOW.  Used in conjunction with Thermax sheathing as a an overall system this allows for R-values unprecedented in the industry.  This system allows for greater air-tightness, reduced energy consumption and overall savings to the environment.

With Capsys adopting Kaizen and Lean Manufacturing into its Manufacturing line, one cannot help but think of a famous quote by Shigeo Shingo, “The most dangerous kind of waste is the waste we do not recognize.” One can locate waste in many different departments in any organization by asking the simple question, “Does this add value?” If it does not, it is waste and must be discarded. 

Waste or “Muda” as it is called in Lean Manufacturing is everywhere and it starts in the system/program that is responsible for everything. When designing an inventory system, production line, supply chain, production process, schedule, site management, quality control system, one must be cognizant of each step in the process because each step is magnified through time and it either focuses or folds to its pressure.  

Starting in February of 2011, Capsys has adopted this kind of Lean thinking and has enjoyed great success in its manufacturing line by nearly doubling its production efficiency in a little over 5 months while controlling costs by changing to a Kanban, pull-type Supply Chain. Its yields have also been increasing due to a more proactive quality control system that locates causes of problems versus just trying to catch after the fact defects.

On June 27^th, 2011, Capsys welded its first Chassis for Phase III of the Nehemiah Spring Creek Townhouse Project. In concurrency, Capsys is setting the Hanac Bathroom Pods, putting the finishing touches on the Ashburton and McDougal Projects, and starting erection of the Victory Blvd projects in early August of 2011.

Bringing these individual systems and projects together in an interconnected system of continuous improvement makes Capsys poised for a strong finish to 2011 and a stronger beginning to 2012. Please contact us if you have any questions or would like a tour of our construction manufacturing plant in New York City.

I’m happy to report that we are making great progress in Astoria.The project is really picking up steam.

Recently Capsys team finished plant production of 66 modular bathrooms for the Senior Living project in Astoria, NY. Today is the second day of setting of the second floor modules. The second floor’s bathrooms were shipped to the job site and now they are being set inside a conventionally constructed building. This six story building is being erected by Capsys’s sister company – Monadnock Construction, Inc.

Check out some pictures from today’s setting!

Pictures by David Parlo

Capsys has now done wide variations to the Greenflex residence hall system.  Our flexible and sustainable pre-designed system can easily be tailored to your specific needs.  Let Capsys produce a residence hall for your long-term needs in the shortest timespan imaginable!

Another shining example of modular construction making a project move quickly with great efficiency!  The Owner and Plaza Construction are pleased to have the steel frame, concrete structural floors and exterior light gauge in place in four days!  Monday morning they will start work on a building that wasn’t even there last monday!

We are excited to be erecting Building 92 right here in the Brooklyn Navy Yard.  Very exciting as this is a unique project and hopefully we will be doing many more like it!

Capsys has announced the new and exciting Green-flex residence hall program.  With our pre-designed modular units we can transform your residence hall needs into a completed building in as little as 11 months from concept to completion.  Visit our website for upcoming information on this program!

Of course if you have an immediate need please feel free to contact us by phone or by e-mail.  tohara@capsyscorp.com

Looks like the foundation will be completed and ready for us to set modules on October 26th!

With Capsys’ modular system of construction the time of construction can be drastically reduced, a building that typically would take up to 18 months of construction can be completed in 6-8 months instead!  Saving money on construction costs, interest and ultimately producing revenue much faster!