From custom to cookie-cutter

To fabricate or not to fabricate? That is a question nearly all landscape contractors have asked themselves at some time in their career. There has been a significant shift in what our clients want out of their landscaping. Ten years ago, the majority of our clients simply wanted a lawn, sprinklers and some planting beds around the foundations of their homes.

Today, the scope of work has broadened greatly. It has gone beyond the basics and focuses on the creation of outdoor living spaces. These spaces include features such as patio areas, outdoor kitchens, natural gas, propane or wood fire pits, and timber structures such as trellises and pergolas. Many of these elements can be quite detailed and intricate to construct, which requires a significant amount of time, skill and experience to fabricate and assemble.

Manufacturers have begun developing kits for nearly every aspect of an outdoor living space. A typical kit has all the parts and pieces needed to complete a project in its entirety. For certain elements such as outdoor kitchen kits, they contain the precise number of blocks, needed to completely assemble a kitchen counter.

Additionally, some manufacturers pre-assemble the unit, pack it up on a pallet and crate and ship it ready to install.

Ultimately the decision of whether or not to use a kit should be made on a case-by-case basis. Team skills, tool requirements, and scheduling demands can all be factors in determining the best course of action.

DIY.

We recently started working with a company that pre-fabricates timber structures. Prior to developing this relationship, we built and installed a number of timber structures. Though the final product we provided our clients was high-quality and unique, these projects weren’t without their share of problems.

One of the largest struggles we faced was directly related to the skills and experience of our employees. Carpentry is a skill that requires a significant amount of time and experience to develop.

Because the skill level of our personnel varies so widely, efficiencies were impacted. The principle of ‘measure twice, cut once’ was learned and re-learned. We also made a high number of trips to the local hardware supplier for the little odds and ends.

Furthermore, we were somewhat limited on what we could offer clients due to our lack of specialized tools and equipment. The investment into this carpentry equipment can be quite significant and difficult to absorb into the cost of just a few projects.

Ready to install.

With the introduction and development of our relationship with our timber structure supplier, we have been able to overcome many of the issues we encountered in the fabrication process. The kits we purchase are shipped to us containing all timbers pre-cut and pre-drilled.

The kits also contain all hardware and supplies needed to complete the project. Along with the hardware and supplies, a list of the tools that may be needed to complete the project is included. This list is typically rather brief and the necessary tools are versatile and relatively inexpensive.

The ability to overcome these challenges allowed us to increase our production rate for these timber structures. Rather than spending a week or more on a custom structure, we have been able to reduce the installation time to just a couple of days or less.

The installation learning curve is significantly less steep when using kits. Typically, each kit includes a set of detailed drawings that indicate the proper placement of each piece. With some advance planning, customization of structures can be accommodated. In some cases, if detailed, dimensioned plans are sent to the supplier, they can prefabricate and send exactly that.

The logistics of installing kits are as variable as the kits themselves. Depending on the supplier, the kits can typically be shipped directly to a holding area, shop, or worksite. Equipment is usually needed for unloading and transportation. Discuss shipping conditions with the kit supplier to ensure you have the proper equipment for unloading and transporting, and adequate area for maneuverability.

Installing kits can greatly reduce labor costs when compared with a comparable custom built structure. Often, more people are needed in the initial stages of unloading and assembly, but those numbers can be quickly reduced to just one or two people to complete the construction and perform the final touch-ups.

Hurdles.

Though using these kits has increased our productivity greatly, they aren’t without their limitations. The primary drawback to the kits is the cost. They can sometimes be twice as much, or more, as the costs for the materials for a similar custom made structure. Higher material costs and lower labor costs often lead to a decrease in the gross profit margin for the project as a whole.

Final inspection.

Offering kits can be a valuable tool in building your business and your clientele. Start-up costs for most products are minimal and marketing tools and professionally produced literature is typically available. Be careful and avoid overestimating your abilities and underestimating product demands. Educate yourself and educate your clients.

As with everything, kits are not ‘one size, fits all’ elements, but can be an excellent way to break into new markets.

The author is general manager of Kimberly Nurseries, Landscape & Irrigation in Twin Falls, Idaho.