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Standardised designs driving TBS’s productivity in offsite construction.
Since its establishment in 2014, Timber Building Systems (TBS) has become a key figure in Australia’s offsite construction sector. Based in a 10,000-square-metre facility in Dandenong South, Victoria, TBS focuses on prefabricated timber solutions for multi-storey, commercial, and residential construction. Michael Dolphin, publisher of Built Offsite, spoke with General Manager Tim Newman, who offered insights into the challenges, strategies, and future directions that have shaped the company’s journey. (main pic: TBS’s offsite manufacturing facility in Dandenong South, Victoria.)
Navigating Volatility in Construction
Unlike traditional manufacturing, where planning and production can be predictable, the construction industry poses unique challenges. “Construction operates very differently from traditional manufacturing,” Newman explained. “In manufacturing, you control the output and can plan years in advance. Construction, on the other hand, is far less predictable where projects encounter delays that can arise from external factors.” Reflecting on his eight years with TBS, Newman described how the company has adapted to these uncertainties. “Initially, we thought securing consistent projects over time would be straightforward, but delays occur in every project, often due to elements that can’t be anticipated. Managing those challenges has been crucial.”
TBS has adopted strategies to minimise these disruptions, including building strong client relationships. “Our partnership with Henley Properties allows us to maintain a steady pipeline of projects and provides stability, even when external factors cause delays,” he noted.
Standardisation as a Turning Point
In its early days of their townhouse program, TBS tailored designs for each project, which proved time-consuming and inefficient. This approach shifted with the adoption of standardised designs, marking a pivotal moment for the company. “Standardising our designs was a turning point,” Newman said. “We’ve been able to triple or even quadruple our productivity.”
The move has had significant implications for the company’s operations. “We’ve gone from producing one townhouse a week to up to three per week. Standardisation has allowed us to refine processes, improve quality, and focus on delivering value to our clients.”
He added, “Initially, each project required a unique design. We’ve streamlined that by creating slight adjustments to a core range, focusing on improving quality and efficiency.”
Engineered Panels Driving Efficiency
TBS’s engineered panels are central to their success. Designed to accommodate structural, plumbing, and electrical services, the panels simplify construction workflows, drastically reduce on-site construction time and project risk. “Our panels are designed to reduce the amount of work required on site,” Newman explained. “It’s about providing a solution that fits seamlessly into the construction process and ensures the highest levels of efficiency and quality.”
Once installed—often within a matter of days—internal fitout can begin work almost immediately. Newman highlighted the importance of these efficiencies: “We’re working on the next townhouse model, incorporating learnings from Henley. It will be easier to manufacture and assemble, reducing costs while maintaining quality.”
Digital Tools Supporting Smarter Processes
To enhance collaboration and reduce planning delays, TBS has embraced digital tools like Development Victoria’s eComply. “eComply saves months of back-and-forth with planners,” Newman said. “It allows TBS designers to quickly evaluate multiple different prefab solutions whilst ensuring they meet the planning requirements”
He also sees opportunities to expand the tool’s use among developers. “If developers were to adopt this tool more widely, it could help align their designs with our processes, making the entire project smoother for everyone involved.”
Collaboration remains a cornerstone of TBS’s approach. “Iterative design between us, consultants, and architects is key to creating scalable, manufacturable designs,” Newman explained.
Developing a Versatile Workforce
TBS’s ability to attract and train employees from diverse industries has been vital to its success. “We’ve had employees join us from hospitality, retail, and even automotive manufacturing,” Newman shared. “Within days, they’re contributing meaningfully to production. For many, it’s been a pathway to a long-term career.”
He described the company’s focus on creating meaningful opportunities. “It’s about more than just jobs; it’s about creating lasting career pathways. We’ve built a team from diverse backgrounds and provided them with opportunities to upskill and contribute meaningfully.”
This workforce development strategy also addresses labour shortages in the construction industry and ensures the company has the skills needed to support its growth.
Exploring New Opportunities
While townhouses remain TBS’s core focus, the company is actively exploring other markets. “We’re keeping our base load of townhouse projects while looking at mid-rise opportunities, particularly in Melbourne and New South Wales,” Newman said. “We’ve done mid-rise projects in Auckland, as well as schools in New South Wales and South Australia. We’re open to similar work if the opportunities align with our capabilities.”
Affordable housing is another area of interest. “Offsite construction is highly effective for townhouses, social housing, and affordable housing, where we can produce high-quality buildings quickly, using a well-trained production workforce without relying too heavily on highly qualified specialists,” he explained.
Government-backed projects, such as pre-approved designs for schools and mid-rise exemplars, also present potential opportunities. “These types of projects provide stability and align with the expertise we’ve developed over the years,” Newman added.
Balancing Prefabrication and Traditional Methods
Newman emphasised that offsite construction is not a one-size-fits-all solution. “Prefabricating certain elements, like walls or floors, allows us to improve quality and reduce costs without trying to move the entire construction process offsite,” he said. “It’s about using the right tool for the job.”
This balanced approach enables TBS to deliver the benefits of prefabrication while maintaining flexibility for projects that require traditional methods.
Preparing for the Future
“Looking ahead, TBS is fine-tuning its processes and enhancing its capabilities. The next generation of townhouse designs aims to simplify manufacturing further while continuing to uphold the company’s high standards of quality.” Newman shared.
Despite the industry’s challenges, Newman is optimistic about the potential of offsite construction. “The biggest challenge is managing volatility in the construction market. Unlike manufacturing, where production is steady, construction often involves peaks and troughs. Building a consistent pipeline of work is critical to navigating those ups and downs.”
He concluded, “We’re proud of what we’ve achieved, but we’re always looking ahead to what’s next. The potential for offsite construction is huge, and we’re excited to be part of it.”
See: TBS
