Unlocking Downtime in Offsite Manufacturing
The UK offsite manufacturing sector is at a critical crossroads. Recent high-profile market exits from leading players like Urban Splash, L&G Modular, and TopHat have highlighted the fragility of the sector’s production capacity and the risks associated with inconsistent demand cycles. To address this, the industry must pivot toward a more collaborative, resilient model — and the upcoming “Unlocking Downtime in Offsite Manufacturing” survey marks a pivotal first step in achieving this goal.
The Challenge: Underutilised Capacity and Market Fragility
Despite the potential for Modern Methods of Construction (MMC) to revolutionise UK housing and infrastructure delivery, the sector faces recurring challenges:
- Cyclical demand creates gaps in production pipelines, leading to downtime and increased fixed overheads.
- Supply chain disruptions and labour shortages further compound these issues, leaving manufacturers unable to operate at full capacity.
- Market exits have exposed the financial vulnerability of offsite manufacturers, where idle production lines and operational inefficiencies threaten business sustainability.
Without a strategic response, these challenges will continue to undermine the sector’s ability to scale, attract investment, and deliver the promised benefits of offsite construction — including faster build times, cost savings, and reduced carbon footprints.
The Solution: A Collaborative Approach to Downtime Management
The survey is a vital first step in a broader initiative to create a framework for collaborative “sprints” — a strategy that would allow manufacturers to fill downtime with smaller or more flexible projects. This approach aims to:
- Identify capacity gaps – Pinpoint when and why production lines go idle.
- Develop a marketplace model – Create a shared platform where manufacturers can list excess capacity and access short-term projects.
- Facilitate industry-wide collaboration – Encourage cross-sector partnerships to fill production gaps and unlock new revenue streams.
Why the Survey Matters
This survey will gather critical baseline data on production capacity, downtime patterns, and interest in a collaborative marketplace. The insights collected will help answer key strategic questions:
- What are the primary causes of underutilised capacity?
- How frequently do downtime periods occur — and what are the financial and operational impacts?
- Are manufacturers open to using a shared marketplace for bidding on capacity-filling projects?
- What type of projects and contract structures would work best to align with existing production cycles?
By understanding these patterns, the industry can begin to craft a solution that delivers real, measurable benefits — not only for manufacturers but also for developers, clients, and policymakers.
Building a Roadmap for Change
The data gathered from this survey will directly shape the structure of the planned workshop series, which will bring together manufacturers across the panelised, light gauge steel (LGS), and timber/hybrid sectors. Through facilitated discussions and real-world case studies, the workshops will explore how manufacturers can:
- Adapt production lines to accommodate “micro-projects” during slack periods.
- Collaborate with other manufacturers, developers, and suppliers to align capacity and demand.
- Secure policy and financial support to incentivise participation in a shared capacity marketplace.
Driving Policy and Investment Support
A key objective of the project is to make the case for government backing — whether through grants, tax incentives, or investment in a national capacity-sharing marketplace. The final output — the “Downtime Sprint Framework” — will provide a clear, actionable roadmap for securing this support and driving sector-wide adoption.
Why Industry Participation is Critical
This is not just another industry study — it’s a strategic initiative with the potential to reshape the UK offsite market. Participation in the survey and workshops will give manufacturers a seat at the table and the opportunity to:
- Influence the structure of the capacity-sharing marketplace.
- Contribute insights that will drive industry-wide efficiencies.
- Access new revenue streams by securing work during traditionally quiet periods.
- Enhance resilience by reducing dependency on cyclical demand patterns.
Conclusion
The success of this initiative depends on engagement from across the UK offsite sector. By completing the survey and participating in the workshops, manufacturers, developers, and policymakers can collectively build a more resilient and efficient offsite construction ecosystem. This is an opportunity to not only address the challenges of underutilised capacity — but to unlock a new era of collaboration, innovation, and growth for the entire UK MMC sector.
Take the survey today and be part of the solution.
Fareita Udoh, Industry Advisor, BOS