PROJECTS

PROJECTS

MODULAR CONSULTING EXPERTISE

Our team brings you a wealth of knowledge we’ve gained by decades of hands-on modular factory design and construction experience. Our factory design and consulting approach is built on this foundation. We break down complex issues, identify key impacts, and adhere to industry standards while working strategically toward our client’s goals. Our consulting success is measured by your modular factory success.
Ilke Homes
Ilke Homes requested our consulting help for a feasibility study to see if an assembly line could be installed in the existing factory.

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Autovol
This first-of-its-kind plant delegates heavy-lifting to robots and automates repetitive tasks for unprecedented precision and efficiency.

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Factory OS
Our consulting team was brought in to develop a modular assembly line that could be adapted to the confines of the building.

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Waypaver challenged us. Things have changed. We are building homes better and much faster. The shop looks amazing and we are wasting less productive time and wasting less money on overhead.
Isaac Lassiter
President at Cutting Edge Modular, Inc.
JCF Housements
JCF’s primary focus will be to develop and manage thoughtfully designed communities, that will provide a game-changing product to the rental industry, that has not seen a substantial change in years.

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Guerdon
Rick Murdock was the Co-Founder and COO of Guerdon Enterprises, where he pioneered major innovations in large scale multi-story, multi-family modular manufacturing.

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American Home Star
U.S. Waypaver’s Founder and CEO spent multiple years as a key leader in the company, heading factory operation and continuous improvement of 11 manufacturing divisions across the United States.

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Kazakhstan
We were able to design a full turnkey modular assembly line factory. Our design needed to meet the required output capable of producing eight modules per eight-hour shift.

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Riga, Latvia
We designed and installed the new production line, which allowed them to build ten fully complete modules per week.

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Learn more about the
P4 Housing Collective

© 2022 Waypaver International, LLC
Riga, Latvia
MANUAL PLANT

Riga, Latvia

sq ft.

A wall panel company in Riga, Latvia contacted us to see if it was feasible to convert part of their factory into a modular assembly line. The company wanted to be able to provide apartment units and other forms of homes throughout the Baltic States and into the United Kingdom. The factory design goal was to double their production with the additional production line. We were able to show them how to use the wall panels from their already existing panel line to supply the modular production line. We designed and installed the new production line, which allowed them to build ten fully complete modules per week. Besides opening a new market for them, using modular homes, they were able to increase their overall sales volume by adding $15 Million in revenue through the sales of modular homes. It also created 85 additional jobs in the community. This was a win-win for this company, and they were pleased with the results that our company provided.
Kazakhstan
MANUAL PLANT

Kazakhstan

sq ft.

A large housing developer in Shymkent was not able to keep up with the demand for large housing development due to labor shortages and unskilled workers. He decided to move to modular production. We were able to design a full turnkey modular assembly line factory. Our design needed to meet the required output capable of producing eight modules per eight-hour shift. In a country where needed materials and machinery not available on a timely basis, we successfully procured all machinery, tools, and equipment in the United States and loaded them into containers for the trip to the factory location. The first module came off the production line eight days after the start of production. The developer is now producing modules for his developments as well as selling housing units to the government.
American Home Star
MANUAL PLANT

United States

sq ft.

Founded in 1971, American Homestar has built a name that is recognized throughout 18 states from New Mexico to the Carolinas. American Homestar sells its homes through a network of company owned and independently owned model home centers, builders and developers throughout the Southcentral and Southeast U.S. Waypaver’s Founder and CEO spent multiple years as a key leader in the company, heading factory operation and continuous improvement of 11 manufacturing divisions across the United States.
Guerdon
MANUAL PLANT

Boise, Idaho

125,000 sq ft.

Our Founder & CEO, Rick Murdock was the Co-Founder and COO of Guerdon Enterprises, where he pioneered major innovations in large scale multi-story, multi-family modular manufacturing that made the company an award-winning industry leader in volumetric modular construction. Rick gained immense experience in developing and perfecting best practices for factory operations during the pioneering time of the industry and beyond.
JCF Housements
MANUAL PLANT

Fayetville, Tennessee

87,000 sq ft.

JCF’s primary focus will be to develop and manage thoughtfully designed communities, that will provide a game-changing product to the rental industry, that has not seen a substantial change in years.

Ilke Homes
MANUAL PLANT

Flaxby, England

250,000 sq ft.

Ilke Homes in the UK is building light gauge steel structures on a static line, a line that does not move as an assembly line but positions each housing unit in a single place such as on-site housing would do. They requested our consulting help for a feasibility study to see if an assembly line could be installed in the existing factory. A new production line was designed, and the company moved forward with producing its products on a 23-station assembly line that would easily produce six modules per eight-hour shift. Compared to the amount of production that was coming out of the static production line, this company was able to realize a five-fold increase in production and revenue—a great success story.
Factory OS
MANUAL PLANT

Vallejo, California

256,000 sq ft.

Two very prominent developers in the San Francisco Bay area partnered to start a modular factory that could provide modular construction for their own developments and for other builder developers in the Bay Area. They secured a vacant building for the modular production line. Our consulting team was then brought in to develop a modular assembly line that could be adapted to the confines of the building. We were asked to design the production line, design all jigs and fixtures, outfit the factory with all tools and machinery, and install a line movement system to carry the modules down the production line. Due to the interior layout of the factory, the production line movement would require two different designs to accommodate the structure. With the new design, Factory OS is now capable of producing six modules per eight-hour shift, and will be one of the largest modular production lines on the West Coast.
Please answer the following questions and we’ll follow up by sending you a summary of the process, the commitment required, and an outline of the services we provide.
Autovol
AUTOMATED PLANT

Nampa, Idaho

430,000 sq ft.

This first-of-its-kind plant delegates heavy-lifting to robots and automates repetitive tasks for unprecedented precision and efficiency. Autovol became the West's highest-volume producer in its second year while setting new standards for productivity, workforce diversity, and award-winning culture.
Please answer the following questions and we’ll follow up by sending you a summary of the process, the commitment required, and an outline of the services we provide.