Falcon Structures

Translating construction-based skills into manufacturing standards is harder than it sounds.

Framing, drywall, electrical… they’re all the same skills you'd see on any job site. But in a factory environment, the expectation is repeatability, precision, and documented process. Those two worlds don't naturally speak the same language.

One of the tools that helps us bridge the gap: the A3 methodology.

Named for the 11"×17" paper it lives on, A3 forces an entire problem-solving cycle — problem, root cause, solution, implementation, review — onto a single page. Being constrained to that one piece of paper forces us to nix any vagueness, getting to the root of the problem.

Our Co-Founder Brian Dieringer put it simply: "We're trying to be a learning organization. This is one of our tools to learn."

The companies that will win in modular and manufactured construction aren't the ones who make the fewest mistakes. They're the ones who build the best systems for learning from them.

How A3 Methodology Improves Shipping Container Manufacturing The A3 methodology is a lean manufacturing problem solving tactic used by Falcon Structures to efficiently manufacture modified shipping containers.

Not your typical 20-foot office.
Two-toned paint, picture windows, diamond tread steel flooring, and a private bathroom all come together in a durable, ready-to-deploy workspace that moves with the team.