In today’s rapidly evolving manufacturing landscape, the smartest construction projects don’t start with concrete and steel— they start with strategy.
At Riley Construction, we’ve seen firsthand how asking the right questions early transforms industrial and manufacturing builds from costly challenges into high-performing spaces.
Erik Dillon, VP at Riley Construction, and Nate Hoffman, Founder and President of Carrus Group, have partnered on numerous industrial projects. Together, they help clients not just build facilities, but reimagine them for long-term operational success.
Both believe Wisconsin’s strong manufacturing climate, which contributes almost $70 billion annually to the economy,[1] continues to look favorable for construction growth. However, ongoing challenges, including supply chain instability, tariffs, and labor pressures, add up to a critical need for more precise construction planning.
Discover The Hidden Costs in Your Operation
Too often, manufacturers focus first on square footage or equipment needs. But the question should be: What are your current operations costing you? That answer will reveal far more than a facility’s size ever could.
When you consider that 98% of large-scale construction projects go over budget by 65% [2] on average it’s a wake-up call that businesses need to take more time to study their operations before the shovel hits the ground.
“Operational inefficiencies are like a boulder in your backpack—you carry it every day, and it’s dragging down performance,” says Hoffman. “Whether it’s outdated equipment, poor layout, or limited storage, identifying that “boulder” helps clients build smarter.”
Whether working on a building renovation or a new construction, 80% of costs are built into the design. By analyzing workflow early, we often determine that clients need less space than anticipated. This frees up capital for reinvestment in technology, staffing, or future expansion.
Planning starts with a process engineer touring your existing facility to learn about your operations. Just because your plant is organized one way in an existing building doesn’t mean it’s the most effective solution at another location. Working with a team that can help map out your goals and the barriers you face can have a major impact on your outcome.
Smarter Design = Greater Efficiency
Today’s facilities, especially in sectors like biotech, food processing, and advanced manufacturing, are more complex than ever. These builds rely on precise MEP (Mechanical, Electrical, Plumbing) systems that support highly specialized equipment.
But here’s the catch: Most owners don’t have those details locked in upfront.
That’s why we:
- Collect critical data to understand actual operational needs vs wants
- Refine our plan first to avoid pricing revisions later.
- Bring MEP designers into the conversation early.
- Use tools like BIM (3D Building Information Modeling) and laser scanning for accurate visualization.
- Account for current and future needs during design
This helps clients visualize their facilities before construction even begins—giving them the confidence to make informed decisions.
This proactive approach reduces rework, accelerates timelines, and accommodates long-lead items. In one instance, this early-stage process evaluation saved an industrial client $1.2 million.
Riley then uses Smart Rates, our streamlined estimation process, to eliminate waste and sharpen budgets. These customized rates look beyond historical costs, considering a combination of client needs, project specs, and current local market conditions and pricing to create a more accurate cost estimate.
Lean Construction Saves Time & Money
From preconstruction planning through the final walk-through, Lean construction principles guide everything we do before and during construction. By eliminating non-value-added activities, streamlining communication, and keeping decisions centralized, we minimize delays and reduce costs.
We don’t just talk about results—we track them. Throughout our process, we measure impact by looking at KPIs like revenue per square foot, operational savings, and throughput efficiency. It’s essential for us to determine early on how we can deliver a meaningful return on investment so we can ensure that we are providing the most value.
Collaboration Is The Secret To Smooth Builds
Industrial projects require a cohesive team from day one. That’s why Riley Construction uses collaborative contract delivery methods like Design-Build or CM at Risk (Guaranteed Maximum Price). These methods provide a single point of accountability and eliminate coordination issues, schedule delays, and cost overruns.
What really sets our partnership apart is trust. Over the past eight years, Riley and Carrus-Group have built a culture of open communication, challenging the status quo, and problem-solving alongside clients every step of the way.
Ready To Reimagine Your Facility?
If this approach speaks to you, we offer a no-obligation walkthrough of your current manufacturing or industrial plant to:
- Explore your operational pain points
- Share ideas for design-driven efficiency
- Uncover potential cost-savings
After all, the best projects aren’t bigger. They’re smarter.
Reach out to Erik Dillon, Vice President and co-owner of Riley Construction at ErikD@rileycon.com and Nate Hoffman, Founder and President of Carrus Group at nhoffman@carrus-group.com.
Learn more about our wide array of visit industrial and manufacturing construction work.