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Designing Efficient Yards And Door Shops For Speed, Safety, And Growth: Scott Morrison, Do it Best
The Grit Blueprint
What if doubling your speed didn’t require a new machine, just fewer steps? We sat down on site at the Do it Best Fall Market with Scott Morrison to unpack how simple, evidence‑based changes turn door shops, warehouses, and lumberyards into faster, safer, and more profitable operations.
Scott walks us through his on‑site approach: capture the current state with brutal honesty, map the “dance steps” between machines, and target non‑value‑added motion that steals hours. From a door shop operator walking 20 to 30 steps for inserts to forklifts hunting for staging space, distance is the hidden tax. When you cut travel time in half, it's as if you've doubled your speed. Scott shares a zone picking case where a member saved 90 minutes per day, eliminated overtime, and rolled first‑out loads by 6:30 to 7:00 a.m., a competitive edge contractors feel on the jobsite.
If you want earlier trucks, fewer headaches, and a culture that hunts waste daily, start by mapping what is true right now. Then remove distance, balance work with real sales data, and design your aisles for where you’ll be in five years.
Topics we covered:
• Mapping current state to expose waste
• Cutting non‑value‑added motion between machines
• Zone picking design and balancing by sales history
• Saving 90 minutes per day and reducing overtime
• Preloading trucks for first‑out morning deliveries
• Building cross‑functional teams with a single quarterback
• Iterating future states and breaking old paradigms
• Planning layouts for 50% growth without new buildings
• Centralizing staging to halve travel
• When to pair layout changes with WMS
LBM Member Operations Form: Sign up for your complimentary 60 minute meeting to discuss your yard's current state and future wants.
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👉 About Stefanie Couch & Grit Blueprint
I'm Stefanie Couch, the founder of Grit Blueprint. I grew up in a third-generation building supply business. I've worked inside dealers, distributors, and manufacturers. I built Grit Blueprint to solve problems I saw in our industry.
Grit Blueprint is a visibility, media, and growth partner for manufacturers, distributors, dealers, service providers, and leaders in the building industry.
We help you get seen, build trust, and become unmistakable.
