Building Levittown with a ‘Reverse Assembly Line’
William Levitt is called the “Henry Ford of homebuilding” and for good reason. Under his leadership, Levitt and Sons developed the world’s most efficient system for mass-producing single-family homes. When Island Trees was finished in 1951, it had 17,447 homes with 80,000-plus residents, and its builder was such a fixture in the press that the massive suburban development was renamed Levittown.
To build Levittown, Levitt perfected what’s called the “reverse assembly line.” On a normal assembly line, the product moves down the factory floor, and the workers stay in one place. But that doesn’t work when the product is an 800-square-foot house. “The land was our factory,” William Levitt explained, as reported by the Construction Physics newsletter. “We found it quicker, less expensive and more efficient to move crews of men in standardized operations over the site than to move the house itself along a factory assembly line.”
Levitt divided home construction into 26 distinct steps performed by 26 different teams of workers. The first team poured the concrete foundation. The second team framed the walls. The third team framed the roof and so on.
“There was one team that all it did was install the washing machine,” Berenson says. “One of Levitt’s selling points was that every one of his houses came with a washing machine, which to working-class people was an incredible luxury.”
The company used new materials like sheets of drywall and plywood that could be installed with power tools like nail guns and routers. Its painters used mechanical sprayers instead of brushes, and all the lumber arrived precut to exact specifications. “You didn’t even need a saw,” Berenson says.
To avoid costly delays of material or machinery, Levitt became an early pioneer of vertical integration. As William Levitt explained, per Construction Physics: “We wouldn’t let ourselves be stopped by shortages. When cement was unavailable in this country, we chartered a boat and brought it in from Europe. When lumber was in short supply, we bought a forest in California and built a mill. When nails were hard to come by, we set up a factory in our backyard and made them ourselves.”
As a result, the reverse assembly line at Levittown completed, on average, between 10 and 12 new houses every day. Meanwhile, “the average home builder right after World War II was building one house a year,” Berenson says.
The California Method
William Levitt wasn’t the only homebuilder churning out cookie-cutter houses on an industrial scale. California was ground zero for both the postwar housing crisis and the ensuing suburban housing boom, as the 2011 state report outlines. By the late 1940s, mass-production techniques like on-site sawmills, bundling complete sets of lumber and bulk ordering fixtures were so common in the state’s fast-growing suburbs that they were called the “California Method.”
The sprawling Lakewood development near Long Beach, California, rivaled Levittown with 17,000 homes constructed between 1950 and 1953. The economies of scale were mind-boggling. The builders of Lakewood ordered 200,000 identical doors for the project, and its reverse assembly line employed 4,000 workers. At San Lorenzo Village outside of Oakland, California, 2,500 workers could complete a new house every 45 minutes.
But it was Levitt and Sons that constructed more suburban housing than any other company in the postwar period. After building 17,447 homes for the original Levittown in New York, the company built three more Levittowns in Pennsylvania, New Jersey and Maryland (poshly named “Belair at Bowie”). Those four planned communities alone contained more than 50,000 homes.
“It wasn’t that Levitt alone figured out how to mass-produce houses,” Berenson says. “At least half a dozen home builders were doing the same thing, but no one was able to build the numbers of houses that Levitt did.”