Automation on the Factory Floor

I’ve had many conversations with manufacturers across the structural building components industry lately, and the topic that keeps coming up is automation. And it’s no surprise – automation is no longer a futuristic concept. It’s here, and it’s delivering real results.

The power of systems and machines working together, with less manual labor, across a streamlined, connected workflow is allowing manufacturers to unlock some serious value. But what really makes automation powerful isn’t just the machines, it’s the connection between every step: from design and software, to cutting, assembly, material handling, and sending out completed frames and trusses. Automation takes on the repetitive, decision-heavy tasks and does the heavy lifting, literally and figuratively, so your team can focus on what matters.

Wherever you are on your automation journey, we’re here to support you step by step, offering practical, scalable recommendations based on your footprint, your budget, and your long-term goals. Whether you’re just exploring automation or you’ve already started down the path, these are some of the things to consider as you move forward. [For photos, See PDF or View in Full Issue.]

What Automation Looks Like in Today’s Frame and Truss Manufacturing

When I talk about automation, I don’t just mean having one high-tech machine in the corner of your shop. I see automation as an integrated approach, touching every part of frame and truss manufacturing – it connects your design, software, systems, machinery, and processes. Here’s how I see automation working today across a factory:

• Cutting – automated saws are faster and more accurate, optimizing cuts from design files and minimizing waste.
• Wall Assembly – feeding lumber, precision nailing, sheathing, and stacking can all be automated to reduce manual labor and boost efficiency.
• Truss Assembly – laser projection systems help with layout, while automated jigging systems and presses take the strain off your crew and provide greater precision.
• Nail Plate Placement – machines handle plate placement with repeatable precision, minimizing rework and increasing throughput.
• Material Handling – conveyors, auto feeders, robotic arms, and stackers improve workflow, reduce injury risk, and keep your factory moving.

All of this is powered by clever design and intelligent software. The software capabilities allow for real-time production metrics and insights, so you can utilize the full potential of your machinery.

At Spida, we’re constantly looking at ways to improve the automation functions we provide our customers. Our expert team of design engineers take the best from around the world and tailors it to the frame and truss industry, to meet the needs of fabricators today and tomorrow.

At the heart of automation is our software, which we design, build, and support in-house. Our TandemOne suite of software has modules to suit all your frame and truss manufacturing needs. We provide automation solutions across cutting, wall assembly, roof truss assembly, floor truss assembly, and material handling. Take a look at some of our machines in action so you can see for yourself the benefits automation can provide.

When Does Automation Pay Off?

This is one of the most frequent questions I hear: “Is it worth it?” And my answer? Absolutely – but timing, approach, and execution matter. Every automated machine adds value to a part of your workflow, but the biggest returns come when you begin to integrate automation across your production line. Here’s what you can expect:

• Labor Savings – you’ll reduce your reliance on manual labor and free up your team for more skilled, higher-value work.
• Increased Productivity – automating previously manual processes leads to more output – and often faster than expected.
• Better Quality and Consistency – tighter tolerances, fewer errors, and less rework means higher product standards.
• Less Waste – optimization tools significantly reduce offcuts, miscuts, and overall material waste.

Automation offers strong ROI and can accelerate in multishift operations where uptime is maximized. You can boost efficiency and cut costs throughout the production process.

Demonstrating the popularity of our machinery, in 2025, we have a Roller Plant being installed every two months in North America, with the individual company specs ranging from 88 ft to 240 ft. The majority of these customers tell us the desire to purchase innovation and efficiency, alongside the strength of build and value for the money, have meant the decision to upgrade and introduce automation was an easy one.

The positive feedback we’ve received really shows how automation is working, with one of our Roller Plant customers sharing, “We now have quicker setup times, much increased production volumes, and effectively it allows us to meet the demands of today as well as the future demands and growth. Production and productivity have increased very quickly and exponentially, and we’re well ahead of our production targets.”

Beyond the Numbers: Additional Benefits of Automation

In my experience, automation’s impact goes beyond output. It changes the whole work environment for the better.

• Safety – less heavy lifting, fewer repetitive motions, and safer workflows mean fewer injuries and reduced worker fatigue.
• Employee Retention – reduced physical strain and workers taking on more meaningful tasks will keep skilled staff longer.
• Scalability – as demand grows, automation helps you scale production without hiring dozens of new employees.

How Automation Affects Your Workforce

I’ve worked with plenty of teams worried that automation would remove all jobs. While it reduces the reliance on manual labor through the manufacturing workflow process (which does save time and money), in practice it’s also an opportunity for transformation and redeployment.

When repetitive or physically demanding tasks are automated, you open up space for your skilled workers to take on roles in areas such as quality control, workflow optimization, data analysis, and machine maintenance. Assigning resources to these higher-value areas will help future-proof your business.

What’s Holding You Back? Common Barriers & How We Solve Them

Many manufacturers share the same concerns about getting started with automation. Here’s what I hear most often and how we help address each one:

• Initial Investment – yes, automation can be a big investment up front, which can be a deterrent for some manufacturers. But financing options and a staggered rollout can help. At Spida, we specialize in factory layouts, where we can help you introduce automation to your factory in a phased approach, which helps you manage costs and scale smartly.
• Implementation Disruption – the introduction of new workflows and installation of new machinery can cause some disruption. While sometimes unavoidable, we work alongside you in the planning stage and are on-site for installation, so we can control the implementation to minimize any downtime.
• Training and Workforce Adoption – new processes, machinery and equipment require operators to use them, which means training of employees. Once we’ve completed the installation, we provide on-site training, so your operators know how to use the machinery correctly, efficiently, and safely. We train your people with ‘your’ jobs, so that they learn in the context they will be working in. Also, our design philosophy is simplicity, and we pride ourselves on building machines that are easy to use.
• Software Integration – when you’ve automated your processes, software integration is key, as poorly integrated systems can lead to bottlenecks and errors (which is what you’re trying to get rid of!). Software integration is a key strength of Spida – and given that we design, build, and support our own software, this independence means we’re free of third-party software suppliers, allowing us to be agile and responsive.

Considering all of this, the bigger question I would challenge you to ask is actually, “What’s the cost of standing still?”

What Happens If You Don’t Automate?

If you stick with purely manual processes, here’s what you’re facing:

• Higher operational costs as manual processes require more labor hours, and therefore more overhead.
• Staff challenges because the skilled labor shortage is already here, and as the industry struggles to attract and retain skilled workers, reliance on manual processes will make this more difficult.
• Production inefficiencies such as slower output and higher error rates which lead to rework, material waste, and of course cost implications.
• Reduced competitiveness as you will not be as flexible as your competitors who have automation, as manual systems make it harder to quickly adapt to design changes or custom orders, which ultimately could result in lost business.
• Lower profit margins result when all of these factors squeeze your margins, whereas automated operations could be increasing your profitability.

Put simply, if you stay manual as opposed to adding automation, you’re likely to experience higher labor costs, lower output, greater material waste, and more error/rework costs.

Final Thoughts

If you haven’t started your automation journey yet, now is the time to take that first step. Review your current workflows, identify the most painful bottlenecks that automation could solve, and explore possible solutions. Start small but start smart – build a roadmap that fits your operation, and scale from there.

And if you’ve already started with automation, ask yourself, “Is it true automation or partial automation?” If you’re still relying on operators to make key decisions, manually manage job lists, or manual steps remain in the workflow, you’re leaving efficiency on the table.

At Spida, we don’t believe in one-size-fits-all. We work with manufacturers to understand your challenges and your goals, so we can recommend automation solutions that deliver value both today and into the future. When you’re ready to take the next step, or even if you’re just curious about what’s possible, I’d love to talk. Let’s explore how automation can work for your factory, your team, and your future.