Automated jig setups for gantry tables and linear saws are a couple of the best things to come along in our truss facilities in a long time. Obviously, we know the most time spent to build a truss is setting it up. Now we are setting up difficult trusses in seconds. Across the country, most markets build different types of trusses; therefore, production numbers are skewed. Facilities track different measures such as pieces, setups, bdft, lineal ft, bdft/mhr, pcs/mhr, and lf/mhr. With technology and better production databases, tracking real time is a tool that helps us get real numbers. No more cheated handwritten math done at the tables by the table foreman (ha ha). So, how does your facility measure across the country? Do you care? Are you working on better efficiencies to create better output and less stress on your employees?
At Truss Fab, we are a higher volume truss plant in Glendale, AZ. We are constantly trying to get better every day. It’s not just the automated equipment that helps us get more efficient, it’s the material handling, size of batches, labeling of trusses, etc. I am probably safe to say that most of us struggle with the same things. Labor is probably at the top of the list. We are trying to attract labor for the truss yard and it’s not easy. How do you get people in the truss yard to build trusses in 125º weather? Make the job less strenuous!! I can go all day about the things we are doing, but I wanted to reach out and see if our numbers are comparable to other facilities across the country. Trust me, we have good days and bad days. What I am going to show you are real numbers. The absolute truth. You will see we have some really good crews and some not so good. It happens.
Here is a recent chart from my plant. G1 and G2 are non-automated gantry tables and G3 and G4 are automated wizard tables. No lasers or printed plate placement are used. Each station has a day shift and night shift. These are our real numbers—how do they compare to yours?
Your competitors may see your production numbers. Who cares? You are not telling people your processes. We are just showing production numbers from our plants and helping our industry get better. Most of you will not want to participate, and I totally understand. But have some fun and let’s have a little fun competition.
Maybe we can help each other improve on processes and have a little forum to discuss.