In today’s volatile economy, there is comfort in knowing the significant housing backlog will rely on the components industry to keep on supplying. Trusses are the original off-site construction industry begun more than 60 years ago, and the number of truss plants and capital investments made over the decades is truly staggering. The labor market has always been tight and investing in automation during a downturn has proven to be a sound business decision. [For all photo and diagrams, See PDF or View in Full Issue.]
Beyond the traditional CapEx ROI calculation saying “Yes,” there are always fear factors that will delay the “Go” decision. It is my job to help component plants overcome their fear factors of space, time, labor, safety, maintenance, and support.
The Space Fear Factor
My May 2022 article, “Debunking the ‘Automation Takes Too Much Space’ Myth,” overcomes some of the “space” concerns by addressing the in-feeding of lumber using PickLine conveyors instead of forklifts. Contrary to the myth, a lumber PickLine can actually save space by utilizing existing truck lanes and by following existing forklift flow.
Interestingly though, while conveyors can be excellent for the out-feeding of finished trusses, in front of truss build tables I have found that a cart system can provide a more efficient and dynamic use of valuable floor space. With an effective cart system, you can boost production for any mix of truss production from intricate single-family houses to high-volume multi-family and high-volume long-span agricultural runs.
If “making space” is one of your top concerns, then you really need to examine your staging area. Think about it. Modern truss tables are now “million dollar tables” with automated jigging, laser projection, and PlantOne TVs; yet all this automation is handcuffed if there is only 16-ft to 25-ft of staging area in front of the tables. That is why, on greenfield truss plant layouts, I suggest investing in additional truss out-feed conveyors so that two lines can share staging areas to take full advantage of the investment in table automation and an always-changing production schedule.
Take a page out of Tom Hollinshed’s playbook from 2017/18 to take advantage of downturns and update production equipment to service your loyal customers:
“Wish we had it up and running last year. We lost some jobs over lead times but very fortunately no customers. We hope we will see last year’s opportunity again soon and have the chance to show our customers that their loyalty with us pays off. We know all too well they can’t lose house sales due to our truss supply issues.” Tom Hollinshed, Owner, Comtech Inc., Fayetteville, NC
Is space one of the primary reasons why you are resisting additional investments in automation? Do you need help envisioning a more effective and efficient plant layout? Don’t let the classic fear factors deter you from improving your process efficiency.
Feed the Beast! with LimTek Process Organization Technology. LimTek can help you squeeze out more truss production and deliver quality trusses with shorter lead times to better service your customers by organizing your truss fabrication processes to maximize your investment in automation. We offer 6 separate processes to meet each need independently or as a complete custom solution. https://limteksolutions.com/#solutions