In last month’s article, “NEXPLATE: Achieving F1 Pit-Stop Speed in Truss Production,” we analyzed a production run of 80 long-span agricultural trusses using an “all-or-nothing” approach to automated plate distribution. We demonstrated how Enventek’s NEXPLATE system delivers a next-gen solution that smashes the hidden automation bottleneck plaguing million-dollar truss tables. Expensive investments in advanced auto-jigging setups and precision laser projection have been neutralized by inefficient manual distribution of truss plates. By replacing outdated manual plate gathering with high-velocity, automated plate sequencing, component manufacturers can finally unlock the true ROI of their table automation. Maintaining a clean, uncluttered work surface facilitates more efficient and safe table operations, allowing for optimized crew re-balancing and superior production sequencing. With NEXPLATE, there is a hybrid plate picking scheme that yields even higher efficiency. [For all images, See PDF or View in Full Issue.]
The Hybrid Plate Picking Strategy
In any complex setup — such as a long-span Ag truss run — certain plates are simply too large to be physically dispensed from the NEXPLATE machine’s hopper magazines. The NEXPLATE operator has to manually gather these oversized, non-stocked plates and place them on top of the NEXPLATE automatically dispensed plates.
But the hybrid scheme eliminates this step entirely. As always, NEXPLATE will automatically dispense all standard truss plates into the bins, “one truss per bin,” but the bin doesn’t need the non-stocked plates added on top. Instead, your team will pre-stage the oversized non-stocked bulk plates ahead of time directly at the truss build table near their corresponding joint locations.
By positioning these oversized plates right where they are needed before the cycle begins, you reduce bin sorting complexity, eliminate operator search-and-select time, and significantly accelerate assembly times for the truss builders.
As shown in the images, the plates circled in red are too large to be dispensed automatically by the NEXPLATE machine. Instead of the NEXPLATE operator manually placing these oversized, non-stocked plates into the NEXPLATE dispensed bins (as detailed in last month’s workflow), the hybrid scheme stages them directly at the truss build table. By positioning these non-stocked plates near their respective joints ahead of time, you eliminate unnecessary handling complexity and significantly accelerate assembly times for the truss builders.
Separating non-stocked bulk plates from the NEXPLATE automated stream reduces bin complexity, minimizes NEXPLATE operator search-and-select time, and maintains maximum velocity at the truss assembly table.
NEXPLATE Space and Safety Considerations
To fully leverage NEXPLATE’s F1-style velocity, the physical placement of the machine must balance material flow with strict forklift safety rules. Much like a traditional lumber PickLine, plants will discover that NEXPLATE automation enhances overall warehouse space utilization by cleanly separating active “picking stock” from dense bulk storage.
The Ideal Footprint (44 ft x 44 ft Layout)
For plants looking to integrate the system into an open layout, a minimum warehouse floor area of 44 ft x 44 ft provides an optimal, highly lean workflow footprint. Maintaining a clear 3-foot access aisle on both sides of the NEXPLATE machine provides ample clearance for the operator to safely replenish the hoppers with tooth-to-tooth truss plates. Plate pallet racks should be positioned directly adjacent to these 3-foot aisles. The bottom row of pallets is used exclusively for immediate hopper refilling (staging cartons, trays, or active pallets).
Forklift and Operator Isolation
The upper tiers of the racking should be reserved strictly for dense bulk storage. Forklifts should replenish the bottom active rows exclusively from behind the racking. This completely isolates the machine operator from forklift traffic.
The 3D layout rendering highlights the physical separation between the forklift and the safe operator zone. Similar to an Enventek Lumber PickLine, implementing NEXPLATE automation optimizes warehouse space utilization by cleanly separating active “picking stock” from dense bulk storage. The NEXPLATE system significantly improves both facility safety and enhances warehouse space.
Not every plant has a blank canvas. In more compact facilities, the system can be adapted successfully to tighter configurations. The plant shown here has successfully integrated their NEXPLATE machine into an existing warehouse nook. The operator currently manages picking stock along both walls using hand carts. Future facility plans include installing low-profile shelving directly alongside the NEXPLATE for fast replenishment, leaving the dense storage racks outside the nook area.
Whether your plant integrates the system into a dedicated 44 ft x 44 ft cellular layout or adapts it into an existing warehouse nook, the goal remains the same: eliminating unnecessary material handling. By pairing automated plate sequencing with a smart hybrid picking scheme for oversized plates, component manufacturers can eliminate the final bottleneck on the production floor and achieve true Formula 1 velocity at the truss assembly tables.
When you’re ready to Feed Your Beast and see these efficient and effective systems for yourself, let us know! Inside and out, LimTek Process Organization Technology will 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.